Union Instruments INCA Series User manual

INCA Analyzer
Series
UNION
Instruments GmbH
INSTRUCTION MANUAL
Gas composition measurement of biogas, raw biogas,
landfill gas and bio-methane
Version: V1.01R06
Stand: 15.03.2010

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 2 of 59 PLEASE READ THIS BEFORE PROCEEDING!
PLEASE READ THIS BEFORE
PROCEEDING!
Read all instructions prior to installing, operating and servicing the instrument.
Follow all important notes and cautions marked on and supplied with the instrument.
If you do not understand any of the instructions contact your Union Instruments
GmbH representative for clarification.
Install your equipment as specified in the installation instructions with appropriate
local and national codes. Connect all products to the proper electrical and pressure
sources.
Use only qualified personnel to install, operate, software update and maintaining the
instrument to ensure proper performance.
When replacement parts are required ensure that you use only spare parts specified
by Union Instruments GmbH. Unauthorized parts and procedures can affect the
instrument‟s performance, place the operation of your process at risk and VOID
YOUR WARRANTY. Look-alike substitutions may result in fire, electrical/chemical
hazards or improper operation.
Equipment door should be closed except when maintenance is being performed by
qualified personnel to prevent electrical shock and personal injury.
The features of the instrument and the information in this document are subject to change
without notice.
For technical or other questions, please contact:
UNION Instruments GmbH
Zeppelinstr. 42
76185 Karlsruhe
Germany
[phone]
[phone]
[e-mail]
http://www.union-instruments.com

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Table of contents Page 3 of 59
TABLE OF CONTENTS
PLEASE READ THIS BEFORE PROCEEDING!................................................................... 2
Table of contents................................................................................................................... 3
1Preface........................................................................................................................... 7
1.1 Purpose................................................................................................................... 7
1.2 Technical description............................................................................................... 7
1.3 Remarks.................................................................................................................. 7
2Safety instructions.......................................................................................................... 8
3General description.......................................................................................................10
3.1 Functionality...........................................................................................................10
3.1.1 Phases of the analyzer....................................................................................10
3.1.2 Diagrams of the phase transition.....................................................................11
3.2 Sensor modules.....................................................................................................12
3.2.1 NDIR module ..................................................................................................13
3.2.2 EC and EC-µPulse module .............................................................................13
3.2.3 Paramagnetic oxygen sensor (Parox) module.................................................14
3.2.4 Specific gravity module ...................................................................................14
3.3 Communication with PC using INCACtrl.................................................................15
3.3.1 Establishing communication with INCACtrl......................................................15
3.3.2 Saving the configuration to the INCA Analyzer................................................17
4System main menu........................................................................................................19
4.1 Display keys...........................................................................................................21
4.1.1 Menu function keys .........................................................................................21
4.1.2 Measurement data keys..................................................................................22
4.2 Analyzer display during warm-up............................................................................24
4.3 Menu structure.......................................................................................................25
4.4 Settings..................................................................................................................26
4.4.1 Language........................................................................................................26
4.4.2 Password........................................................................................................26
4.4.3 Calibration purge gas (on/off)..........................................................................27
4.4.4 Output data (on/off).........................................................................................27
4.4.5 Communication...............................................................................................27
4.5 Parameters ............................................................................................................28
4.5.1 Gas cooler temperature...................................................................................28
4.5.2 EC measurement cycle...................................................................................28
4.6 Commands.............................................................................................................29
4.6.1 Change channel..............................................................................................29
4.6.2 Restart system................................................................................................29
4.6.3 Clear messages..............................................................................................29
4.6.4 Calibration purge gas......................................................................................29
4.6.5 Calibration gas I..............................................................................................29
4.6.6 Calibration gas II.............................................................................................29
4.6.7 Reset calibration .............................................................................................30
4.7 System info............................................................................................................30
4.8 System messages..................................................................................................30
5Calibration.....................................................................................................................31
5.1 Calibration..............................................................................................................31
5.1.1 Type of calibrations.........................................................................................31
5.1.2 Preparation for calibration ...............................................................................32
5.1.3 INCACtrl calibration setting .............................................................................33
5.1.4 Automatic calibration.......................................................................................37
5.1.5 Manual calibration...........................................................................................38

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 4 of 59 Table of contents
6Output option.................................................................................................................40
6.1 Auto-output implementation....................................................................................40
6.1.1 Data structure .................................................................................................40
6.1.2 Interface parameter.........................................................................................41
6.1.3 Data description..............................................................................................41
6.2 H-Bus protocol (Master-Slave) ...............................................................................44
6.2.1 Data structure .................................................................................................44
6.2.2 Commands description....................................................................................44
7Service and maintenance..............................................................................................48
7.1 Pumps....................................................................................................................49
7.1.1 Diaphragm pump unit......................................................................................49
7.1.2 Peristaltic pump...............................................................................................49
7.1.3 Ejector with valves ..........................................................................................49
7.2 Sensor modules.....................................................................................................50
7.2.1 Electrochemical sensor...................................................................................50
7.2.2 Optical sensor.................................................................................................50
7.2.3 Paramagnetic sensor ......................................................................................50
7.2.4 Specific gravity sensor ....................................................................................50
8Spare parts list..............................................................................................................51
9Appendix.......................................................................................................................53
9.1 Abbreviations .........................................................................................................53
9.2 Errors and events list..............................................................................................53
9.2.1 State machine errors.......................................................................................53
9.2.2 Communication errors.....................................................................................53
9.2.3 Errors reading from or writing to EEPROM......................................................54
9.2.4 Sensor errors ..................................................................................................55
9.2.5 Command list and task request list errors........................................................57
9.2.6 Menu errors.....................................................................................................58
9.2.7 Storage errors.................................................................................................58
9.2.8 SD card errors.................................................................................................59
9.2.9 H-Bus errors....................................................................................................59
9.2.10 Event messages (not defined as errors)..........................................................59

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Table of contents Page 5 of 59
Figures
Figure 3-1: Phase transition in standard analyzer.................................................................11
Figure 3-2: Phase transition in continuously measuring analyzer .........................................11
Figure 3-3: NDIR module......................................................................................................13
Figure 3-4: EC/EC-µPulse module .......................................................................................13
Figure 3-5: Parox module.....................................................................................................14
Figure 3-6: Specific gravity measuring cell, heated and insulated.........................................14
Figure 3-7: INCACtrl COM port settings ...............................................................................15
Figure 3-8: Establishing connection between INCACtrl and INCA Analyzer..........................16
Figure 3-9: Configuration changed .......................................................................................17
Figure 3-10: Saving the configuration...................................................................................17
Figure 3-11: Green check mark - saving configuration was successful.................................18
Figure 4-1: Display overview ................................................................................................19
Figure 4-2: Display for continuous measurement configuration ............................................20
Figure 4-3 Main menu keys..................................................................................................21
Figure 4-4 Measurement data keys......................................................................................22
Figure 4-5: Start-up display..................................................................................................24
Figure 5-1: Requirement for calibration ................................................................................32
Figure 5-2: Communication between the INCA Analyzer and PC.........................................33
Figure 5-3: INCACtrl –gas composition and calibration setting............................................33
Figure 5-4: INCACtrl - calibration gas composition...............................................................34
Figure 5-5: INCACtrl - calibration setting..............................................................................34
Figure 5-6: INCACtrl - setting of calibration points................................................................35
Figure 5-7: INCACtrl - setting of calibration duration.............................................................35
Figure 5-8: Saving the configuration to the analyzer.............................................................36
Figure 5-9: New configuration is successfully saved to the analyzer.....................................36
Figure 5-10: Calibration intervals..........................................................................................37
Figure 6-1: Data structure with a frame ................................................................................40
Figure 6-2: H-Bus data structure ..........................................................................................44

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 6 of 59 Table of contents
Tables
Table 1: Measurement phases.............................................................................................10
Table 2: List of sensor modules............................................................................................12
Table 3: Measurement keys description ...............................................................................22
Table 4: Example of calibration gases..................................................................................31
Table 5: Calibration points measured by the example of calibration gases...........................32
Table 6: Data description......................................................................................................43
Table 7: Commands description...........................................................................................47
Table 8: Maintenance work ..................................................................................................49

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Preface Page 7 of 59
1 PREFACE
1.1 Purpose
The INCA Analyzer Series are a (semi)continuous1measuring instruments to analyze gas
compositions in biogas, raw biogas, poor gas and bio-methane. With their capability to
measure gas components such as CO2, CH4, O2, H2S, H2, specific gravity and additional
calculated values, the INCA Analyzer Series can be applied in biogas plants for monitoring,
optimization and evaluation of biological processes.
1.2 Technical description
Measurement phase: discontinuous/continuous/semi-continuous
Channel: single stream/multiple stream
Autocalibration: after every purge gas phase (approx. 15 min)
Calibration interval: manually or automatically
(configurable between 1 hour to several weeks)
Calibration duration: 10 minutes (recommended)
Measurement ranges: depending on the configuration
Ambient conditions
Temperature: 10 - 40 °C
Humidity: 0 - 95 % relative humidity
Protection class: IP44
Interfaces: RS-232
3x digital output (customizable functionality)
Optional:
4x or 8x analog output 0 - 20 mA or 4 - 20 mA
Ethernet
Profibus-DP
Modbus RTU
1.3 Remarks
Content of the manual
This manual contains general information of all series of INCA Analyzer. Information
concerning specific model of INCA Analyzer are available in the manual of the series.
Further information
Manual INCA xxxx2Txxx3(e.g. Manual INCA 4000 T100)
1Continuous measurement for certain variables of certain INCA types only (see subchapter functionality)
2Model of the analyzer
3Configuration of the analyzer

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 8 of 59 Safety instructions
2 SAFETY INSTRUCTIONS
This manual should be reviewed with special attention to all the instructions and cautions
before the analyzer is out into operation
Power plug and main fuse switch
Before opening the analyzer the power plug has to be disconnected from the power supply.
After opening the analyzer the main fuse switch should be turned to OFF position during all
installation processes.
Installation
The electrical connection for the analyzer must be carried out by qualified personnel in
accordance with all applicable national codes, local regulations and the power supply voltage
listed on the rating plate.
Gas connections
Gas connections must be carried out only by qualified personnel in accordance with all
applicable national codes and local regulations.
The analyzer will work within the permissible temperature range. To meet the specifications a
cooling or heating device might be needed e.g. if the analyzer is placed into another
enclosure enough air flow must be provided in the additional casing to purge the analyzers
thermal heat and always provide fresh air, which is needed for correct measurement. The
analyzer should only be operated indoors. Humidity could affect the measurement and
eventually break the analyzer. After assembly all gas-flowing parts should be checked for
leakage.
Formation of Ex-mixtures in the device
The analyzer has been carefully leak tested during the production process. There is no
operational situation possible, at which gas could penetrate into the device. The enclosure
has two independent fans (outside fan and power supply fan) which provide 1~2 m3of air
circulation per hour. No gas is released inside the enclosure and the flow rate of the gas
pump is mechanically restricted to a maximum value of 30 l/h.
Operating and maintenance
The analyzer has left the factory in compliance with all applicable safety regulations. To
maintain this operation condition, the user must strictly follow the instructions and consider
the warnings in this manual.
Before switching on the analyzer, verify that the electrical supply voltage matches the
analyzer‟s operating voltage as described in the manual.
Substances hazardous to health may emerge from the analyzer‟s output. Please pay
attention to the safety of your operation personnel. Protective measures must be taken, if
required.

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Safety instructions Page 9 of 59
Application
The analyzer has been designed as a process gas analyzer and is not applicable for
personnel protection, area monitoring or detection of MAC or UEL limits.
All applicable safety regulations must be observed when working with toxic or flammable
gases.
Definitions
The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout
this manual.
Warning
Highlights an operation or maintenance procedure, condition, statement, etc.
If not strictly observed, could result in injury, death, or long-term health
hazards of personnel.
Caution
Highlights an operation or maintenance procedure, condition, statement, etc.
If not strictly observed, could result in injury, damage to or destruction of
analyzer or loss of effectiveness.
Note
Highlights an essential operating procedure, condition, statement, etc.

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 10 of 59 General description
3 GENERAL DESCRIPTION
The INCA Analyzer Series offers a group of gas measurement instruments to analyze gas
compositions in different applications such as the production of biogas, raw biogas, poor gas
and bio-methane. With their capability to measure gas components such as CO2, CH4, C2H6,
O2, H2S, H2, specific gravity and additional calculated values of the gas, the INCA Analyzer
Series can be applied in biogas plants for monitoring, optimization and evaluation of
biological processes.
The analyzer is designed as a modular system. It can be equipped with different sensors
selectable from a list as the analyzer is ordered. The customers are able to order a specific
INCA Analyzer with specific number, range and accuracy of the sensors. Gas conditioning
systems including gas cooler is also optional. Please see list of the available sensors.
3.1 Functionality
3.1.1 Phases of the analyzer
The measurement principle of the standard analyzer consists of four phases in an adjustable
cycle.
Phases
Description
Purge gas
Purge gas (usually air) is pumped through the system to clean out the
pipes from process gas of previous measurement and to moisturize the
electrochemical sensors to increase their lifetime.
Condensate drain
If system has a gas cooler the pump will run during that cycle to drain
the condensate from the gas cooler. For this purpose the system is
either equipped with a hose pump or an ejector using compressed air.
Change channel
The analyzer starts to run the process gas of the active channel
(maximum of 10 channels are available depending on system
configuration) through the system. This allows the pumps to build up
pressure and also for the process gas to reach the sensor before the
measurement is started.
Pressures of the pumps are checked and errors are stored if minimum
pressures are not reached.
Measurement
The sensors are exposed to the process gas and measurement is
performed. At the beginning of this cycle the pumps inside the analyzer
are calibrated. At the end of the cycle the measured values are stored in
memory.
Table 1: Measurement phases
Note
Continuous measurement analyzers do not operate in this cycle scheme.
See Figure 3-2.

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
General description Page 11 of 59
3.1.2 Diagrams of the phase transition
Figure 3-1: Phase transition in standard analyzer
Figure 3-2: Phase transition in continuously measuring analyzer
Purge gas
Condensate drain
Change channel
Measurement
Calibration
Check for
Autocalib.
Yes
No
Purge gas
calibration
Measure continuous channels:
(e.g. CO2, CH4, etc)
Discontinuous channels every 15 minutes:
(e.g. H2, H2S, O2)
Calibration
Check for
Autocalib
Yes
No

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 12 of 59 General description
3.2 Sensor modules
The following sensor modules are available in the INCA Analyzer series.
Type
Variable
Principle
Cross
sensitivity
Accuracy
Range
Note
0
[CO2]
NDIR
(4.26 µm)
CH4
±1 % of range
0 –100 vol.%
P ,T compensated
1
[CH4]
NDIR
(3.5 µm)
CxHy
±1 % of range
0 –100 vol.%
P, T compensated
5
[CH4]
NDIR
(3.5 µm)
CxHy
±1 % of range
0 –20 vol.%
P, T compensated
6
[H2S]
EC
H2, CO
±1 ppm
0 –25 ppm
High sensitive,
linear output
7
[H2S]
EC
H2, CO
±5 ppm
0 –100 ppm
High sensitive,
linear output
8
[H2S]
EC; µPulse
H2, CO
±10 % of
range
0 –10000 ppm
High sensitive,
linear output
9
[O2]
EC
H2, CO
±3 % of range
0 –25 vol.%
Linearity :
S=k loge1/(1-C)
104
[O2]
Paramagnetic
---
±3 % of range
0 –5 vol.%
Maintenance-
free, long lifetime
115
[O2]
Paramagnetic
---
±1.5 %
of range
0 –25 vol.%
Maintenance-
free, long lifetime
12
[H2]
EC
CO
±3 % of range
0 –4000 ppm
Output linear
14
[CO2]
NDIR
(4.26 µm)
CH4, CO
±1 % of range
0 –5000 ppm
P, T compensated
156
SG
Acoustic
---
±1.5 %
of range
0.2 –2.2
Maintenance-
free, long lifetime
16
[CO2]
NDIR
(4.26 µm)
CH4
±1 % of range
0 –10 vol.%
P, T compensated
19
[H2S]
EC
H2, CO
±5 ppm
0 –2000 ppm
High sensitive,
linear output
22
[H2S]
EC; µPulse
H2, CO
±10 % of
range
0 –50000 ppm
High sensitive,
linear output
23
[CH4]
EC
CxHy
±1 % of range
0 –5 Vol.%
P, T compensated
24
[CO2]
EC
CH4
±1 % of range
0 –20 Vol.%
P, T compensated
Table 2: List of sensor modules
All infrared sensors are pressure and temperature compensated.
4under development
5under development
6under development

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
General description Page 13 of 59
3.2.1 NDIR module
The NDIR module is used for measuring CO2, CH4and other possible hydrocarbon gas.
Using non-dispersive infrared (NDIR) technique and dual beam method, the setup of two IR
sensors and two IR detectors detects two different wavelengths depending on the type of
gas, accuracy and range of the measurement. Please see the sensors list for more details.
The module is temperature and pressure compensated and capable to detect and correct the
IR-source aging, which is typical for devices using the NDIR technique. If necessary, the
sensor head can be individually replaced. See spare parts list at the end of this manual.
The accuracy is better than 1% of full range.
Figure 3-3: NDIR module
3.2.2 EC and EC-µPulse module
The electrochemical module with or without the µPulse module can measure the following
gases: O2, H2and H2S. It has a high durability and a low sensor load using a patented
measurement process (µPulse). This technique allows very wide measurement ranges, for
example H2S (0 - 10000 ppm) without burdening the sensor life time.
If necessary, the sensor head can be individually replaced. See spare parts list at the end of
this manual.
Figure 3-4: EC/EC-µPulse module

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 14 of 59 General description
3.2.3 Paramagnetic oxygen sensor (Parox) module
The Parox sensor measures the oxygen concentration in a gas by using the oxygen
paramagnetic properties.
The paramagnetic sensor offers better accuracy and is practically insensitive to other gases.
Compared to EC sensors, it needs no maintenance and offers a longer life time.
Figure 3-5: Parox module
3.2.4 Specific gravity module
The specific gravity module is designed for a continuous, on-line analysis of a gas stream. It
determines the specific gravity of the process gas in a specially designed sample chamber
using presence of a modulated acoustical field.
The module has high intrinsic linearity, long term stability and a short response time. It
requires no regular maintenance. After installation the sensor housing must be able to move
freely on the springs.
19
gas-inlet
ST2
Insulation
12
3
4
gas-outlet
LFE 209C
Figure 3-6: Specific gravity measuring cell, heated and insulated
1 Potentiometer 1 Zero 3 Suspension springs
2 Potentiometer 2 Span 4 Insulating discs
Measurement range : 0.2 –2.2
Specific gravity of air : 1

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
General description Page 15 of 59
3.3 Communication with PC using INCACtrl
The INCA Analyzer comes with INCACtrl, a software running on MS Windows XP/Vista™
serving as an interface to communicate through a PC with the analyzer. The software serves
as a configuration tool and allows to
- set device specific configuration data
- set measurement specific parameter data
- read the current measurement data from the analyzer
- log current measurement data from the analyzer
- set calibration gas compositions and calibration settings
Requirements:
1. INCA Analyzer
2. INCACtrl software
3. A PC/laptop (operating system: MS Windows XP/Vista™)
4. Null modem cable
3.3.1 Establishing communication with INCACtrl
Do the following steps to establish a communication between INCACtrl running on a
PC/laptop with the INCA Analyzer:
1. Connect the RS-232 interfaces between the INCA Analyzer and a PC/laptop using a
null modem cable.
2. Start INCACtrl.exe
3. Click Options COM port settings to configure the communication port. By default,
Autodetect COM port is selected. A port can be manually selected in the menu.
Figure 3-7: INCACtrl COM port settings

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 16 of 59 General description
4. Click the icon to establish a connection.
Figure 3-8: Establishing connection between INCACtrl and INCA Analyzer
If you get an error message, check the modem cable. The COM-port setup should
also be checked by deactivating the auto-detect and manually choose the port where
the null modem cable is connected.
to establish a connection
communication successfully established
communication failed

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
General description Page 17 of 59
3.3.2 Saving the configuration to the INCA Analyzer
Note
Any change of INCACtrl configuration will only become effective after saving
them to the INCA Analyzer.
1. Check the following sign in the INCACtrl. Red cross shows that some changes are
made in the INCACtrl configuration
Figure 3-9: Configuration changed
2. Click on this button to save the INCACtrl configuration to the INCA Analyzer.
Figure 3-10: Saving the configuration

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 18 of 59 General description
3. The green check mark is shown if the saving was successful.
Figure 3-11: Green check mark - saving configuration was successful

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
System main menu Page 19 of 59
4 SYSTEM MAIN MENU
Main menu structure of the analyzer can be broke down as:
Main menu
Settings
Language
Password
Cal. purge gas7
Output data
Communication
Parameters
Cooler gas temp8
EC meas. cycle9
Commands
Change channel10
Restart system
Clear messages
Cal. purge gas
Cal. gas I
Cal. gas II11
Reset cal.
System info
System messages
Figure 4-1: Display overview
7only active for certain configurations
8only active for INCA Analyzers with gas cooler
9only active for certain configurations
10 only active for INCA Analyzers with more than one channel (multi-channel analyzer)
11 under development
MEASURING 4:57
Channel : 1/3
07/22/2009
14:42:21

UNION Instruments GmbH
INCA Analyzer Series –Instruction Manual
Page 20 of 59 System main menu
In the figure above the measuring phase is active and the analyzer will switch to next phase
in 4 minutes 57 seconds. Channel 1 of 3 available channels is active and currently
measured.
For a continuous measurement setup the display indicates the continuous measurement with
a blinking asterisk (“*”) symbol.
Figure 4-2: Display for continuous measurement configuration
Note
All the keys are active as soon as the display is set to its high brightness.
Pressing any key makes the display illuminate, which means that keys are
active.
MEASURING *
Channel : 1/1
01/05/2010
11:41:01