Union INCA4004 Translation Of The Original Operating Instructions Download

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Apr-2016 V1.10

Translation of the original operating

instructions

Process gas analyser

INCA4004

Summary of Contents for INCA4004

Page 1: ...Apr 2016 V1 10 Translation of the original operating instructions Process gas analyser INCA4004 ...

Page 2: ... instruments com Item No 08608199951 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: ...4 ...

Page 5: ...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 6: ...y wet 100 condensate possible Condensate trap yes Calibration gas Calibration interval manual 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 250 VA max Protection class I Degree of protection IP20 external fusing 16A delay ...

Page 7: ...humidity Ambient pressure 900 1250 hPa 0 9 1 2 bar Storage temperature 20 60 C Weight Weight up to 30 kg ATTENTION When using the INCA outside of normal ambient conditions coordinate additional measures air conditioning of the process analyser etc with Union Instruments GmbH ...

Page 8: ...8 ...

Page 9: ...ions 22 5 3 Installing and connecting 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 Safety precautions by the operator 31 5 5 Startup after setup 31 5 6 Documentation 31 6 Startup switching on 33 7 Description of the workplaces operating elements 35 7 1 Working areas 35 8 Operation 37 8 1 Description of displa...

Page 10: ... 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 List for troubleshooting 56 12 Service 57 13 Accompanying documents 59 14 Disposal 61 15 Spare parts 63 16 Annex 65 EU Declaration of Conformity Flame arrester 66 Index 68 List of figures 69 ...

Page 11: ...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 12: ...EU Declaration of Conformity 12 ...

Page 13: ...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 14: ...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 t...

Page 15: ...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 16: ...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 17: ... 2 Housing fan and fan monitoring Housing fan rinses housing with ambient air If the housing fan fails the process gas analyser is de energized The power supply unit and fan monitor control still have power WARNING Insufficient rinsing Cleaning and maintenance of the filter mat of the supply filter should be done according to maintenance instructions See 10 2 ...

Page 18: ...Safety equipment 18 3 3 Markings and warnings Fig 3 2 Markings and warnings 1 Type plate Fig 3 3 Warning note in housing 1 ...

Page 19: ...enoid valve display on off 5 Intake air filter 13 Operating element 6 Input process gas dry quantity optional 14 Output process gas 15 Output pressure regulator leakage 7 Input calibration gas 16 Cable bushings 8 Hose pump 17 Fan NOTE Up to 6 sampling points can be connected 1 sampling point for condensate containing gas up to 5 sampling points for dry gas 17 2 4 3 6 14 15 16 13 9 8 12 5 11 1 7 10...

Page 20: ...defect Use of non approved accessories can cause defects and be hazardous This will render the warranty null and void The operator is liable for incurring damage Only use original accessories or accessories that have been approved by Union Instruments GmbH ...

Page 21: ...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 transport ...

Page 22: ...ost 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 with the exception of INCA5000 INCA6000 No direct exposure to sun Protect from climate influences with a heater or air condition...

Page 23: ...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 24: ...aw 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 must be free of condensate and dust if the process gas analyser has no gas preparation system or gas cooler ATTENTION Device damage meas...

Page 25: ...t guidelines When the process gas analyser has 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 ...

Page 26: ...port setup and acceptance 26 Fig 5 2 Voltage supply X2 with fuses 1 Connection of power supply Connect the process gas analyser via terminals L1 N PE to the voltage supply according to national regulations 1 ...

Page 27: ... Electrical interfaces Fig 5 3 Electrical interfaces Item No Designation 1 Relay X10A Fig 5 4 and 5 5 2 Analogue outputs X11A optional Fig 5 6 3 Remote maintenance module RCM X15 optional Fig 5 7 4 Profibus module X12 optional 3 2 1 4 ...

Page 28: ...NCA operation Relay K2 INCA failure inverted Relay K3 OFF 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 29: ...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 30: ...ED 3 Ethernet active from top to bottom 8 Micro USB local connection to PC if no active Ethernet field bus communication possible Communication module for integration into Ethernet networks for communication with and operation of the device Off works DHCP function activated RCM obtains IP address automatically via a DHCP server Manual assignment of IP address with separate software example DeviceI...

Page 31: ...nto 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 Instrument...

Page 32: ...Transport setup and acceptance 32 ...

Page 33: ...apter on page 6 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 water filter for condensate if necessary X X Check if necessary that the calibration gas is correct X X Establish switch on the op...

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

Page 35: ...rating elements NOTE This chapter only discusses the elements used by normal operators to operate the process gas analyser 7 1 Working areas Fig 7 1 Workplaces Item No Designation Function activity 1 Display with status LED Display status 1 ...

Page 36: ...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 37: ...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 ...

Page 38: ...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 39: ... 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 40: ...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 41: ...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 42: ...splay other data Err displays the number of saved errors MSGS shows the number of saved messages pAir 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...

Page 43: ...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 44: ...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 45: ... 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 46: ...Operation 46 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 47: ...7 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 48: ...Operation 48 ...

Page 49: ...umn Switch off Steps Turn off Removing from service 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 off the main 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: ...ll be live even when the main switch has been switched off If necessary disconnect the process gas analyser from the power mains 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 als...

Page 52: ... unobstructed particularly in case of frost weekly Quarterly inspection Calibrate device acc to manufacturer s specifications message on display Service Type ZERO Service Type SPAN Service Type 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 ...

Page 53: ...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 sensors service life depends on type message on display Service Type age or Service Type usage If neces...

Page 54: ...Maintenance 54 ...

Page 55: ...has 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 anal...

Page 56: ... list includes faults messages displayed in the visualization system Troubleshooting measures Troubleshooting list The required measures 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 List for troubleshooting The following list...

Page 57: ...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 23652 Lübeck Germany 49 0 721 680381 30 support union instruments com http www union instruments com ...

Page 58: ...Service 58 ...

Page 59: ...59 13 Accompanying documents Declaration of conformity for the flame arrester1 Inspection and maintenance schedule Service documentation optional 1 if installed ...

Page 60: ...Accompanying documents 60 ...

Page 61: ...d 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 62: ...Disposal 62 ...

Page 63: ...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 64: ...Spare parts 64 ...

Page 65: ...65 16 Annex ...

Page 66: ...Annex 66 EU Declaration of Conformity Flame arrester ...

Page 67: ...Annex 67 ...

Page 68: ...ection 52 L load resistor 29 M Main switch 17 Maintenance 51 Maintenance work 52 Measurement display 44 Measuring channel display 44 N Navigation with arrow keys 41 42 Navigation with ESC and MENU 43 O Operation 37 Membrane keypad 38 with arrow keys 41 42 with ESC and MENU 43 P Password 47 Personnel and qualifications 14 Process gas 24 R Removing from service 49 61 S Safety devices 17 Safety notes...

Page 69: ...escription 19 Fig 5 1 Wall attachment 23 Fig 5 2 Voltage supply X2 with fuses 26 Fig 5 3 Electrical interfaces 27 Fig 5 4 Relay X10A outputs K1 K3 28 Fig 5 5 Relay terminal assignment 28 Fig 5 6 Analogue output X11A connections 29 Fig 5 7 Remote maintenance module RCM X15 30 Fig 7 1 Workplaces 35 Fig 7 2 Status LED 36 Fig 8 1 Operating elements 38 Fig 8 2 Display area 39 ...

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