Union Instruments INCA6004 Translation Of The Original Operating Instructions Download | Manualshive

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Summary of Contents for INCA6004

Page 1: ...Apr 2016 V1 10 Translation of the original operating instructions Process gas analyser INCA6004 ...

Page 2: ... instruments com Item No 08608199938 2016 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: ...3 Dimensions ...

Page 4: ...easuring accuracy Refer to type plate on device also attached data and information Example of Measuring ranges on type plate Fig 1 1 Type plate exemplary 1 Device description 2 Technical Information 3 Measurement ranges 2 3 1 ...

Page 5: ...nual or automatic 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 max 1500 VA with optional second heater Protection class I Degree of protection IP54 Interfaces Relay 3 Dig interface RS232 Field bus optional Optional relay optional Remo...

Page 6: ...t Weight up to 100 kg ATTENTION When using the process gas analyser outside of normal ambient conditions coordinate additional measures air conditioning of the process analyser etc with Union Instruments GmbH ...

Page 7: ...age conditions 21 5 3 Set up and connection 21 5 4 Setup site 21 5 4 1 Wall attachment 22 5 4 2 Process gas 23 5 4 3 Electrical connection 24 5 4 4 Electrical interfaces 24 5 4 5 Operator safety precautions 30 5 5 Startup after setup 30 5 6 Documentation 30 6 Startup switching on 31 7 Description of the workplaces operating elements 33 7 1 Workplaces 33 8 Operation 35 8 1 Description of display 36...

Page 8: ...53 11 2 Changing replacing fuses 54 11 3 Messages malfunctions on the display 54 11 3 1 Display of messages malfunctions 54 11 3 2 Visualizing the error list 54 11 3 3 Troubleshooting list 54 12 Service 55 13 Associated documents 57 14 Disposal 59 15 Spare parts 61 16 Annex 63 EU Declaration of Conformity Flame arrester 64 Index 66 Table of figures 67 ...

Page 9: ...mits Angewandte harmonisierte Normen Used harmonized standards EN 61010 1 2010 Sicherheitsbestimmungen für elektrische Mess Steuer Regel und Laborgeräte Teil 1 Allgemeine Anforderungen Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements EN 61326 1 2013 Elektrische Mess Steuer Regel und Laborgeräte EMV Anforderungen Teil 1 Allgemeine A...

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

Page 11: ...danger 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 ...

Page 12: ...to direct sunlight Any 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 no...

Page 13: ...ation 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...

Page 14: ...nalyser 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 33 support union instruments com http www union instrume...

Page 15: ...h example 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 ...

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

Page 17: ...17 4 Connections Fig 4 1 Product description 1 Connections see Fig 4 2 2 Display 3 Door lock lockable 4 Master switch NOTE Up to 4 process gas lines can be connected 4 1 2 3 ...

Page 18: ... Input Calibration gas 1 8 Input Process gas 4 3 Input Process gas 1 9 Input Calibration gas 2 4 Input Process gas 2 10 Output Condensate 5 Lead throughs for power supply 11 Output Condensate pressure regulator 6 Input Ambient air 12 Input Compressed air 5 1 6 7 8 12 10 9 11 2 3 4 ...

Page 19: ... Use 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 ...

Page 20: ...2 Service 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 dur...

Page 21: ...defects Protect the process gas analyser against frost when putting it into storage Ambient temperature 20 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 Insure a c...

Page 22: ...alyser is 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 ...

Page 23: ...n sticker 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...

Page 24: ...been 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 ...

Page 25: ...5 Power Supply Connections Fig 5 2 Power supply X4 connections 1 Relay and analogue outputs 2 Power supply connections X4 Connect the process gas analyser to the power supply in accordance with national regulations via L1 N and PE 1 2 ...

Page 26: ...ctrical connections Fig 5 3 Electrical connections 1 Relay X10 2 Profibus Depending on the type and equipment used these are attached to the top hat rail NOTE Current assignment depends on the configuration see attached wiring diagram 2 1 ...

Page 27: ...1 K3 12 32 52 Relay output assignment of terminal blocks Fig 5 4 Terminal block X10 Relay outputs Number optional at least 3 contacts Fig 5 5 Relay 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 ...

Page 28: ...1 Output 2 signal signal 4 20 mA 15 Output 6 signal signal 4 20 mA 31 2 GND 35 6 GND 12 Output 3 signal signal 4 20 mA 16 Output 7 signal signal 4 20 mA 32 3 GND 36 7 GND 13 Output 4 signal signal 4 20 mA 17 Output 8 signal signal 4 20 mA 33 4 GND 37 8 GND With optional equipment with analogue outputs assignment is by factory as follows Assignment of analog interface configurable with Software INC...

Page 29: ... 3 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 ...

Page 30: ...safe 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 Instrument...

Page 31: ... the 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 th...

Page 32: ...Startup switching on 32 ...

Page 33: ... 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 with status LED Display status 2 Main switch Switch on device 1 2 ...

Page 34: ...tates are displayed through those LEDs LED Operation Output state Description flashing Device functionality OK even Service might be pending flashing Device functionality is affected by errors Service message pending flashing Device stopped by fatal error Error pending Fig 7 2 Status LED ...

Page 35: ...35 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 ...

Page 36: ...may be damaged if you use other objects to operate it apart from your fingers 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 4 Display Display values times and measurement results 5 Menu ...

Page 37: ... 2 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 ...

Page 38: ...Output 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 ...

Page 39: ...ctive Switch 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 ...

Page 40: ...splay other data Err displays the number 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 i...

Page 41: ...8 2 4 Navigation with ESC and MENU With the MENU key to the main menu Select the submenu with the up and down keys Confirm the selection by pressing the MENU key Press the ESC key in the menu to go one level higher ...

Page 42: ...ndicates 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 Use the up or down keys to select the individual channels ...

Page 43: ... figure 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 pha...

Page 44: ...Operation 44 8 2 9 Select language Select the language with the keys Confirm the selection by pressing the MENU key Available languages German English Italian and Spanish ...

Page 45: ...5 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 the keys Confirm the entry by pressing the MENU key ...

Page 46: ...Operation 46 ...

Page 47: ...ted 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 ...

Page 48: ...Decommissioning switching off 48 ...

Page 49: ...ll 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 al...

Page 50: ...y in 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 conden...

Page 51: ...l every 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 neces...

Page 52: ...Maintenance 52 ...

Page 53: ...been 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...

Page 54: ...ns 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...

Page 55: ...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 Maria Goeppert Straße 22 23562 Lübeck Germany 49 0 721 680381 30 support union instruments com http www union instruments com ...

Page 56: ...Service 56 ...

Page 57: ...57 13 Associated documents Declaration of Conformity for flame arrester 1 Operating and service log Service documentation optional Operating Instructions Ball Valves 1 if installed ...

Page 58: ...Associated documents 58 ...

Page 59: ...ss 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 ...

Page 60: ...Disposal 60 ...

Page 61: ...ge 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 ...

Page 62: ...Spare parts 62 ...

Page 63: ...63 16 Annex ...

Page 64: ...Annex 64 EU Declaration of Conformity Flame arrester ...

Page 65: ...Annex 65 ...

Page 66: ... 15 Maintenance 49 Maintenance work 50 Measurement display 42 Measuring channel display 42 N Navigation with arrow keys 39 40 Navigation with ESC and MENU 41 O Operating elements 33 Operation 35 Membrane keypad 36 with arrow keys 39 40 with ESC and MENU 41 P Password 45 Personnel and qualifications 12 Process gas 23 Proper use 12 S Safety equipment 15 Safety notes 11 13 Saved measured values 43 Se...

Page 67: ...g 5 1 Wall attachment 22 Fig 5 2 Power supply X4 connections 25 Fig 5 3 Electrical connections 26 Fig 5 4 Terminal block X10 Relay outputs Number optional at least 3 contacts 27 Fig 5 5 Relay terminal assignment 27 Fig 5 6 Terminal block X11 Analogue outputs Number optional 28 Fig 5 7 Remote Control Unit RCM X15 29 Fig 7 1 Workplaces 33 Fig 7 2 Status LED 34 Fig 8 1 Operating elements 36 Fig 8 2 D...

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