Dr.Fodisch MCA 10 HWIR User manual

Multi Component Analyser
MCA 10 HWIR
Operation Manual

Dr. Födisch Umweltmesstechnik AG
Zwenkauer Strasse 159
04420 Markranstädt
Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.foedisch.de
Version/date of operation manual: Version 3.3, 14.09.2021
© Dr. Födisch Umweltmesstechnik AG
This operation manual is not subject to the service of change. Distribution and duplication of the
operation manual and all related documents as well as use and communication of its content are
forbidden unless it has not been permitted explicitly in written way by Dr. Födisch Umweltmesstechnik
AG. Any violation obliges to compensate the loss.
All rights are reserved for the case of a registration of a patent, utility patent or design patent.

Content
Version 3.3
Operation Manual MCA 10 HWIR
3
Content
1General .......................................................................................................................................6
1.1 Information for operation manual ................................................................................................6
1.2 Intended use................................................................................................................................6
1.3 Warranty......................................................................................................................................7
1.4 Standards and regulations...........................................................................................................7
1.5 Declaration of conformity.............................................................................................................7
2Safety..........................................................................................................................................8
2.1 Safety instructions.......................................................................................................................8
2.1.1 General safety instructions..........................................................................................................8
2.1.2 Specific safety instructions..........................................................................................................9
2.1.3 Personal protective equipment..................................................................................................10
2.2 Requirements for personnel......................................................................................................11
2.3 Electrical power supply..............................................................................................................12
2.4 Gas supply.................................................................................................................................14
2.5 Components ..............................................................................................................................15
2.6 Electronic elements...................................................................................................................15
2.7 Configuration settings................................................................................................................15
3Basics.......................................................................................................................................16
3.1 Photometry ................................................................................................................................16
3.1.1 Bi-frequency measuring method ...............................................................................................17
3.1.2 Gas filter correlation ..................................................................................................................18
3.1.3 Oxygen measurement...............................................................................................................19
3.2 Compensation of measuring components.................................................................................20
4Functional description............................................................................................................21
5Design.......................................................................................................................................23
5.1 Emitter unit.................................................................................................................................24
5.2 Cuvette ......................................................................................................................................25
5.3 Detector unit..............................................................................................................................26
5.4 Gas distribution block................................................................................................................27
5.5 Pressure and flow measurement...............................................................................................27
5.6 Oxygen sensor (optional)..........................................................................................................27
5.7 Mainboard..................................................................................................................................28
5.8 Power supply unit......................................................................................................................29
5.9 Interfaces...................................................................................................................................29
5.10 Connection assignment.............................................................................................................30
5.11 System design (application example)........................................................................................31
5.11.1 Gas circuit diagram....................................................................................................................32
5.11.2 Design of CPU components......................................................................................................34
5.11.3 Signal plan.................................................................................................................................35
6Transport and scope of supply..............................................................................................36
6.1 Transport ...................................................................................................................................36
6.2 Scope of supply.........................................................................................................................36

Content
4
Operation Manual MCA 10 HWIR
Version 3.3
7Placement and mounting....................................................................................................... 37
7.1 Placement................................................................................................................................. 37
7.2 Mounting................................................................................................................................... 37
7.3 Placement and mounting of additional devices........................................................................ 37
8Commissioning....................................................................................................................... 38
8.1 Commissioning of MCA 10 HWIR............................................................................................. 38
8.2 Test gas provision..................................................................................................................... 39
8.3 Software installation.................................................................................................................. 40
9Operating................................................................................................................................. 41
9.1 Display and operating elements............................................................................................... 42
9.1.1 General screen design.............................................................................................................. 42
9.1.2 Display and operating elements within menus......................................................................... 43
9.1.3 Display “data transfer” .............................................................................................................. 45
9.2 Menu structure.......................................................................................................................... 46
9.3 Password levels........................................................................................................................ 49
9.4 Main menu................................................................................................................................ 50
9.4.1 Change language...................................................................................................................... 51
9.4.2 Input password.......................................................................................................................... 51
9.5 Measurement............................................................................................................................ 52
9.6 System control.......................................................................................................................... 54
9.7 Diagnostics ............................................................................................................................... 55
9.8 Messages.................................................................................................................................. 56
9.9 Auto calibration......................................................................................................................... 58
9.10 Calibration................................................................................................................................. 59
9.11 Configuration............................................................................................................................. 62
9.12 Service mode............................................................................................................................ 64
10 Maintenance/Upkeep.............................................................................................................. 65
10.1 Exchange injector screwing-in.................................................................................................. 66
10.2 Exchange sinter metal filter of cuvette / exchange gaskets at cuvette inlet block.................... 66
10.3 Exchange screwing-in with nozzle at gas distribution block..................................................... 67
11 Error search and failure clearance........................................................................................ 68
11.1 Service qualification of the specialised personnel.................................................................... 68
11.2 Displaying of current messages and clearing of failures.......................................................... 69
11.2.1 Messages “failure” .................................................................................................................... 70
11.2.2 Messages “maintenance” ......................................................................................................... 79
11.2.3 Messages “maint. req.”............................................................................................................. 81
11.2.4 Info message ............................................................................................................................ 88
12 Shutdown and Disposal......................................................................................................... 89
12.1 Shutdown.................................................................................................................................. 89
12.2 Disassembling........................................................................................................................... 90
12.3 Storage ..................................................................................................................................... 90
12.4 Disposal.................................................................................................................................... 90
13 Technical data......................................................................................................................... 91
13.1 Multi component analyser MCA 10 HWIR................................................................................ 91
13.2 Measuring ranges of MCA 10 HWIR ........................................................................................ 93
14 Spare and wear parts ............................................................................................................. 94

Content
Version 3.3
Operation Manual MCA 10 HWIR
5
15 System application with analyser cabinet............................................................................97
15.1 Design of analyser cabinet........................................................................................................97
15.2 Transport of analyser cabinet....................................................................................................98
15.3 Placement and Mounting...........................................................................................................99
15.3.1 Placement..................................................................................................................................99
15.3.2 Mounting..................................................................................................................................100
15.4 Commissioning........................................................................................................................101
15.5 Automatic zero point setting via “Thermocal”..........................................................................102
15.6 Test gas provision ...................................................................................................................103
15.6.1 Local test gas provision at MCA 10 HWIR..............................................................................104
15.6.2 Test gas provision via gas sample probe (optional)................................................................104
15.7 Maintenance/Upkeep...............................................................................................................106
15.8 Error search and failure clearance..........................................................................................106
15.9 Shutdown and disposal ...........................................................................................................107
15.9.1 Shutdown.................................................................................................................................107
15.9.2 Disassembling.........................................................................................................................108
15.9.3 Storage....................................................................................................................................108
15.9.4 Disposal...................................................................................................................................108
15.10 Technical data.........................................................................................................................109
15.11 Spare and wear parts..............................................................................................................110
16 Index .......................................................................................................................................112

1General
6
Operation Manual MCA 10 HWIR
Version 3.3
1 General
1.1 Information for operation manual
This operation manual contains the required information for intended use of the described
product. It is firm part of the scope of supply, also if the possibility of separated order
respectively delivery had been planned due to logistic reasons. By reasons of clarity it does
not contain all details for all types of the described product and it cannot consider each
possible case in operation with the product.
Read the operation manual completely and attentively. Observe the safety instructions and
operation directions in this operation manual as well as the labelling at the device and the
packaging. For later use keep the operation manual at a safe place.
If you should need further information or if problems should occur which are not described
elaborately in this operation manual, please refer to Dr. Födisch Umweltmesstechnik AG
(contact details: see cover inside).
For operation with the optional additional devices please read the technical documentations of
the suppliers (see appendix). The contents are at responsibility of the respective
manufacturers.
1.2 Intended use
The product described in this operation manual has been developed, manufactured, tested
and documented in observation of the corresponding safety standards and has left the factory
in safety-related correct and tested condition.
By observing the actions and safety instructions described for configuring, assembly, intended
use and upkeep, there is no danger coming up by the product itself in normal case. The
correct and safe operation presupposes furthermore the proper transport, professional
storage, placement and assembly as well as careful operating and upkeep.
The multi component analyser MCA 10 HWIR serves the continuous emission measurement
of pollutants in flue gas. It is applicable all-purpose for measurement of emissions, raw gases
or processes. As system in regulatory and operational emission measurement systems it
serves the exhaust concentration control in combustion plants with different types of fuel,
thermal waste treatment, combustion optimisation or process management control.
To keep the correct condition of the device and to achieve a proper and safe operation it must
solely be used in the way described by the manufacturer. Any kind of differing use as
described in this operation manual is regarded as non-intended use and can result in personal
or material damage.
Non-intended use results in termination of guarantee.

1General
Version 3.3
Operation Manual MCA 10 HWIR
7
1.3 Warranty
The Dr. Födisch Umweltmesstechnik AG advises that the content of this operation manual is
not part of a prior or present arrangement, commitment or legal relationship or that does not
change these. All liabilities result from the respective sales contract which also contains the
complete and solely legal warranty regulations. These contractual warranty terms are neither
extended nor limited by the contents in this operation manual.
Rebuilding and modification at the product is not permitted. Any intervention into the device as
well as any kind of non-intended use results in termination of guarantee. The manufacturer
assumes no liability at all.
1.4 Standards and regulations
As far as possible, the harmonised European standards have been applied to specification
and production of this device. If no harmonised European standards have been applied, the
standards and regulations for the Federal Republic of Germany apply.
1.5 Declaration of conformity
The multi component analyser MCA 10 HWIR has a CE label. Therewith we declare that the
device in its conception and design as well as in the execution put into circulation by us
corresponds to the fundamental safety and health requirements.
NOTICE
On request the document of conformity declaration is placed at the disposal by
Dr. Födisch Umweltmesstechnik AG (contact details: see cover inside).

2Safety
8
Operation Manual MCA 10 HWIR
Version 3.3
2 Safety
The device must solely be operated in correct condition and in strict observation of the safety
instructions.
Working at the device must solely be executed by qualified specialised personnel
(see section 2.2 “Requirements for personnel”, page 11). Personal protective equipment
according to the current legal accident prevention regulations must be worn.
Please read the safety instructions for the optional additional devices in the technical
documentations of the suppliers (see appendix). The contents are at responsibility of the
respective manufacturers.
2.1 Safety instructions
Safety instructions serve the prevention of hazards for life and health of users or upkeep
personnel respectively for avoiding material damage. In this operation manual they are
emphasised by the here defined signal terms. Furthermore, special safety instructions can be
characterised by additional symbols.
2.1.1 General safety instructions
DANGER
Notes with signal word “DANGER” indicate possible hazards which cause personal
damage in terms of death or most serious injury in case of non-observing the safety
precautions.
WARNING
Notes with signal word “WARNING” indicate possible hazards which cause personal
damage in terms of simple up to serious injury in case of non-observing the safety
precautions.
CAUTION
Notes with signal word “CAUTION” indicate possible hazards which cause material
damage in case of non-observing the safety precautions.
NOTICE
Notes with this indication describe helpful information and tips for operation with the
product and serve the avoidance of failure.

2Safety
Version 3.3
Operation Manual MCA 10 HWIR
9
2.1.2 Specific safety instructions
DANGER
Hazardous voltage!
Parts of the device can be energised with hazardous voltage.
Danger of electric shock.
Any work at the device must solely be executed by qualified personnel.
DANGER
Explosion hazard!
Personal damage in immediate surround as well as material damage at the device and
its vicinity can be caused.
The device must not be operated in potentially explosive atmosphere.
DANGER
Poisonous substances!
Poisonous gases can cause serious health damage or death.
Irritating of eyes, skin or respiratory system organs can be caused.
Exhaust of the gas output must be conducted into an exhaust system.
The correct operation of ventilation in the analyser cabinet must be assured.
WARNING
Corrosive substances!
Irritating or corrosive gases or substances can cause chemical burn of body tissue and
serious eye injury in case of contact.
In case of contact with skin or eyes the affected spots must be cleaned immediately!
Objects which have been contacted with irritating or corrosive gases or substances must
be cleaned accurately.
WARNING
Hot surface!
Several device parts can develop high temperatures.
Burn of skin can be caused!
For protection against possible injury protective gloves must be worn.

2Safety
10
Operation Manual MCA 10 HWIR
Version 3.3
2.1.3 Personal protective equipment
WEAR PROTECTIVE CLOTHING
For protection against injury at any kind of hazard protective clothing must be worn.
WEAR PROTECTIVE FOOTWEAR
For protection against possible injury protective footwear (e.g. safety shoes) must be
worn.
WEAR PROTECTIVE GLOVES
For protection against possible injury at touching of device components protective gloves
must be worn.
WEAR HEAD PROTECTION
For protection against possible injury by falling objects or bouncing hazard a head
protection must be worn.
WEAR RESPIRATORY PROTECTION
For protection against possible suffocation hazard or injury of respiratory system organs
by poisonous gases a respiratory protection must be worn.
WEAR EYE PROTECTION
For protection against possible eye irritation by corrosive gases or substances eye
protection must be worn.
WEAR HEARING PROTECTION
For protection against possible hearing impairment by high noise level hearing protection
must be worn.