Union Instruments INCA4003 Quick guide

Translation of the original
operating instructions
Process gas analyser
INCA4003
Device type:
Device number:
Jun-2013 V1.06
T100-02
xxxxx

Union Instruments GmbH
Zeppelinstrasse 42
76185 Karlsruhe
Germany
! [phone]
! [phone]
"! [e-mail]
#! http://www.union-instruments.com
© 2013
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.

Dimensions
3

Measuring ranges and measuring accuracy 3–
Measuring und Components Unit Measuring ranges and measuring accuracy
CH4Vol%
CO2Vol%
H2Sppm
O2Vol%
H2ppm
C2+Vol%
Hi kWh/m³
Wi kWh/m³
SG
1FS = linearity error in relation to full scale value
2MV = linearity error in relation to measured value
3Applies for one measuring point only during continuous measurement
4
0 – 100 Vol% ± 1% FS 1
0 – 100 Vol% ± 1% FS 1
µPulse
0 – 10000 ppm ± 3 ppm ( 25ppm) ±15% MV ² (>25 ppm)
electrochemical
discontinuous
discontinuous
discontinuous
0 – 25 Vol% ± 3% MV ²
- -
- -
- -
- -
- -
discontinuous measurement
discontinuous
discontinuous
discontinuous

Technical data
Gas inlets
Number of measuring points:
Calibration inlets:
Purge gas inlets:
1
Gas connections:
Clamp ring connection 6 mm
Max. distance between
measuring point and analyser:
10 m
Max. gas inlet pressure:
20 mbar relative (optional 300 mbar)
Min. gas inlet pressure:
-100 mbar relative
Flame arrester:
ATEX certification G IIC
Relative gas humidity:
!"##$!%&'()*(+,-*!.'++/01*2
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
Interfaces
Relay:
3
Dig. interface:
RS232
Field bus:
Optional relay:
Remote control unit:
Sample gas cooler
Cooling principle:
thermoelectric
Dew point:
3 - 30 °C adjustable
Condensate drain:
Hose pump
Ambient conditions
Operating temperature:
5 - 40°C
Humidity:
0 - 95 % relative humidity
Ambient pressure:
900 - 1250 hPa (0.9 - 1.2 bar)
Storage temperature:
-15 - 60°C
5
2
1
Modbus-RTU
- -
RCM

Weight
Weight:
up to 30 kg
ATTENTION
When using the process gas analyser in other ambient conditions, consult UNION
Instruments GmbH for additional measures.
6

Table of contents
1EC Declaration of Conformity....................................................................................... 9
2Safety notes ................................................................................................................. 11
2.1 Warnings and symbols ............................................................................................... 11
2.2 Fundamentals of proper use....................................................................................... 12
2.3 Personnel and qualifications....................................................................................... 12
2.4 Safety notes ............................................................................................................... 13
2.4.1 General notes on safety ........................................................................................... 13
2.4.2 Notes regarding special hazards .............................................................................. 13
2.5 Regular operator training............................................................................................ 13
2.6 Workplace hazard analysis......................................................................................... 14
3Safety equipment......................................................................................................... 15
3.1 Main switch................................................................................................................. 15
3.2 Safety equipment........................................................................................................ 15
3.2.1 Door - not electronically queried............................................................................... 15
3.2.2 Ventilator monitoring ................................................................................................ 15
3.3 Markings and warnings............................................................................................... 16
4Connections................................................................................................................. 17
Connection of process gas and electric ball valve.......................................................... 18
4.1 Accessories................................................................................................................ 19
5Transport, setup and acceptance............................................................................... 21
5.1 Transport.................................................................................................................... 21
5.2 Ambient conditions ..................................................................................................... 22
5.2.1 Storage conditions.................................................................................................... 22
5.3 Set up and connection............................................................................................... 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 Operator safety precautions ..................................................................................... 32
5.5 Startup after setup...................................................................................................... 32
5.6 Documentation ........................................................................................................... 32
6Startup /switching on .................................................................................................. 33
7Description of the workplaces/operating elements .................................................. 35
7.1 Workplaces ............................................................................................................... 35
8Operation ..................................................................................................................... 37
8.1 Description of display ................................................................................................. 38
8.1.1 Using the membrane keypad................................................................................... 38
8.1.2 Displayarea .............................................................................................................. 39
8.2 Available displays....................................................................................................... 39
8.2.1 Menu structure ......................................................................................................... 40
8.2.2 Navigate with the arrow keys left 4 ,()!5/67-!8 ...................................................... 41
8.2.3 Navigation with arrow keys up 9!,()!)':(!;......................................................... 42
8.2.4 Navigation with ESC and MENU .............................................................................. 43
8.2.5 Measurement display ............................................................................................... 44
8.2.6 Measuring channel display....................................................................................... 44
8.2.7 Saved measured values........................................................................................... 45
8.2.8 Display in the warmup phase ................................................................................... 45
7

8.2.9 Select language........................................................................................................ 46
8.2.10 Password ................................................................................................................. 47
9Decommissioning/switching off................................................................................. 49
10 Maintenance................................................................................................................. 51
10.1 Preparations ............................................................................................................... 51
10.2 Maintenance work/Inspection ..................................................................................... 52
11 Troubleshooting .......................................................................................................... 55
11.1 Preparations ............................................................................................................... 55
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 Troubleshooting list .................................................................................................. 56
12 Service ......................................................................................................................... 57
13 Associated documents ............................................................................................... 59
14 Disposal ....................................................................................................................... 61
15 Spare parts................................................................................................................... 63
16 Annex ........................................................................................................................... 64
Index ................................................................................................................................... 64
Table of figures .................................................................................................................... 65
8

1 EC Declaration of Conformity
Der Hersteller / The manufacturer
Union Instruments GmbH
Zeppelinstrasse 42
76185 Karlsruhe
erklärt hiermit, dass folgend bezeichnete Produkte / hereby declares, that following named products:
Produktbezeichnung: Gasanalysator Gerätegruppe: INCA4003
Product name Gas Analyzer device group INCA4003
konform sind mit den Anforderungen, die in der EG – Richtlinie festgelegt sind / are compliant with the
requirements as defined in the EC directive:
2006/42/EG Maschinenrichtlinie
200 /42/EC Machinery directive
2004/108/EG Elektromagnetische Verträglichkeit
2004/108/EC Electromagnetic compatibility
Angewandte harmonisierte Normen / Used harmonized standards:
DIN EN 61010-1:2011 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
DIN EN ISO 12100:2011 Sicherheit von Maschinen- Allgemeine Gestaltungsleitsätze - Risikobeurteilung und
Risikominderung
Safety of machinery - General principles for design - Risk assessment and risk reduction
DIN EN 61326-1:2006 Elektrische Mess-, Steuer-, Regel- und Laborgeräte - EMV-Anforderungen - Teil 1:
Allgemeine Anforderungen
Electrical equipment for measurement, control and laboratory use - EMC requirements -- Part 1:
General requirements
Name des Dokumentationsbevollmächtigten: Schlichter
Name delegate of documentation
Adresse des Dokumentationsbevollmächtigten: siehe Adresse des Herstellers
address delegate of documentation see address of manufacturer
Bei einer nicht autorisierten Änderung des Gerätes verliert diese Erklärung ihre Gültigkeit. / Any unauthorized modification of
the device results in invalidity of this declaration.
9

EC Declaration of Conformity
10

2 Safety notes
2.1 Warnings and symbols
In the operating instructions, the following names and symbols are used to
denote particularly important information:
DANGER
Immediate 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.
11

Safety notes
2.2 Fundamentals of proper use
The process gas analyser serves to identify gases and their quality in biogas,
crude biogas, lean gas and biomethane.
Applications are biological process optimisation during motor control, controlling
preparation systems, analysing biogas, landfill gas and gas from purification
plants.
The gas analyser is not suitable for determining the workplace threshold or lower
explosion limit.
In the case of toxic and explosive gases, observe the safety instructions at the
setup site.
The process gas analyser is permanently installed and is intended for use inside
closed rooms in a sufficient quantity of clean ambient air.
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 the safety instructions of the linked system
components.
Additional equipment or accessories that are not installed, delivered or
manufactured by UNION Instruments GmbH require the approval of UNION
Instruments GmbH as the manufacturer! Otherwise the guarantee expires.
2.3 Personnel and qualifications
Gas connections and work on the electrical equipment of the process gas
analyser may only be performed by a professional while observing safety
regulations.
12

Safety notes
2.4 Safety notes
2.4.1 General notes on safety
WARNING
The process gas analyser may only be operated when all of the protective
equipment is available and operable.
Additional safety notes:
before the corresponding chapters!
2.4.2 Notes regarding special hazards
WARNING
After installation, 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 the operator must be
observed, in particular training on handling gases and electrical equipment.
13

Safety notes
2.6 Workplace hazard analysis
NOTE
Depending on the national regulations, the operator must perform a workplace
hazard analysis, if applicable independent of the CE mark for this process gas
analyser.
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
!" [phone]
! [phone]
#" [e-mail]
%" http://www.union-instruments.com
14

3 Safety equipment
3.1 Main switch
Abb. 3.1: Main switch (exemplarisch)
3.2 Safety equipment
3.2.1 Door - not electronically queried
Door of the process gas analyser.
3.2.2 Ventilator monitoring
If the housing fan fails, the process gas analyser is de-energized. The power
supply unit and fan monitor control still have power.
15

Safety equipment
3.3 Markings and warnings
Fig. 3.2: Markings and warnings
1. Type plate
Fig. 3.3: Warning in housing
1
16

4 Connections
Abb. 4.1: Product description
1. Power supply cable bushing
10. Hose pump
2. Gas cooler
11. Main Switch
3. Gas cooler fan
12. Solenoid valve display, inlet on/off
4. Input gas cooler
13. Operating element
5. Intake air filter
14. Output process gas
6. Input calibration gas
15. Output pressure regulator leakage
7. Input purge gas
16. Cable bushings
8. Condensate pump connection
17. Fan
9. Input process gas
NOTE
Up to 4 process gas lines can be connected.
17
2
4
3
6
14
15
16
13
7
10
12
8
5
11
1
9
17

Connections
Connection of process gas and electric ball valve
Fig. 4.2: Connection of process gas and electric ball valve
Observe the following during installation:
Mount ball valves directly at withdrawal point.
Diameter of outgoing line at ball valve 6 mm.
The process gas line must not overcome larger height differences.
Install the lines to the process gas analyser frost-free.
WARNUNG
Closing ball valves!
If the process gas analyser is switched off or after a failure of the power supply,
ball valves are without power supply.
Valves must be closed manually! Observe the operating instructions of the ball
valves.
18

Connections
4.1 Accessories
WARNING
Risk of injury/defective!
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.
19

Connections
20