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Union Instruments INCA Series, Instruction Manual

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UNION Instruments GmbH

INCA Analyzer Series

– Instruction Manual

Calibration

Page 39 of 59

Note

A running calibration can always be interrupted or stopped by choosing
Restart system in the display command menu.

Note

INCACtrl software is always required to set up the calibration gas
compositions and the calibration points for the calibration process.
The setting cannot be performed via display menu.

More information on calibration setting and procedure of certain type of INCA Analyzer, see
the corresponding manual.

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Summary of Contents for INCA Series

Page 1: ...INCA Analyzer Series UNION Instruments GmbH INSTRUCTION MANUAL Gas composition measurement of biogas raw biogas landfill gas and bio methane Version V1 01R06 Stand 15 03 2010...

Page 2: ...pdate and maintaining the instrument to ensure proper performance When replacement parts are required ensure that you use only spare parts specified by Union Instruments GmbH Unauthorized parts and pr...

Page 3: ...ration to the INCA Analyzer 17 4 System main menu 19 4 1 Display keys 21 4 1 1 Menu function keys 21 4 1 2 Measurement data keys 22 4 2 Analyzer display during warm up 24 4 3 Menu structure 25 4 4 Set...

Page 4: ...istaltic pump 49 7 1 3 Ejector with valves 49 7 2 Sensor modules 50 7 2 1 Electrochemical sensor 50 7 2 2 Optical sensor 50 7 2 3 Paramagnetic sensor 50 7 2 4 Specific gravity sensor 50 8 Spare parts...

Page 5: ...as successful 18 Figure 4 1 Display overview 19 Figure 4 2 Display for continuous measurement configuration 20 Figure 4 3 Main menu keys 21 Figure 4 4 Measurement data keys 22 Figure 4 5 Start up disp...

Page 6: ...le 1 Measurement phases 10 Table 2 List of sensor modules 12 Table 3 Measurement keys description 22 Table 4 Example of calibration gases 31 Table 5 Calibration points measured by the example of calib...

Page 7: ...rox 15 min Calibration interval manually or automatically configurable between 1 hour to several weeks Calibration duration 10 minutes recommended Measurement ranges depending on the configuration Amb...

Page 8: ...ng to purge the analyzers thermal heat and always provide fresh air which is needed for correct measurement The analyzer should only be operated indoors Humidity could affect the measurement and event...

Page 9: ...gases Definitions The following definitions apply to WARNINGS CAUTIONS and NOTES found throughout this manual Warning Highlights an operation or maintenance procedure condition statement etc If not st...

Page 10: ...yzer consists of four phases in an adjustable cycle Phases Description Purge gas Purge gas usually air is pumped through the system to clean out the pipes from process gas of previous measurement and...

Page 11: ...se transition in standard analyzer Figure 3 2 Phase transition in continuously measuring analyzer Purge gas Condensate drain Change channel Measurement Calibration Check for Autocalib Yes No Purge gas...

Page 12: ...H2 CO 3 of range 0 25 vol Linearity S k loge 1 1 C 10 4 O2 Paramagnetic 3 of range 0 5 vol Maintenance free long lifetime 11 5 O2 Paramagnetic 1 5 of range 0 25 vol Maintenance free long lifetime 12 H...

Page 13: ...correct the IR source aging which is typical for devices using the NDIR technique If necessary the sensor head can be individually replaced See spare parts list at the end of this manual The accuracy...

Page 14: ...ic gravity module is designed for a continuous on line analysis of a gas stream It determines the specific gravity of the process gas in a specially designed sample chamber using presence of a modulat...

Page 15: ...measurement data from the analyzer set calibration gas compositions and calibration settings Requirements 1 INCA Analyzer 2 INCACtrl software 3 A PC laptop operating system MS Windows XP Vista 4 Null...

Page 16: ...re 3 8 Establishing connection between INCACtrl and INCA Analyzer If you get an error message check the modem cable The COM port setup should also be checked by deactivating the auto detect and manual...

Page 17: ...nge of INCACtrl configuration will only become effective after saving them to the INCA Analyzer 1 Check the following sign in the INCACtrl Red cross shows that some changes are made in the INCACtrl co...

Page 18: ...uments GmbH INCA Analyzer Series Instruction Manual Page 18 of 59 General description 3 The green check mark is shown if the saving was successful Figure 3 11 Green check mark saving configuration was...

Page 19: ...gas temp8 EC meas cycle9 Commands Change channel10 Restart system Clear messages Cal purge gas Cal gas I Cal gas II11 Reset cal System info System messages Figure 4 1 Display overview 7 only active fo...

Page 20: ...ailable channels is active and currently measured For a continuous measurement setup the display indicates the continuous measurement with a blinking asterisk symbol Figure 4 2 Display for continuous...

Page 21: ...and right keys are used to show the measured values MEASURING 4 57 Channel 1 3 07 22 2009 14 42 21 The display shows the Measuring phase is active Press and to show the measured values REMARK An aste...

Page 22: ...ows measured concentration of the previous measurements up to 10 previous values Table 3 Measurement keys description 1 2 3 MEASURING 4 57 Channel 1 3 07 22 2009 14 42 21 Press up or down to show the...

Page 23: ...es are updated in the display after each measurement phase For continuously measuring gases no asterisk is shown since the value is updated continuously O2 Chnl 1 10 0 Vol H2S Chnl 1 210 ppm MEASURING...

Page 24: ...or group and the status of the Parox sensor Since the T IR already meets its operating temperature OK is shown in the display Operating temperature NDIR sensor module 49 or 64 C If the Parox sensor re...

Page 25: ...mmands Press MENU to enter Main menu Press and to highlight the submenu Press MENU to enter the selected submenu The symbol and on the left side of the display shows the previous or next submenu on th...

Page 26: ...y changes Setting the password to 0 will deactivate the password lock of the menu Caution There is no master password It is not possible to restore password from the analyzer s menu Use INCACtrl to re...

Page 27: ...ff when using the H Bus protocol to communicate with the analyzer and to read its measurement data 4 4 5 Communication The menu provides the communication option of the RS 232 connectivity for bidirec...

Page 28: ...e the cycle runs 2 means that only every other measuring phase the cycle for EC sensor runs and the gas is measured Parameters Gas cooler temp EC meas cycle Under Parameters menu press and to highligh...

Page 29: ...and can also be used to interrupt the calibration process 4 6 3 Clear messages Clear the messages that are stored in the system 4 6 4 Calibration purge gas Calibration using purge gas is started 4 6 5...

Page 30: ...en in the figures above Otherwise they are displayed only in their codes Please see the messages errors and events description list in the appendix to understand the messages Main menu Commands System...

Page 31: ...erred to as calibration Gases used in calibration process codes Composition CO2 CH4 H2S O2 N2 Purge gas S 20 9 vol 80 1 vol Calibration gas A1 A1 48 vol 52 vol 25 ppm Calibration gas B1 B1 100 vol 25...

Page 32: ...at reason a CO2 zero calibration with air would destroy this special calibration and lead to wrong measurements CO2 zero calibration is only possible with 100 vol CH4 5 1 2 Preparation for calibration...

Page 33: ...he INCA Analyzer and PC Note Attention The following procedure only shows an example of INCACtrl setting for a calibration using calibration gas B1 100 vol CH4 and 25 ppm H2S Setting up calibration ga...

Page 34: ...Gas Conc concentration and Unit according to the calibration gas you want to use Note Pay attention on step 3 if you are using different composition of calibration gas See the list of calibration gase...

Page 35: ...In this example the following points are selected Zero CO2 Span CH4 Span H2S Zero O2 Figure 5 6 INCACtrl setting of calibration points Close the window 6 Check the measure phase time of calibration g...

Page 36: ...n to the analyzer Click the following button to save the configuration into the analyzer Figure 5 8 Saving the configuration to the analyzer Figure 5 9 New configuration is successfully saved to the a...

Page 37: ...continuous measurement a purge gas phase is run through from every 15 minutes up to 12 hours between the calibration phases For automatic calibration the calibration gas must be permanently connected...

Page 38: ...command from user interface of the display Commands Cal purge gas Cal gas I Reset calibration Under the Commands menu press and to highlight Cal purge gas and press MENU Press MENU to execute the com...

Page 39: ...choosing Restart system in the display command menu Note INCACtrl software is always required to set up the calibration gas compositions and the calibration points for the calibration process The sett...

Page 40: ...us Communicator ABC field bus module and will therefore not be displayed in the data buffer of the device If data is received directly through a RS 232 connection the header and the tail need to be fi...

Page 41: ...the transmitted error information 6 1 2 Interface parameter Configuration 9600 bit s 8 Data bit n 1 Stop bit no parity Interval for sending Values are automatically transmitted every 15 seconds 6 1 3...

Page 42: ...alErrorMessage 2 Fatal error Error code refer to document INCA Error codes and description pdf or INCA manual errorMessages 10 20 Instrument errors Last ten errors of instrument These errors do NOT co...

Page 43: ...er if information is available otherwise 65535 or 0xFFFF is returned Value is transmitted with decimal place information DPI Word T_COOL DPI yes 2 Unit C irTemp 2 Temperature of infrared cuvette if in...

Page 44: ...le DIP switch For Modbus RTU Output buffer 5 words 2 word command 3 word command 2 word command Register number 1025 1026 3 word command Register number 1027 1028 1029 Address Baud rate Adjustable in...

Page 45: ...rd Channel 1 CH4 DPI yes 2 Unit vol 2 Word Channel 1 CO2 DPI yes 2 Unit vol 2 Word Channel 1 O2 DPI yes 2 Unit vol 3 Word Channel 1 H2S DPI no Unit ppm 4 Word Channel 2 CH4 DPI yes 2 Unit vol 5 Word C...

Page 46: ...old data of each channel minutes Format 0x0001 0x0016 CRC16 Response 0x000B 0x0016 data_block CRC16 Data_block 1 Word Reading 1 2 Word Reading 2 10 Word Reading 10 The value 1 Hexadecimal 0xFFFF shows...

Page 47: ...ation 1 Word CO2 Zero point deviation value 10000 DPI yes 2 2 Word CO2 the last span deviation value 10000 DPI yes 2 3 Word CO2 before the last span deviation value 10000 DPI yes 2 4 Word CH4 Zero poi...

Page 48: ...s Warning Periodic maintenance All the gas connections should be leak tested every 6 months Note Use only original spare parts from the manufacturer to ensure the safety and the accuracy of the analyz...

Page 49: ...nce work 7 1 Pumps 7 1 1 Diaphragm pump unit In normal operation the lifetime of both diaphragm pumps is approximately 16000 hours approx 2 years The air pump does not have a valve The gas pump has a...

Page 50: ...dard 2 years Pre calibrated electrochemical sensors are supplied as a spare part Easy replacement guarantees very little down time of the analyzer 7 2 2 Optical sensor The CH4 and CO2 optical sensors...

Page 51: ...bly group diaphragm air pump Accessories hoses Weight 550 grams Description Assembly group diaphragm air pump Item number Electrochemical Sensor H2S complete with brackets and electronics calibrated b...

Page 52: ...Flame arrestor maximum pressure 1 1 bar absolute maximum temperature 60 C explosion group IIC Weight 200 grams Description Flame arrestor SS Item number 1 9 LFE 209C Specific Gravity Sensor heated 15V...

Page 53: ...chine Fatal state machine error Error code Display description Full description 0x0180 ERROR LIST FULL Error list is full Can be configured by INCACtrl if this error is supposed to be triggered by sof...

Page 54: ...receiving all data due to a timeout 0x021B COMM CMD TIMEOUT HEADER PRT 2 Bus protocol communication error Failed receiving all data while communicating with extended bus communication due to a timeou...

Page 55: ...ion buffer Solution Increase communication buffer or reduce size of data to be stored on EEPROM 0x022C COMM SAVE DATA NO DATA Reading or writing saved EEPROM sensor slave data error Size of data not s...

Page 56: ...ENS IR PRESS PROCESS GAS Error for continuous measurement instrument Minimal required pressure in process gas stream not reached pressure measured through absolute pressure sensors of IR electronic 0x...

Page 57: ...high 0x0397 SENS IR CHNL 2 ADC0 ERROR Measured ADC0 signal of IR sensor channel 2 too high 0x0398 SENS IR CHNL 2 ADC1 ERROR Measured ADC1 signal of IR sensor channel 2 too high 0x0399 SENS IR TEMP AD...

Page 58: ...rror Adding task to scheduler failed a changed value was not saved 0x0507 MENU ADD SEND COMM COMMAND Firmware development error Adding task to scheduler failed a changed value was not sent to end slav...

Page 59: ...File writ error 0x0750 SDCARD FILE IO SEEK File seek error 0x0760 SDCARD FILE IO UNLINK File delete error 9 2 9 H Bus errors Error code Display description Full description 0x0801 HBUS CRC Error occur...

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