Union Instruments INCA4003 Translation Of The Original Operating Instructions Download | Manualshive

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Safety notes

2.6

Workplace hazard analysis

NOTE

Depending on the national regulations, the operator must perform a workplace
hazard analysis, if applicable independent of the CE mark for this process gas
analyser.

Technical developments can give rise to deviations from these operating
instructions. If you require additional information or if particular problems arise
that are not fully addressed in this manual, please contact the following address:

Union Instruments GmbH

Zeppelinstrasse 42

76185 Karlsruhe

Germany

!"

+49 (0)721-680381-0

!

+49 (0)721-680381-26

#"

[email protected]

%"

http://www.union-instruments.com

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Summary of Contents for INCA4003

Page 1: ...Translation of the original operating instructions Process gas analyser INCA4003 Device type Device number Jun 2013 V1 06 T100 02 xxxxx ...

Page 2: ... www union instruments com 2013 This documentation is copyrighted The engendered rights are retained in particular the rights to translation reprinting taking pictures radio transmission reproduction by photomechanical or similar methods and storage in data processing systems including excerpts The right to technical changes is retained ...

Page 3: ...Dimensions 3 ...

Page 4: ...inearity error in relation to full scale value 2 MV linearity error in relation to measured value 3 Applies for one measuring point only during continuous measurement 4 0 100 Vol 1 FS 1 0 100 Vol 1 FS 1 µPulse 0 10000 ppm 3 ppm 25ppm 15 MV 25 ppm electrochemical discontinuous discontinuous discontinuous 0 25 Vol 3 MV discontinuous measurement discontinuous discontinuous discontinuous ...

Page 5: ...ic configurable between one hour and up to several weeks Duration of calibration 10 minutes recommended by the manufacturer Gas consumption 5 l calibration Power supply Voltage 100 240 V 50 60 Hz Power consumption 250 VA max Protection class I Degree of protection IP20 Interfaces Relay 3 Dig interface RS232 Field bus Optional relay Remote control unit Sample gas cooler Cooling principle thermoelec...

Page 6: ...Weight Weight up to 30 kg ATTENTION When using the process gas analyser in other ambient conditions consult UNION Instruments GmbH for additional measures 6 ...

Page 7: ...1 Transport 21 5 2 Ambient conditions 22 5 2 1 Storage conditions 22 5 3 Set up and connection 22 5 4 Setup site 22 5 4 1 Wall attachment 23 5 4 2 Process gas 24 5 4 3 Electrical connection 25 5 4 4 Electrical interfaces 25 5 4 5 Operator safety precautions 32 5 5 Startup after setup 32 5 6 Documentation 32 6 Startup switching on 33 7 Description of the workplaces operating elements 35 7 1 Workpla...

Page 8: ... 52 11 Troubleshooting 55 11 1 Preparations 55 11 2 Changing replacing fuses 56 11 3 Messages malfunctions on the display 56 11 3 1 Display of messages malfunctions 56 11 3 2 Visualizing the error list 56 11 3 3 Troubleshooting list 56 12 Service 57 13 Associated documents 59 14 Disposal 61 15 Spare parts 63 16 Annex 64 Index 64 Table of figures 65 8 ...

Page 9: ...il 1 Allgemeine Anforderungen Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements DIN EN ISO 12100 2011 Sicherheit von Maschinen Allgemeine Gestaltungsleitsätze Risikobeurteilung und Risikominderung Safety of machinery General principles for design Risk assessment and risk reduction DIN EN 61326 1 2006 Elektrische Mess Steuer Regel un...

Page 10: ...EC Declaration of Conformity 10 ...

Page 11: ...ger that can lead to serious physical injury or death WARNING Potentially hazardous situations that can lead to serious injury or death ATTENTION Potentially hazardous situations that can lead to minor physical injury This can also be used for property damage NOTE Denotes information that can make it easier to handle the process gas analyser or help prevent property damage 11 ...

Page 12: ...ny other use is considered improper The manufacturer is not liable for the resulting damage the associated risk is borne by the installer fitter operator or user Only certified professionals may alter the process gas analyser mechanical electrical or pneumatic modifications WARNING Proper use includes following these operating instructions In addition to the following safety notes always follow th...

Page 13: ...on all gas conducting parts must be checked for leaks according to national regulations All repairs that require the protective covering to be opened may only be performed by trained personnel Sensors can contain sulphuric acid This may leak in case of improper use Protect from contact with skin and eyes 2 5 Regular operator training NOTE Country specific regulations about regular user training by...

Page 14: ...yser Technical developments can give rise to deviations from these operating instructions If you require additional information or if particular problems arise that are not fully addressed in this manual please contact the following address Union Instruments GmbH Zeppelinstrasse 42 76185 Karlsruhe Germany 49 0 721 680381 0 49 0 721 680381 26 support union instruments com http www union instruments...

Page 15: ...plarisch 3 2 Safety equipment 3 2 1 Door not electronically queried Door of the process gas analyser 3 2 2 Ventilator monitoring If the housing fan fails the process gas analyser is de energized The power supply unit and fan monitor control still have power 15 ...

Page 16: ...Safety equipment 3 3 Markings and warnings Fig 3 2 Markings and warnings 1 Type plate Fig 3 3 Warning in housing 1 16 ...

Page 17: ...display inlet on off 4 Input gas cooler 13 Operating element 5 Intake air filter 14 Output process gas 6 Input calibration gas 15 Output pressure regulator leakage 7 Input purge gas 16 Cable bushings 8 Condensate pump connection 17 Fan 9 Input process gas NOTE Up to 4 process gas lines can be connected 17 2 4 3 6 14 15 16 13 7 10 12 8 5 11 1 9 17 ...

Page 18: ...int Diameter of outgoing line at ball valve 6 mm The process gas line must not overcome larger height differences Install the lines to the process gas analyser frost free WARNUNG Closing ball valves If the process gas analyser is switched off or after a failure of the power supply ball valves are without power supply Valves must be closed manually Observe the operating instructions of the ball val...

Page 19: ...e of non approved accessories can cause defects and be hazardous This will render the warranty null and void The operator is then liable for any damage that may occur Only use original accessories or accessories that have been approved by Union Instruments GmbH 19 ...

Page 20: ...Connections 20 ...

Page 21: ...ervice 5 1 Transport WARNING Possible injury from the process gas analyser tipping over or falling from pallets and load carrying equipment At least two persons are required to unpack and transport the analyser for weight see technical data Check the load bearing capacity and condition of the slinging equipment and carefully attach it Never stand under suspended loads NOTE In case of damage during...

Page 22: ...ainst frost when putting it into storage Ambient temperature 15 60 C Humidity 0 95 relative humidity Ambient pressure 700 1400 hPa 0 7 1 4 bar 5 3 Set up and connection 5 4 Setup site The setup site for the process gas analyser must satisfy the following conditions Clean dry room with the exception of INCA5000 INCA6000 No direct exposure to sun Protect from climate influences with a heater or air ...

Page 23: ... intended for wall installation The wall brackets are permanently attached to the housing The wall on which the process gas analyser is to be installed needs to be sufficiently stable to bear its weight Attach process gas analyser to brackets Fig 5 1 Wall attachment 500 mm 19 69 23 ...

Page 24: ...ticker on the process gas analyser Each connection needs to be carefully checked for leaks If there are any leaks the system will draw air and the measurements will be incorrect Do not use sealing compound to seal the gas connections as this can lead to inaccurate measurements Use PTFE sealing tape Only use suitable pipes Use a separate line to drain off the condensate ATTENTION The process gas mu...

Page 25: ...n opened the parts identified by the adjacent symbol may still be live even when the master switch has been turned off If necessary disconnect the process gas analyser from the power supply 5 4 4 Electrical interfaces WARNING Untrained personnel starting the process gas analyser may endanger people and equipment Only trained service technicians may start up the analyser NOTE Only operate relay wit...

Page 26: ... and acceptance Power Supply Connections Fig 5 2 Power Supply X2 with fuses 1 Power supply connections Connect the process gas analyser to the power supply in accordance with national regulations via L1 N and PE 1 26 ...

Page 27: ...nsport setup and acceptance Electrical Interfaces Fig 5 3 Electrical interfaces Item No Designation 1 Relay X10A Fig 5 4 and 5 5 2 Analogue outputs X11A optional 5 6 3 Profibus module X12 optional 3 2 1 27 ...

Page 28: ...1 Operation 2 Relay K2 Failure inverted 3 Relay K3 OFF Fig 5 5 Relay X10A terminal assignment left middle normally closed right middle normally open NOTE Only operate relay with functional extra low voltage Do not connect to the power supply Maximum load of the relay connections 30VDC 1A Kn NC Kn COM Kn NO 28 ...

Page 29: ...t 2 signal signal 4 20 mA 6 Output 6 signal signal 4 20 mA 2 GND 6 GND 3 Output 3 signal signal 4 20 mA 7 Output 7 signal signal 4 20 mA 3 GND 7 GND 4 Output 4 signal signal 4 20 mA 8 Output 8 signal signal 4 20 mA 4 GND 8 GND With optional equipment with analogue outputs assignment is as follows Item No Measuring Point Channel No Measurand Source Unit Type Range from Range to 1 2 3 4 5 6 7 8 The ...

Page 30: ...Ethernet active from top to bottom 8 Micro USB local connection to PC if used no connection via Ethernet Fieldbus Communication module for integration into Ethernet networks to communicate and operate the process gas analyser DHCP is enabled as factory setting RCM received IP address automatically from a DHCP server Manual assignment of IP address with separate software example DeviceInstaller Lan...

Page 31: ...l valves are established from the left with the first relay channel 1 to the right channel 2 to channel 4 The first two terminals of each relay are assigned in each case Pos No X13A Channel cable of ball valve 1 1 red 2 black 3 4 2 red 5 black 6 7 3 red 8 black 9 10 4 red 11 black 12 Maximum load of the relay connections 30VDC 1A 31 ...

Page 32: ...e environment Identify the exit point of the diverted gas with a warning Danger of tripping due to improperly installed supply lines Install the supply lines in a suitable manner 5 5 Startup after setup WARNING Untrained personnel starting the process gas analyser may endanger people and equipment Only trained service technicians may start up the analyser 5 6 Documentation NOTE Union Instruments G...

Page 33: ...e requirements X X Check that the process gas analyser has been fastened securely X Check that the device is suitable for the process gas X Check that the process gas is correct X Check that the gas connections are correct and tight X X Check the integrated filters water fine filter for condensate if necessary X X Check if necessary that the calibration gas is correct X X Establish switch on the o...

Page 34: ...Startup switching on 34 ...

Page 35: ...es operating elements NOTE This chapter only discusses the elements used by normal operators to operate the process gas analyser 7 1 Workplaces Fig 7 1 Workplaces Item No Designation Function Activity 1 Display Display status 1 35 ...

Page 36: ...Description of the workplaces operating elements 36 ...

Page 37: ...8 Operation WARNING Danger of injury Only use the process gas analyser when all lines have been installed and checked for leaks according to national regulations 37 ...

Page 38: ...membrane keypad may be damaged if you use other objects to operate it apart from your fingers MEASURING 4 57 Channel 1 3 07 22 2009 14 42 21 Fig 8 1 Operating elements Item No Designation Function 1 Measurement display Display the current sensor measurements 2 Measuring channel display Display the current channel measurements 3 Saved measured values Switch between the last 10 saved measured values...

Page 39: ...Bottom display area Switch between various measured values with the arrow keys 8 2 Available displays NOTE The available displays and corresponding functions are described below The navigation path to the displays is indicated by the menu and function keys in the chapter headings The control system is based on the structure shown below 1 2 39 ...

Page 40: ...put data Screen change Parameter ABC built in EC meas Cycle1 Purge time1 Commands Start measurement Stop measurement Restart System Clear messages Calib purge gas Calib gas 1 Calib gas 21 Reset cal data Test gas 1 Abort calib Check OK System info Version firmware System messages The menu structure refers to firmware version V1 08 1 only available for certain device configurations 40 ...

Page 41: ...itch between the measurements by pressing the left and right keys The asterisk indicates that a saved value is being displayed The values are updated in the display depending on the measuring status With continuous measurement an asterisk is not displayed since the value is measured and updated continuously 41 ...

Page 42: ...ber of saved errors MSGS shows the number of saved messages pLuft and pGas are the differential pressures measured for the individual gas pathways air and process gas in the process gas analyser T_IR is the current temperature of the infrared measuring unit TCool is the current temperature of the gas cooler TCase is the current temperature in the housing Tout is the current ambient temperature 42 ...

Page 43: ...Operation 8 2 4 Navigation with ESC and MENU With the MENU key to the main menu 1 2 4 56 7 0 8 9 Confirm the selection by pressing the MENU key Press the ESC key in the menu to go one level higher 43 ...

Page 44: ...erisk indicates that a saved value is being displayed The values are updated in the display depending on the measuring status With continuous measurement an asterisk is not displayed since the value is measured and updated continuously 8 2 6 Measuring channel display 0 8 9 select the individual channels 44 ...

Page 45: ...gure shows the display during the warm up phase In the figure the infrared electronics T IR have reached operating temperature Depending on the type of sensor this is 49 C or 64 C The Parox sensor T POX is not ready Once it reaches its operating temperature the display shows T POX 0x0000 and OK Devices with sensors that do not require a specific operating temperature start without a warm up phase ...

Page 46: ...Operation 8 2 9 Select language 1 2 4 2 7 0 keys Confirm the selection by pressing the MENU key Available languages German English Italian and Spanish 46 ...

Page 47: ...8 2 10 Password ATTENTION The password has a maximum of four characters If you forget the password you cannot change the configuration Enter the password using 0 8 9 Confirm the entry by pressing the MENU key 47 ...

Page 48: ...Operation 48 ...

Page 49: ... Switch off column Steps Turn off Decommi ssioning Disconnect the device from the process close the line professionally X X Rinse the process gas analyser with ambient air Start calibration with purge gas X Shut down the linked system components X X Turn of the master switch X X If you only wish to switch off the process gas analyser temporarily follow the procedure here to the end If required dis...

Page 50: ...Decommissioning switching off 50 ...

Page 51: ...be live even when the main switch has been switched off If necessary disconnect the process gas analyser from the power supply Switch off the main fuse and if necessary secure it to prevent it from switched back on Only a trained electrician may work on the electrical equipment of the process gas analyser WARNING Serious risk of injury from exiting gas Switch off the process gas analyser and also ...

Page 52: ...n case of frost weekly Quarterly inspection Calibrate device according to manufacturer s specifications message in display Service Typ ZERO Service Typ SPAN Service Typ MID every 3 months latest annually or when required Half yearly inspection Check integrated filter in the device every 6 months Check compressed air supply1 negative pressure during drainage every 6 months Check lines for condensat...

Page 53: ...very 6 months Annual service Replace integrated filters every 12 months 2 yearly service Replace pump hoses every 24 months Replace flame arrester1 every 24 months 8 yearly service Replace integrated pressure reducer every 8 years If necessary Replace gas delivering pumps if necessary Replace sensor lifetime depends on sensor type message in display Service Typ age or Service Typ usage if necessar...

Page 54: ...Maintenance 54 ...

Page 55: ... resumed they need to be reopened WARNING Serious risk of injury from electricity and exiting gas Switch off the process gas analyser and also linked system components if required before carrying out maintenance work Switch off the main fuse and if necessary secure it to prevent it from switched back on Only a trained electrician may work on the electrical equipment of the process gas analyser Par...

Page 56: ...errors and messages that are visually displayed Troubleshooting measures Troubleshooting list Measures required are assigned via column no Error text Error message No 0x30D Minimum pump pressure not reached Sensor EC Pressure Air 1 0x30E Minimum pump pressure not reached Sensor EC Pressure Gas 2 Additional All additional 3 11 3 3 Troubleshooting list The following list contains causes of faults No...

Page 57: ...se have the customer number telephone number for return calls the type and number of the process gas analyser see the type plate and the required spare parts and parts list numbers to hand Union Instruments GmbH Service Alfstraße 28 23552 Lübeck Germany 49 0 721 680381 30 support union instruments com http www union instruments com 57 ...

Page 58: ...Service 58 ...

Page 59: ...13 Associated documents Declaration of Conformity for flame arrester 1 Operating and service log Service documentation optional Operating Instructions Ball Valves 1 if installed 59 ...

Page 60: ...Associated documents 60 ...

Page 61: ...gas analyser WARNING Serious risk of injury from electricity and exiting gas in the process gas analyser Before disassembly disconnect the process gas analyser from the energy supply If necessary purge the gases NOTE Observe the national regulations on disposing of machines and operating materials Grade the parts according to group and recycle properly 61 ...

Page 62: ...Disposal 62 ...

Page 63: ...that occurs as a result When replacing standard components only use identical components by the original manufacturer If components are discontinued or components by different manufacturers are used request the manufacturer approval by Union Instruments GmbH Spare parts can be ordered from Union Instruments GmbH Chapter 12 Service Note the type and number type plate of the process gas analyser If ...

Page 64: ...ntenance work 52 Measurement display 44 Measuring channel display 44 N Navigation with arrow keys 41 42 Navigation with ESC and MENU 43 O Operating elements 35 Operation 37 Membrane keypad 38 with arrow keys 41 42 with ESC and MENU 43 P Password 47 Personnel and qualifications 12 Process gas 24 Proper use 12 S Safety equipment 15 Safety notes 11 13 Saved measured values 45 Select language 46 Servi...

Page 65: ...all valve 18 Fig 5 1 Wall attachment 23 Fig 5 2 Power Supply X2 with fuses 26 Fig 5 3 Electrical interfaces 27 Fig 5 4 Relay X10A outputs K1 K3 28 Fig 5 5 Relay X10A terminal assignment 28 Fig 5 6 Analogue outputs X11A connections 29 Fig 5 7 Remote Control Unit RCM X15 30 Fig 5 8 Relay X13A Connections ball valves 31 Fig 7 1 Workplaces 35 Fig 8 1 Operating elements 38 Fig 8 2 Display area 39 65 ...

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