Union INCA4004 Quick guide

Apr-2016 V1.10
Translation of the original operating
instructions
Process gas analyser
INCA4004

Union Instruments GmbH
Zeppelinstrasse 42
76185 Karlsruhe
Germany
 [phone]
 [phone]
 [e-mail]
 http://www.union-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.

3
Dimensions

4

5
Measuring ranges and measuring 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

6
Technical data
Gas inlets
Number of measuring
points, dry:
1 - 5
Number of measuring
points, wet:
1
Calibration inlets:
1
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
Min. gas inlet pressure:
-100 mbar relative
Flame arrester:
ATEX certification G IIC
Relative gas humidity,
dry:
< 95% (condensate free)
Relative gas humidity,
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
Interfaces
Relay:
3
Dig. interface:
RS232
Field bus:
optional
Optional relay:
optional
Remote maintenance
module:
optional
Sample gas cooler
Cooling principle:
thermoelectric
Dew point:
3 - 30 °C adjustable
Condensate drain:
Hose pump

7
Ambient conditions
Operating temperature:
5 - 45°C
Humidity:
0 - 95 % relative 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!

8

9
Table of Content
1EU Declaration of Conformity.....................................................................................11
2Safety notes.................................................................................................................13
2.1 Warnings and symbols ...............................................................................................13
2.2 Principle, correct use..................................................................................................14
2.3 Personnel and qualifications.......................................................................................14
2.4 Safety notes ...............................................................................................................15
2.4.1 General notes on safety...........................................................................................15
2.4.2 Notes on specific hazards ........................................................................................15
2.5 Regular operator training............................................................................................15
2.6 Workplace hazard analysis.........................................................................................16
3Safety equipment.........................................................................................................17
3.1 Main switch.................................................................................................................17
3.2 Safety devices............................................................................................................17
3.2.1 Door - not electronically queried...............................................................................17
3.2.2 Housing fan and fan monitoring................................................................................17
3.3 Markings and warnings...............................................................................................18
4Connections.................................................................................................................19
4.1 Accessories................................................................................................................20
5Transport, setup and acceptance...............................................................................21
5.1 Transport....................................................................................................................21
5.2 Ambient conditions.....................................................................................................22
5.2.1 Storage conditions....................................................................................................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
6Startup /switching on..................................................................................................33
7Description of the workplaces/operating elements ..................................................35
7.1 Working areas...........................................................................................................35
8Operation .....................................................................................................................37
8.1 Description of display .................................................................................................38
8.1.1 Using the membrane keypad...................................................................................38
8.1.2 Display area.............................................................................................................39
8.2 Available displays.......................................................................................................39
8.2.1 Menu structure.........................................................................................................40
8.2.2 Navigate with the arrow keys left ◄and right ► ......................................................41
8.2.3 Navigation with arrow keys up ▲ and down ▼.........................................................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 warm-up phase..................................................................................45
8.2.9 Select language .......................................................................................................46
8.2.10 Password .................................................................................................................47

10
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 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

11
1 EU 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: INCA4000
Product name Gas Analyzer device group: INCA4000
konform sind mit den Anforderungen, die in der EG – Richtlinie festgelegt sind / are compliant with the
requirements as defined in the EC directive:
2014/30/EU Elektromagnetische Verträglichkeit
2014/30/EU Electromagnetic compatibility
2014/35/EU Elektrische Betriebsmittel zur Verwendung innerhalb bestimmter Spannungsgrenzen
2014/35/EU Electrical equipement designed for use with certain voltage limits
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 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.

EU Declaration of Conformity
12

13
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.

Safety notes
14
2.2 Principle, correct use
The process gas analyser serves to identifygases 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.

Safety notes
15
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 on specific 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.

Safety notes
16
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

17
3 Safety equipment
3.1 Main switch
Fig. 3.1: Main switch (example)
3.2 Safety devices
3.2.1 Door - not electronically queried
•Door of the process gas analyser.
3.2.2 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

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

19
4 Connections
Fig. 4.1: Product description
1. Power supply cable bushing
9. Input purge gas
2. Gas cooler
10. Condensate pump connection
3. Gas cooler fan
11. Master switch
4. Input process gas wet
12. Solenoid 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

Connections
20
4.1 Accessories
WARNING
Risk of injury/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.