Union INCA1021 User Manual Download

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Apr-2016 V1.10

Translation of the original operating

instructions

Process gas analyser

INCA1021

Summary of Contents for INCA1021

Page 1: ...Apr 2016 V1 10 Translation of the original operating instructions Process gas analyser INCA1021 ...

Page 2: ... instruments com Item No 08608199967 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: ... 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 100 VA max Protection class I Degree of protection IP40 Interfaces Relay 3 Dig interface RS232 Field bus optional Optional relay optional Remote Control Unit optional Ambient conditions Operating temperature 5 45 ...

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

Page 7: ...ns 20 5 3 Installing and connecting 20 5 4 Setup site 20 5 4 1 Wall attachment 21 5 4 2 Process gas 22 5 4 3 Electrical connection 23 5 4 4 Electrical interfaces 23 5 4 5 Operator safety precautions 28 5 5 Startup after setup 28 5 6 Documentation 28 6 Startup switching on 29 7 Description of the workplaces operating elements 31 7 1 Workplaces 31 8 Operation 33 8 1 Description of display 34 8 1 1 U...

Page 8: ... 51 11 2 Changing replacing fuses 52 11 3 Messages malfunctions on the display 52 11 3 1 Display of messages malfunctions 52 11 3 2 Visualizing the error list 52 11 3 3 Troubleshooting list 52 12 Service 53 13 Associated documents 55 14 Disposal 57 15 Spare parts 59 16 Annex 61 EU Declaration of Conformity Flame arrester 62 Index 64 List of figures 65 ...

Page 9: ...imits 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 ...

Page 10: ...EU 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: ...r 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 notes always follow...

Page 13: ...tion 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: ...Door not electronically queried Door of the process gas analyser 3 1 2 Ventilator monitoring In cases of failure of the housing ventilator the process gas analyser is switched currentless The power supply unit and fan monitor control still have power ...

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

Page 17: ...ation gas 2 7 Operating element 3 Input calibration gas 1 8 Power supply on off switch fuse holder 4 not assigned locked 9 Power supply cable bushing 5 Input purge gas 10 Fan NOTE The gas connection position 4 is used for device internal purposes Do not open or use this connection 10 4 9 7 5 6 8 3 2 1 ...

Page 18: ... 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 19: ...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 20: ...er from frost during storage Ambient temperature 20 60 C Humidity 0 95 relative humidity Ambient pressure 700 1400 hPa 0 7 1 4 bar 5 3 Installing and connecting 5 4 Setup site The place of installation of the process gas analyser must meet the following requirements Clean dry room except INCA5000 INCA6000 OUTDOOR No direct exposure to sun Protect from climate influences with a heater or air condit...

Page 21: ...lyser is designed for wall mounting 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 Mount the process gas analyser by the brackets Fig 5 1 Wall attachment ...

Page 22: ...on 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 Sealing compound can distort measurements Use PTFE sealing tape Only use suitable pipes Use a separate line to drain off the condensate ATTENTION The process gas ...

Page 23: ...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 mains 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 w...

Page 24: ...Transport setup and acceptance 24 Fig 5 2 Electrical interfaces Item No Designation 1 Relay X10A Fig 5 3 and 5 4 2 Analogue outputs X11A optional 5 5 3 Profibus module X12 optional 3 2 1 ...

Page 25: ...n Function Relay K1 INCA operation Relay K2 INCA failure inverted Relay K3 OFF Fig 5 4 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 Kn NC Kn COM Kn NO ...

Page 26: ...utput 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 by factory as follows Assignment of analog interface configurable with Software INCACtrl The load resistor is...

Page 27: ...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 28: ...o a safe environment Identify the exit point of the diverted gas with a warning Danger of stumbling over improperly laid 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 ...

Page 29: ... 5 meet 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 switc...

Page 30: ...Startup switching on 30 NOTE For first stating or starting up after a long downtime ensure the device configuration Checks by service technicians or according to the separate service instructions ...

Page 31: ...erating 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 with status LED Display status 1 ...

Page 32: ...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 33: ...33 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 34: ...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 35: ... 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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ... 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 42: ...Operation 42 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 43: ...3 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 44: ...Operation 44 ...

Page 45: ...ted Column Switch off 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 46: ...Decommissioning switching off 46 ...

Page 47: ...even when the main switch has been switched off If necessary disconnect the process gas analyser from the power mains Turn off main switch disconnect from power supply if necessary and secure against connecting turning on again 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 analy...

Page 48: ...ticularly 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 fo...

Page 49: ...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 50: ...Maintenance 50 ...

Page 51: ...sumed 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 Turn off main switch disconnect from power supply if necessary and secure against connecting turning on again Only a trained electrician may work on the electrical equipment of the proce...

Page 52: ...d 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 Primary pressure too low The following list contains cau...

Page 53: ...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 54: ...Service 54 ...

Page 55: ...55 13 Associated documents Declaration of conformity for the flame arrester1 Operating and service log Service documentation optional 1 if installed ...

Page 56: ...Associated documents 56 ...

Page 57: ... of by UNION Instruments GmbH WARNING Risk of injury from electricity and gas in the process gas analyser Before disassembly disconnect process gas analyser from the energy supplies If necessary purge the gases NOTE Observe the national regulations on disposing machines and operating materials Sort the parts according to group and recycle properly ...

Page 58: ...Disposal 58 ...

Page 59: ...incurring damage 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 Write down type and number of the process gas analyser Type plate If neces...

Page 60: ...Spare parts 60 ...

Page 61: ...61 16 Annex ...

Page 62: ...Annex 62 EU Declaration of Conformity Flame arrester ...

Page 63: ...Annex 63 ...

Page 64: ...holder 17 I Inspection 48 L load resistor 26 M Maintenance 47 Maintenance work 48 Measurement display 40 Measuring channel display 40 N Navigation with arrow keys 38 Navigation with ESC and MENU 39 O Operating elements 31 Operation 33 Membrane keypad 34 with arrow keys 37 38 with ESC and MENU 39 P Password 43 Personnel and qualifications 12 Process gas 22 Proper use 12 S Safety equipment 15 Safety...

Page 65: ...7 Fig 5 1 Wall attachment 21 Fig 5 2 Electrical interfaces 24 Fig 5 3 Relay X10A outputs K1 K3 25 Fig 5 4 Relay X10A terminal assignment 25 Fig 5 5 Analogue output X11A connections 26 Fig 5 6 Remote Control Unit RCM X15 27 Fig 7 1 Workplaces 31 Fig 7 2 Status LED 32 Fig 8 1 Operating elements 34 Fig 8 2 Display area 35 ...

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Union INCA1021, Translation Of The Original Operating Instructions

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