Multi Component Analyser

MCA 10 HWIR

Operation Manual
Dr. Födisch Umweltmesstechnik AG
Zwenkauer Strasse 159
04420 Markranstädt
Germany

Phone: +49 34205 755-0

Fax: +49 34205 755-40
E-mail: info@foedisch.de
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

Content
1 General ....................................................................................................................................... 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

2 Safety .......................................................................................................................................... 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

3 Basics ....................................................................................................................................... 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

4 Functional description ............................................................................................................ 21

5 Design ....................................................................................................................................... 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

6 Transport and scope of supply .............................................................................................. 36

6.1 Transport ................................................................................................................................... 36
6.2 Scope of supply ......................................................................................................................... 36

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Content

7 Placement and mounting ....................................................................................................... 37

7.1 Placement ................................................................................................................................. 37
7.2 Mounting ................................................................................................................................... 37
7.3 Placement and mounting of additional devices ........................................................................ 37

8 Commissioning ....................................................................................................................... 38
8.1 Commissioning of MCA 10 HWIR............................................................................................. 38
8.2 Test gas provision ..................................................................................................................... 39
8.3 Software installation .................................................................................................................. 40

9 Operating ................................................................................................................................. 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

4 Operation Manual MCA 10 HWIR Version 3.3

 Content

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

Version 3.3 Operation Manual MCA 10 HWIR 5

1 General

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.

6 Operation Manual MCA 10 HWIR Version 3.3

 1 General

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).

Version 3.3 Operation Manual MCA 10 HWIR 7

2 Safety

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.

8 Operation Manual MCA 10 HWIR Version 3.3

 2 Safety

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.

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2 Safety

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.

10 Operation Manual MCA 10 HWIR Version 3.3

 2 Safety

2.2 Requirements for personnel

This operation manual is directed to technically qualified personnel which have been specially
instructed or which possesses appropriate knowledge in the field of measuring, control and
feedback control technology, called automation technology further on.
Qualified personnel are persons who
 are either familiar as configuring personnel with the safety concepts of automation
technology
 or are instructed as operating personnel in operation with automation technology equipment
and are acquainted with the contents of these instructions referring to operation
 or have been instructed as commissioning and/or service personnel to be qualified for
repair of such automation technology equipment respectively who are authorised to
energise, ground and tag circuits and devices/systems according to the standards of safety
engineering.

The knowledge and the technically correct realisation of the safety instructions and operating
directions described in this operation manual are the requirement for hazard-free assembly
and commissioning as well as for safety at operation and upkeep. The specialised personnel
must be familiar with the general risks and hazards and know and observe the respective
safety precautions.
Unqualified interventions into the device or non-observance of the operation manual or of the
affixed labels on the product can result in personal or material damage.
Any work at the device must solely be executed by qualified specialised personnel in
observation of the corresponding regulations (central association of electrical engineering and
industry).

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2 Safety

2.3 Electrical power supply

DANGER
Hazardous voltage! Danger of electric shock.
Also when the device is switched off, there can be high voltage inside it.
Any work at the device must solely be executed by qualified personnel. The following
requirements must be observed.

 Insulation: protection class I according to IEC 1010-1:1993

 Insulation co-ordination: overvoltage category II according to IEC 1010-1:1993
 Pollution: safe work of device in an area up to pollution degree 2 according to
IEC 1010-1:1993 (light, normal pollution which can become conductive by occasional
condensation)
 The power supply has to be installed and secured according to the corresponding legal
safety regulations and prescriptions.
 The device must only be connected to the supply voltage designated on the type plate.
 A protective separation between primary and secondary circuit is generally ensured. Low
voltage which is connected must also be generated by protective separation.
 Grounding contact:
- The device must always be grounded. It has only to be operated at a power supply with
grounding contact.
- The grounding conductors in the device or the feeder must not be separated or removed.
- The protection effect must not be abolished by an extension without grounding conductor.
Every kind of interruption of the grounding conductor inside or outside of the device is
hazardous and not permitted.
- In the case of insufficient grounding or damaged grounding conductor the device must be
shut down and secured against unauthorised or inadvertent activation.
 Fuses:
- In the case of a required fuse change, only fuses must be used which are according to
the old fuses in type and capacity.
- Auxiliary fuses must not be used.
- Fuse holders must not be shorted.
 Cables must be laid that an accident risk by tripping or getting caught is excluded.
 Covers:
- The device must not be operated when covers or other parts have been removed,
because current carrying parts are divested of covering in operation.
- If not explicitly requested, work inside the device must not be executed.
- Before opening the device it must be de-energised by exerting the pre-fuse.
- If work at the opened device is necessary (adjustment, maintenance etc.), this work must
only be executed by appropriate qualified personnel which is familiar with the hazard
points and which has knowledge of avoiding hazards by proper safety precaution.

12 Operation Manual MCA 10 HWIR Version 3.3

 2 Safety

Electrical safety
If the electrical safety of the device is not given anymore, the device must be shut down and
secured against unauthorised or inadvertent activation.
The electrical safety of the device is not given any more if it:
 has visible external damage
 does not work correctly anymore
 has been stored under impermissible or inappropriate conditions for any length of time
 has been encountered impermissible strain during transport

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2 Safety

2.4 Gas supply

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.
Observe the safety instructions of the gas supplier.

DANGER
Poisonous substances!
Vapours and gases escaping from the cuvette are poisonous. Filters from cuvette, gas
sample probe and pump can contain poisonous substances. Also leakage inside the
analyser cabinet results in accumulation of poisonous or corrosive gases.
Serious health damage (e.g. irritation of eyes, skin or respiratory system organs) or death
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.
Observe the safety instructions of the gas supplier.

WARNING
Corrosive substances!
Depending on the measuring gas incidental substances can be corrosive and/or
poisonous.
Contact can cause chemical burn of body tissue and serious eye injury.
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.

 The compressed-gas cylinders and equipment (gas bottles, valves, pipes, pressure reducer
etc.) must be installed and operated according to the corresponding legal safety regulations
and prescriptions.
 In the bottle room and near of compressed-gas cylinders naked light, fire, smoking and
sparking are forbidden.
 Compressed-gas cylinders:
- All compressed-gas cylinders must be positioned upright into steady mounted holders
and secured against toppling by chains or rods.
- The compressed-gas cylinders, theirs content and all continuative gas pipes must be
designated clearly.
- In case of storage in closed rooms sufficient ventilation must be ensured.
- The compressed-gas cylinders must be kept away from heat sources and protected
against direct solar radiation and temperature fluctuation.
 For every kind of gas solely the respective permissible pressure reducer must be used.
 Pressure gas hoses must be laid that an accident risk by tripping or getting caught is
excluded. Likewise they must be protected against damage caused by falling objects and
treading on.
 In case of standstill for any length of time the bleeder valves of the compressed-gas
cylinders respectively of gas supply must be closed, the pressure inside the gas pipes to
the device must be released and all valves must be closed.

14 Operation Manual MCA 10 HWIR Version 3.3

 2 Safety

2.5 Components
The device as well as the single components must only be operated as original variant. In
case of exchanging single elements only the original parts of the manufacturer must be used.
Components are configured device-specific and hence they are not interchangeable between
different devices.

2.6 Electronic elements

Electrostatic discharges can cause damage at the electronic elements. The following
precautions must be taken:
 Electronic elements must be stored in the original packaging directly until use.
 Electronic elements must be touched at housing. The contacts must not be touched.
 Electronic elements and conductor plates must be kept away from statically charged
surfaces (PVC plastics, plastic bags etc.).
 Wear a special ESD wrist band or use a grounded, antistatic working surface.

2.7 Configuration settings

Changes of configuration can endanger the safety and function of the device. Configuration
settings must solely be executed by an authorised service technician or by factory personnel
of the manufacturer.

Version 3.3 Operation Manual MCA 10 HWIR 15

3 Basics

3 Basics

3.1 Photometry
The principle of the gas component measurement is based on the substance-specific
extinction of infrared light. This is directed through the measuring gas whereat the lessening of
the light intensity within the substance-specific absorption wave length is a degree for its
concentration.

1 2 3 4 5 6

9 8 7

Fig. 1: Measuring technological implementation of photometry

1 Infrared emitting source 6 Indicator

2 Aperture wheel 7 Test gas outlet
3 Comparison cuvette 8 Measuring cuvette
4 Gas detector 9 Test gas inlet
5 Amplifier

The physical basis for photometric measurement is the Lambert-Beer’s law.

E Extinction
l0 Intensity of emitted light
l Intensity of received light
e Extinctions coefficient
c Concentration of the measured component
d Transmitted wave length

For calculation of gas concentrations in the MCA 10 HWIR three different measuring methods
are applied:
 Bi-frequency measuring method
 Gas filter correlation
 Oxygen measurement

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 3 Basics

3.1.1 Bi-frequency measuring method

At bi-frequency measuring method a measuring filter and subsequently a reference filter are
directed into the light path. Thereby the transmission range of the measuring filter lies in the
range of the absorption wave length of the measuring component. The transmission range of
the reference filter lies in the spectral range outside of the absorption wave length of the
measuring component. So the light intensities with and without gas influence can be
determined successively.
Measurement of: NO2, SO2, HF, H2O, CO2

1 2

5 4

Fig. 2: Bi-frequency measuring method – scheme

1 Measuring filter 4 Measuring cell (cuvette)

2 Receiver 5 Light source
3 Reference filter

1
Transmission [%]

Wave number [cm-1]

Fig. 3: Bi-frequency measuring method – spectrum

1 SO2 band 3 Measuring filter

2 Reference filter

Version 3.3 Operation Manual MCA 10 HWIR 17

3 Basics

3.1.2 Gas filter correlation

At gas filter correlation the spectral sphere of action of the reference filter is identical with the
one of the measuring gas filter. The reference filter position possesses an additional gas filter
which is filled with a high concentration of the gas to be measured in order to reach the
saturation of the infrared absorption. Thereby the substance-specific spectrum of the infrared
light is almost completely faded out.
Measurement of: CO, NO, HCl, NH3, N2O, CH4

1 2 3

6 5

Fig. 4: Gas filter correlation – scheme

1 Gas filter 4 Free aperture

2 Interference filter 5 Measuring cell (cuvette)
3 Receiver 6 Light source

1
Transmission [%]

Wave number [cm-1]

Fig. 5: Gas filter correlation – spectrum

1 HCl band 2 Interference filter

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 3 Basics

3.1.3 Oxygen measurement

The oxygen measurement is carried out by means of a zirconium dioxide cell. Inside the cell
the measuring gas is separated from the reference gas (ambient air) via a zirconium
membrane. Depending on the oxygen partial pressure the oxygen ions move through the
membrane. This results in an electric potential difference.
The used oxygen sensor consists of a measuring cell and a pump cell which provides a
constant oxygen concentration in the measuring cell. The thereby spent energy is a degree for
the oxygen concentration.
Due to the proven proportionality of the signal to the concentration a steady exactness in all
oxygen concentration ranges is ensured.

1 2

5 4 3

Fig. 6: Oxygen measurement – functional principle

1 Exhaust 4 Reference medium

2 Pump cell 5 Heater
3 Measuring cell

Version 3.3 Operation Manual MCA 10 HWIR 19

3 Basics

3.2 Compensation of measuring components

The following table shows the cross sensitivities of the single measuring components in
correlation. In case of an existing cross sensitivity compensation is required.

Cross sensitivity component

HF* CO2 HCl H 2O CH4 CO NO2 SO2 N2O NO NH3 O2 TOC

HF* -   
CO2 -  
HCl  -  
H2O  - 
Measuring component

CH4   -

CO   -

NO2   - 
SO2    - 
N2O    - 
NO   -

NH3   -

O2  -

TOC  -

 compensation required

not suitability tested according to DIN EN 15267‑3; certified in compliance with MCERTS
* Performance Standards

Tab. 1: Compensation table

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 4 Functional description

4 Functional description
The multi component analyser MCA 10 HWIR serves the continuous emission measurement
of pollutants in flue gas (e.g. CO, NO, N2O, NO2, NH3, CH4, HCl, SO2, HF; as system
additionally TOC) and the measurement of CO2, H2O and O2 as well as the continuous
process control.

The device is applicable all-purpose for measurement of emissions, raw gases or processes.
As system in regulatory and operational emission measurement systems, amongst others, it
serves the:
 Exhaust concentration control in combustion plants with different types of fuel (oil, gas, coal,
biomass, specified recovered fuels etc.)
 Thermal waste treatment
 Combustion optimisation
 Process management control

Application examples:
 Power plants
 Waste incineration plants
 Refineries
 Cement industry
 Industrial exhaust air
 Paper mills
 Glass industry
 Chemical industry

By the functional principle of the multi component analyser MCA 10 HWIR up to twelve
infrared gas components can be detected simultaneously. Optionally, an oxygen
measurement is possible by means of an oxygen sensor.

The optical bench for the measurement of the infrared components consists primarily of an
infrared light source with chopper wheel, a measuring cell, a motor-driven filter wheel and a
detector.
The infrared light source located in the emitter unit emits a wide-band light beam. This
radiation is focused by a focussing mirror, modulated by the chopper wheel and transmitted
into the measuring cell which is continuously streamed by the measuring gas.
The gas suction is carried out by a low-maintenance air-jet pump. Pressure sensors control
the cuvette pressure and the suction-side injector pressure, so that all measuring values are
standardised for pressure.

Version 3.3 Operation Manual MCA 10 HWIR 21

4 Functional description

The reflexion of the infrared light starts at the couple-in area at the spherical mirror in the
cuvette and is transmitted to the second mirror. By variable interreflections over the three
mirrors in all, a path length up to 10 m can be achieved. Over the couple-out area at the
spherical mirror the infrared radiation is directed out of the cuvette into the detector unit. There
the filter wheel, a focussing mirror and the pyroelectric detector with its control electronics are
located. The infrared radiation is transmitted through the measuring and reference filters
located at the filter wheel and over the focussing mirror to the detector.
The positioning of the filter wheel is realised by a step motor and controlled continuously by an
optical photo sensor. Thereby the arrangement of the filter wheel is depending on the type of
the measured gas ingredients.
The multi component analyser MCA 10 HWIR evaluates internally all specification-depending
required concentrations with all necessary compensations and standardisations. The
mainboard is responsible for all tasks of photometer control, sensor evaluation, concentration
calculation and interface communication. The measuring data is provided as Modbus protocol
via the RS232 interface. Via USB interface the communication to an external PC is realised.
There the visualisation and operating are executed by device-own user software.
The operating surface is designed for one-click operating via touch function without additional
input acknowledgement. Optionally, the operating can be carried out by a connected mouse
respectively a trackpad and a keyboard. All menus, messages and navigation fields are
displayed as self-explanatory clear text. The menu navigation extends over several pages
which can be navigated by clicking the buttons. Device parameters can be reviewed in the
form of pop-up menus.
Optionally, the additional connections at the gas distribution block can be used for connection
of external devices (e.g. Thermo-FID, HG measuring device).

22 Operation Manual MCA 10 HWIR Version 3.3

 5 Design

5 Design
The MCA10 HWIR has a robust chassis design, where the photometer is structurally
separated from the control electronics respectively computer electronics.

Device components at the top side:

 Gas suction and gas distribution
 Photometer (consisting of emitter unit, measuring cell and detector unit)
 Measuring relevant sensors
 Oxygen sensor (optional)

Device components at the bottom side:

 Power supply unit
 Mainboard

7 2

3
5
4

Fig. 7: Design of multi component analyser MCA 10 HWIR (top view)

1 Measuring cell 5 Pressure sensor of cuvette

2 Emitter unit 6 Oxygen sensor
3 Gas distribution block 7 Detector unit
4 Pressure sensor of injector

Version 3.3 Operation Manual MCA 10 HWIR 23

5 Design

5.1 Emitter unit

Fig. 8: Emitter unit

1 Infrared emitter 3 Connection for emitter and chopper wheel

2 Focussing mirror 4 Chopper wheel

24 Operation Manual MCA 10 HWIR Version 3.3

 5 Design

5.2 Cuvette

1
5 2

4 3

Fig. 9: Cuvette

1 Spherical mirror 4 Mirror S3

2 Couple-in area 5 Couple-out area
3 Mirror S2

Version 3.3 Operation Manual MCA 10 HWIR 25

5 Design

5.3 Detector unit

Fig. 10: Detector unit

1 Pyroelectric detector 4 Cable feedthrough

2 Filter wheel with step motor 5 Focussing mirror
3 Over-temperature protection 6 Detector board

NOTICE
The configuration of the filter wheel is in accordance to the device specification.

NOTICE
At a temperature of more than 70 °C the over-temperature protection interrupts the
heater control.
If the internal temperature resistance displays more than 65 °C, the cuvette heater and
the detector heater are set at a target value of 20 °C to avoid detector damages. A failure
message is displayed.

26 Operation Manual MCA 10 HWIR Version 3.3

 5 Design

5.4 Gas distribution block

6
5
4 2

Fig. 11: Gas distribution block

1 Connection of pressure sensor S1 4 Internal connection to C6

2 Internal connection to C2 (see Fig. 14, page 30)
(see Fig. 14, page 30) 5 Measuring gas cell outlet
3 Over-temperature protection 6 Measuring gas cell inlet
7 Heater and temperature sensor

NOTICE
Connections at rear side of the gas distribution block:
See Fig. 15 “Connection assignment (view from right side)”, page 30.

The gas conveyance in the MCA10 HWIR is executed by an air-jet pump. This is arranged
behind the exhaust connection at the gas distribution block.

NOTICE
The primary pressure of the forced air must be standard adjusted at 1 bar. Thereby a
suction performance of 400 mbar will be reached.

5.5 Pressure and flow measurement

At the front of the left chassis side there are two absolute pressure sensors (4 and 5, Fig. 7)
(0...1600 mbar). These measure the cuvette pressure and the suction-side injector pressure.
By means of the sensors the analyser flow is controlled and all measuring values are
standardised for pressure.

5.6 Oxygen sensor (optional)

The oxygen measurement takes place at exhaust side in the outlet block of the measuring
cuvette. The oxygen sensor (6, Fig. 7) is attached above the measuring cuvette.

Version 3.3 Operation Manual MCA 10 HWIR 27

5 Design

5.7 Mainboard
The mainboard is responsible for all tasks of photometer control, sensor evaluation,
concentration calculation and interface communication.

23
1

2,54
2

3
4
SD2

5
1
6

6
7
8
1
20

9
6

10
2
1

11
12
13
14
15
16
17
18
22
19
21 20

Fig. 12: Mainboard, connection plan

1 Power supply for detector 13 Pressure of cuvette

2 Power supply for Mainboard (10 V) 14 Pressure of injector
3 Service interface 15 Power supply (24 V)
4 USB interface (PC) 16 Detector-board
5 Power supply unit control 17 Heater of injector
6 PT100 1 (detector, bottom) 18 Heater of oxygen sensor
7 PT100 2 (cuvette) 19 Heater of cuvette
8 PT100 3 (detector, top) 20 Heater of detector
9 PT100 4 (power supply unit) 21 Filter wheel
10 PT100 5 (injector) 22 Chopper wheel
11 PT100 6 (free) 23 RS232 interface (PLC)
12 Oxygen sensor

28 Operation Manual MCA 10 HWIR Version 3.3

 5 Design

5.8 Power supply unit

The power supply unit in the MCA10 HWIR consists of a solid aluminium case and is cooled
via two fans. It is designed for a supply voltage of 110 V to 230 V, 50/60 Hz and provides all
necessary voltage levels in the analyser.

10 V 10 V 24 V 38 V
(optional)

Fig. 13: Power supply unit, voltage levels

5.9 Interfaces
The following interfaces are located at the left side of the device:
 USB: communication to PC
 RS232: communication to cabinet control (PLC), provision of measuring data via Modbus
protocol
 RJ-45: Service interface of factory

NOTICE
The precise protocol description of Modbus communication can be reviewed in the
document “Description for digital interface - Modbus” (see appendix).

Version 3.3 Operation Manual MCA 10 HWIR 29

5 Design

5.10 Connection assignment

1 2 3 4 5 6

Fig. 14: Connection assignment (view from left side)

1 C1: Power supply (IEC) 4 C4: USB interface to PC (USB-B)

2 C2: Test gas / zero gas (for 4/6-type hose) 5 C5: Service interface Ethernet (RJ-45)
3 C3: RS232 interface to PLC (D-sub, 9-pin) 6 C6: Forced air connection (for 4/6-type hose)

1
2

3
4

Fig. 15: Connection assignment (view from right side)

1 in 1: Measuring gas connection (suction-side 3 in 2: Optional measuring gas distribution

measuring gas input) (suction-side measuring gas input)
2 exhaust: Exhaust connection (screwing-in 4 in 3: Optional measuring gas distribution
injector) (suction-side measuring gas input)
(All connections with G ¼” for 6/8-type hose resp. tube)

30 Operation Manual MCA 10 HWIR Version 3.3

 5 Design

5.11 System design (application example)

In conjunction with the MCA 10 HWIR the measuring device arises from the following main
components:
 Infrared photometer (MCA 10 HWIR)
 Analyser cabinet, incl. control panel in the cabinet door
 Gas sample probe (optional device): connection of up to three heated gas sample probes
with changeover via probe valve
 Heated measuring gas pipe
 Automatic test gas provision: up to ten test gases (single or multi gases)
 Gas return: PTFE exhaust pipe (optional: heated exhaust pipe)
 Optional system extensions:
- Thermo-FID (mounting in analyser cabinet, control/visualisation via control panel
integrated in the analyser cabinet)
- Mercury measuring device (HG)

A possible design as a system with optional additional devices is shown in the following
application example.

Control Control system

Cabinet
cooling unit

Analyser cabinet Gas sample

probe

HG measuring
device
MCA 10 HWIR
Exhaust

Thermo-FID
Exhaust

Fig. 16: System design (application example)

NOTICE
For precise design of optional additional devices please read the technical
documentations of the suppliers (see appendix).
The contents are at responsibility of the respective manufacturers.

Version 3.3 Operation Manual MCA 10 HWIR 31

32
5.11.1
5 Design

Fig. 17:
Instrument Compressed-
air air controller MV probe changeover

Test gas
controller Throttle non-return valve
MV local changeover
Test gas 1

optional Test gas 2

Gas circuit diagram

Test gas 3

Test gas 4

Test gas 5
Controller
for MCA 10 optional
air

Controller
Heated measuring for FID Forced air

Gas circuit diagram (application example)

Forced

gas pipe, external

Test gas Analyser

MCA 10

Operation Manual MCA 10 HWIR

Heated gas
sample probe
Heated measuring
FID
Burnable gas gas pipe, internal

Test gas Analyser

=measuring staging
(19” insertion)

Exhaust
optional
Exhaust

provided

Propane
by
customer

optional

Version 3.3
 5 Design

The measuring gas conveyance is carried out by the air-jet pump integrated in the
MCA 10 HWIR. Forced air of 1 to 4 bar is supplied to this pump. Up to three heated measuring
gas pipes can be connected suction-side at the gas distribution block of the analyser module.
The unused connections at the analyser will be sealed gas-tight. The exhaust is a mixture of
forced air and sucked measuring gas and shows a large flow. The zero gas provision is
standard conducted through the connection C2. Thereby the flow may be maximal 600 l/h.

Version 3.3 Operation Manual MCA 10 HWIR 33

5 Design

5.11.2 Design of CPU components

Control
Modbus - Analyser cabinet control
MCA 10 HWIR (heater/fan)
- Connection to control system

USB I/O BUS

EMI-PC / Control system

Visualisation PC
- Communication: Modbus protocol
- Interface type: RS232 (2-wire)

Fig. 18: Design of CPU components (application example)

The system design consists basically of three CPU components:

 Multi component analyser MCA 10 HWIR
 Visualisation PC with software “MCA10_HID”
 Control for analyser cabinet automation

The parameter set of the MCA10 HWIR contains information for all three components. The
user software arranges the necessary synchronisation between PC and analyser. This
synchronises itself automatically with the analyser cabinet control. At modification of
parameters the complete parameter set is read from the MCA 10 HWIR. Thereby the
synchronisation is ensured, so that all current data are transferred at later writing.

34 Operation Manual MCA 10 HWIR Version 3.3

 5.11.3

Version 3.3
FID (optional)

Fig. 19:
RS232 Serial Communication: Status FID, measuring value FID

RS232
Signal plan

USB Modbus RTU

PC / Laptop / Tablet / Touch MCA 10 analyser module PLC

(OS: Windows)
the analyser cabinet (PLC).

 Visualisation of the  USB connection (protocol)  Continuous measurement of  Modbus RTU  Control of system cabinet
measuring results and  Transfer of analyser the streaming gas, gas (MCA10 – Slave / (heaters)
parameters in a comfortable parameterisation conveyance via internal air- PLC – Master)  Control of zero point cycle /
and clear way (photometer adjustment, jet pump  open protocol span point cycle
 Storage of all result values in calibration tables, heating  Calculation of concentration  Transfer of PLC parameters  Synchronisation of PLC

Signal plan (application example)

daily files controllers, …) (corrected by pressure, (external heating control, parameters
 Storage of parameter  Transfer of result values humidity, …) automatic zero point setting,
 Communication to external
modifications  No visualisation, no action measuring ranges, automatic
 Transfer of PLC parameters systems
on user-side possible span point calibration, …)
 Remote access via Ethernet  Control signals for (control system, …)
(other possibilities can also  Provision of measuring  Exchange of system ticks
photometer and for PLC  Evaluation of FID printer
be realised) results via RS232 (open between MCA 10 and PLC as
(manual zero point setting, interface (FID status and FID
proof of life

Operation Manual MCA 10 HWIR

 FID Remote Software is automatic zero point setting) protocol) as Modbus RTU measuring value)
Slave  Exchange of error signals
implemented  control and  Transfer of PLC time (system
visualisation via PC (FID time)  Zero point setting and  Transfer of measuring
Remote Software) calibration have to be results of MCA10
started externally (either via
 Transfer of PLC values
USB(PC) connection or
(controller values, external
Modbus(PLC) connection)
signals)
 PLC parameters are
transferred
 Storage of results in ring
buffer (max. 2000 entries)

The Modbus protocol is open and can be programmed independently. Thereby it is not necessary to use all parts of the protocol. Certain parts, e.g. status of PLC, its proof of life or
automatic zero point setting, have to be realised on the PLC in order to ensure a proper operation and reasonable visualisation.
The following figure shows and describes the communication paths and tasks of the system
components. The signal connection to the control system is solely done via the control unit of

35
5 Design
6 Transport and scope of supply

6 Transport and scope of supply

6.1 Transport
The device is stored in a special handling case. This is generally secured against vibration at
transport.

CAUTION
Through heavy percussion at transport (e.g. by falling) susceptible elements can be
damaged.
Chose appropriate means of transport.

1. Check the device as well as the packaging material for transport damage.
2. Document possibly existing damage.

6.2 Scope of supply

According to the legal sales contract the respective scope of supply is specified in the shipping
documents attached to the supply.

The scope of supply includes:

 1 analyser module
 1 operation manual
 1 documentation CD for installation of the user software

NOTICE
Depending on purchase configuration deviations in technical design are possible, e.g. by
analyser cabinet or optional additional devices.

1. Check the scope of supply for completeness and intactness.

2. Remove the packaging material.
3. Keep the packaging material for possible re-use.

36 Operation Manual MCA 10 HWIR Version 3.3

 7 Placement and mounting

7 Placement and mounting

7.1 Placement

CAUTION
The device must not be operated in potentially explosive atmosphere.

For correct operation of the multi component analyser MCA 10 HWIR the following ambient
conditions apply:
 Ambient temperature: 25...35 °C (temperature stability max. 2 K/h)
 Relative humidity: max. 90% (non-condensing)
 Operation in rooms (outdoor operation not permissible)
 Protection against wetness
 Location free of percussion

7.2 Mounting

NOTICE
The mounting must be executed according to the delivered circuit diagram and gas
circuit diagram.
Depending on application please observe the procedure in combination with the analyser
cabinet respectively with optional additional devices if necessary (see appendix).

1. Insert the MCA10 HWIR horizontally into the mounting place and fix the device.

CAUTION
Insufficient ventilation can cause damage at the device.
Take care that the ventilation slots (also at bottom side of device) are not covered.

2. Connect the measuring gas pipe, the exhaust pipe and if necessary additional devices
with the connections at the right device side (see Fig. 15, page 30).
Furnish possibly non-used connections with seal caps.
3. Connect the forced air with connection C6 (6, Fig. 14, page 30) at the left device side.
4. Connect the communication cable to PC with connection C4 (4, Fig. 14).
5. Connect the power cord with connection C1 (1, Fig. 14).

7.3 Placement and mounting of additional devices

NOTICE
For placement and mounting of optional additional devices please read the technical
documentations of the suppliers (see appendix).
The contents are at responsibility of the respective manufacturers.

Version 3.3 Operation Manual MCA 10 HWIR 37

8 Commissioning

8 Commissioning

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
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.

NOTICE
If the MCA 10 HWIR shall be commissioned again after storage, before commissioning it
must stand unused at installation location at least one day under permissible ambient
conditions.
Requirements for location: see section 7.1 “Placement”, page 37.

NOTICE
Depending on application please observe the procedure in combination with the analyser
cabinet respectively with optional additional devices if necessary (see appendix).

8.1 Commissioning of MCA 10 HWIR

CAUTION
The device must be operated with compressed air. Permanent operation without
compressed air can cause false measuring results or material damage.
If there is no possibility for compressed-air supply, the system must immediately be shut
down.

1. Connect the power plug to the power supply.

2. Adjust the forced air to 1 bar.

CAUTION
The measuring medium must have atmospheric pressure (1013 mbar absolute).

3. Purge the device with instrument air.

4. Check the temperatures and the instrument air during the heat-up phase at regular
intervals.
5. Wait until temperatures, pressures and regulation parameters are stable.
6. Carry out the zero point setting (see section 9.10 “Calibration”, page 59).

38 Operation Manual MCA 10 HWIR Version 3.3

 8 Commissioning

8.2 Test gas provision

WARNING
Hot surface!
The MCA 10 HWIR is standard heated to a temperature of 185 °C.
Burn hazard!
Personal protective equipment according to the current legal accident prevention
regulations must be worn.

CAUTION
 Before test gas provision a stable zero point setting must have been carried out
(control of drift correction values not more than 0.2 %/h).
 For zero point calibration of the oxygen sensor, solely nitrogen must be used.

To avoid damage at the measuring system and falsification of the measuring results, the
following requirements must be observed at test gas provision via gas distribution block in the
MCA 10 HWIR:
 cuvette pressure max. 1050 mbar
 constant pressure conditions during provision
 constant temperature conditions
 internal temperature controllers in steady state
 provision of test medium always via evaporator unit
 sensitivity tests as standard with a concentration of 80% of the measuring range

Provide test gas

1. Connect the pipes for test gas provision with the connections at the gas distribution block
(“in 1”/“in 2”/“in 3”, see Fig. 15, page 30).
Take care that the provision is carried out pressure-free (overflow method).
2. Furnish possibly non-used connections at the gas distribution block with seal caps.
3. Open the test gas supply.
4. Close the zero gas supply.
5. Wait until the settling time is over.
6. Read the measuring result from the connected visualisation PC.

To change into normal measuring operation after test gas provision, please proceed as
follows:
1. Open the zero gas supply.
2. Purge the device with zero gas.
3. Close the test gas supply.
4. Remove the pipes of test gas provision from the connection at the gas distribution block.

Version 3.3 Operation Manual MCA 10 HWIR 39

8 Commissioning

8.3 Software installation

For installation of the PC software “MCA10_HID” of Dr. Födisch Umweltmesstechnik AG the
following preconditions must be fulfilled:
 Communications cable between PC and MCA 10 HWIR connected (USB, connection C4)
 MCA 10 HWIR and PC switched on
 Preconditions for visualisation PC:
- Operating system: Windows XP or higher
- CPU: Pentium II or higher
- Main memory: 500 MB
- Read-only memory: 5 GB free memory for data storage
- Interfaces: USB 2.0
- Display screen: min. 1024 x 768 pixel

The user software “MCA10_HID” is stand-alone software and requires no installation routine
before execution.

Install software
1. Insert the delivered documentation CD with user software into the PC.
2. Open the file “MCA10_HID.exe”.
› The data is automatically read.

NOTICE
For uninstallation of no longer required user software displace the correspondent file into
the recycle bin.

40 Operation Manual MCA 10 HWIR Version 3.3

 9 Operating

9 Operating

CAUTION
Incorrect operating can cause false measuring results, interferences in measuring
process or material damage.
Basic requirement for safe operating is exact knowledge of the functioning of the
MCA 10 HWIR and the complete system as well as knowledge of measuring method,
windows-based applications and system-dependent details.
For operation with the software the instructions and calibration directions must be obeyed
exactly. The respective setting possibilities as well as their effects and parameter limits
have to be observed.
Operating must solely be executed by qualified personnel (see section 2.2
“Requirements for personnel”, page 11).

NOTICE
The user software “MCA10_HID” of Dr. Födisch Umweltmesstechnik AG must be on the
intended visualisation PC.

The user software has the following functions:

 Visualisation of measuring results
 Modification of analyser parameters
 Control of complete system respectively of the analyser cabinet (if present)
 Saving of parameter data and measuring data on PC memory

NOTICE
The operating surface is designed for one-click operating without additional input
acknowledgement.
To prevent incorrect operation, please avoid double-clicking. Extended setting
possibilities as well as parameter modification get active by leaving the respective menu.
Observe the additionally shown info texts within the menus.

Version 3.3 Operation Manual MCA 10 HWIR 41

9 Operating

9.1 Display and operating elements

9.1.1 General screen design

1 2 3 4

10 5

8 7

Fig. 20: General screen design (main menu for example)

1 Status information “operation mode” 7 Lower status bar

2 Status information “maintenance requirement” 8 Display for specific failure messages
3 Status information “maintenance” according to maintenance and communication
4 Status information “failure” status
5 Upper status bar 9 Main area (menu content)
6 Current date / current time 10 Display of currently selected menu

Status information
At the right side of the upper status bar the status information (1 to 4, Fig. 20) for operation,
maintenance requirement, maintenance and failure is visualised. Depending on mode or
possibly upcoming failure the respective field is coloured.

operation mode The device is in operation mode. All values are within the normal range.

maint. req. Maintenance is required. The list of the current messages has to be reviewed.

maintenance The device is in maintenance mode. Modifications are active.

failure A failure currently exists. The list of the current messages has to be reviewed.

42 Operation Manual MCA 10 HWIR Version 3.3

 9 Operating

Date and time

The current date and the current time (6, Fig. 20) are displayed at the right side of the lower
status bar.

Display for specific failure messages according to maintenance and communication

status
In case of an active maintenance or an upcoming failure of the communication status of the
MCA 10 HWIR an additional message (8, Fig. 20) is displayed at the left side of the lower
status bar. In normal operational state the display does not contain any messages.

Actually selected menu

The main area (9, Fig. 20) in the middle of the screen varies depending on the menu selection.
The content of the currently selected menu is displayed. For orientation the name of the
selected menu (10) is displayed at the left side of the upper status bar.

9.1.2 Display and operating elements within menus

Info text

CAUTION
Text fields with the designation “info text” provide important notes for safe operating.
Read all displayed info texts attentively and observe them.

Selection list

Selection lists serve the navigation within a selected menu. In a selection list several
possibilities are available for menu display. By clicking the arrow symbol at the right side of the
field a list with all possibilities opens. If the selection is adopted by another clicking within the
list, the contents within the menu are adapted.

Selection field

Selection fields serve the assignment of a predefined function. For example, functions can be
switched on/off or a specific function can be selected from several possibilities.

Version 3.3 Operation Manual MCA 10 HWIR 43

9 Operating

Input field

Fields for value input are coloured green. By clicking a pop-up window opens, in which set
point values can be input and adopted.

Input window
By clicking an input field or for password input an input window opens. Values can be input
and adopted/revoked by the numeral buttons.

9 1

8
6

Fig. 21: Input window (pop-up window)

1 Current value 6 Button “BS” (delete last numeral of input

2 Min./max. input of limit value value)
3 Input field of new value 7 Button “Enter” (adopt input value)
4 Button “ESC” (revoke input value) 8 Numeral buttons
5 Button “Del” (delete input value) 9 Title/value name

Function button

By clicking a function button a function is carried out directly. The respective function is
specified as clear text on the button.

44 Operation Manual MCA 10 HWIR Version 3.3

 9 Operating

Button “back”

The button “back” is located in all menu screens (except main menu) at the right side of the
lower status bar. By clicking the button the main menu is selected again.

Arrow button

Arrow buttons signalise the availability of additional data. If in a menu more data is available
as the screen is able to show, the next/last screen page can be selected by clicking an arrow
button.
Besides, the buttons are used for going forward/back within the time line of a diagram.

9.1.3 Display “data transfer”

When data is interchanged between MCA 10 HWIR and PC, the display “data transfer”
appears. Additionally, the progress of the transfer is displayed by a loading bar. The screen in
the background fades for the respective duration.

CAUTION
During data transfer the USB connection must not be interrupted.

The data transfer between MCA 10 HWIR and PC serves the synchronisation of data and is
started automatically.
An automatic data transfer is carried out at the following actions:
 Starting of the user software “MCA10_HID” (readout of the parameter storage of
MCA 10 HWIR)
 Manual setting of span point for transfer of the new calculated calibration value (readout of
the parameter storage of MCA 10 HWIR)
 Actualising of history (readout of the history storage at opening the menu)
 Configuration of parameters (readout of the parameter storage of MCA 10 HWIR at leaving
the configuration menu)
 Change into service mode (readout of the parameter storage of MCA 10 HWIR)

Version 3.3 Operation Manual MCA 10 HWIR 45

9 Operating

9.2 Menu structure

concentration
measurement
development

system control

CO2
diagnostics IR-components
(example)

H2O
(example)

...
(other components)

O2-sensor

heater detector

cuvette

injector

O2-sensor

...
(external heater circuits)

pressure cuvette

injector

flow

general

Fig. 22: Menu structure (1/3)

46 Operation Manual MCA 10 HWIR Version 3.3

 9 Operating

current
messages
messages

history

auto calibration

calibration IR zero point

IR span point CO2

manually (example)

H2O
O2-sensor
(example)

...
flow
(other components)

drift correction

Fig. 23: Menu structure (2/3)

Version 3.3 Operation Manual MCA 10 HWIR 47

9 Operating

configuration IR-components general

CO2*
* general
(example)

H2O*
linearity
(example)

... * H2O
interference (add) **
(other components) (example)

interference CO
(mul) ** (example)

...
(other components)

O2-sensor * The selection of general information, linearity

and additive/multiplicative interference is
available for every selectable component.

heater
** The selection of the possible interference
detector
component is available for additive as well as
multiplicative interference.

cuvette

injector

O2-sensor

...
(external heater circuits)

pressure cuvette

injector

flow

system general

password

back purging

Fig. 24: Menu structure (3/3)

48 Operation Manual MCA 10 HWIR Version 3.3

 9 Operating

9.3 Password levels

For operating the user software of the MCA 10 HWIR four password levels are existing. As
standard, these are configured as follows:

Password level Access facilities

0  View of all IR measuring values, diagnostic values and

messages
 Setting of maintenance mode
 Provision of measuring gas, zero gas and test gas
 Starting of auto calibration
1 - not existing -
(The password is defined with the value “0”. After input the
password level 0 is set automatically.)
2  View of all IR measuring values, diagnostic values and
messages
 Setting of maintenance mode
 Provision of measuring gas, zero gas and test gas
 Starting of auto calibration
 Manual calibration of IR measurement
 Access to internal sensors
3  All possibilities of password level 2
 Setting of all parameters
 Access to calculation tables
4 - Service mode (unlimited access) -
Notice:
The access is exclusively reserved for authorised service personnel
of Dr. Födisch Umweltmesstechnik AG.

Tab. 2: Password levels – standard

If for the password of password level 1 a different value than “0” is defined, specific access
facilities apply for the password levels 0 and 1:

Password level Access facilities

0  View of all IR measuring values

1  View of all IR measuring values, diagnostic values and

messages
 Setting of maintenance mode
 Provision of measuring gas, zero gas and test gas
 Starting of auto calibration
The access facilities of the password levels 2 to 4 remain unaffected by this.

Tab. 3: Password levels – specific

NOTICE
Input password: see section 9.4.2, page 51.
Administrate passwords: see section 9.11 “Configuration”, page 64.

Version 3.3 Operation Manual MCA 10 HWIR 49

9 Operating

9.4 Main menu

1 2 3

6
5

Fig. 25: Main menu

1 Language selection 4 Device information

2 Key symbol for password input 5 Display of component configuration
3 Display of currently selected password level 6 Menu buttons

Language selection
In the field “language selection” (1, Fig. 25) the acronym of the selected language is displayed.

Password levels and password input

In the field (3, Fig. 25) the currently selected password level is displayed. By clicking the key
symbol (2) the respective password can be input.

Device information
In the area of device information (4, Fig. 25) device type, serial number, software version, date
of manufacture and depending on configuration the next service date (settable in menu:
configuration – system – general) are displayed.

NOTICE
The designation of the software version is subdivided into three parts and marked by
lines. The designation of the separate software versions is due to the following:
PC | MCA | SPS

50 Operation Manual MCA 10 HWIR Version 3.3

 9 Operating

Display of component configuration

In the area of component configuration (5, Fig. 25) the measuring ranges of all measurable
components are displayed.

Menu buttons
The menu buttons (6, Fig. 25) displayed in the main menu serve the navigation between the
particular menus.
By clicking the menu buttons the respective screens can be selected:
 Measurement
 System control
 Diagnostics
 Messages
 Auto calibration
 Calibration (from password level 2)
 Configuration (from password level 3)
 Service mode (password level 4)

The currently selected menu is displayed at the left side of the upper status bar.

9.4.1 Change language

1. Select the main menu.
2. Click the acronym of the displayed language (1, Fig. 25).
› The language setting changes automatically to the next language.

NOTICE
Depending on the device configuration the languages German (Deu) and English (eng)
can be displayed.

9.4.2 Input password

1. Select the main menu.
2. Click the key symbol (2, Fig. 25).
› An input window opens.
3. Input the password.
4. Acknowledge the input with “Enter”.
› The password is adopted and the access to the respective level is enabled.

NOTICE
After 60 min without operating activity the menu is automatically reset to password
level 0.

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9 Operating

9.5 Measurement
In the menu “measurement” all measuring results of the IR components and the oxygen
sensor are displayed as diagram.

1
2

Fig. 26: Menu “measurement”

1 Current measuring value 3 Display of measuring range limit

2 Button “development”

The current measuring values of the respective components are displayed as value as well as
in form of a bar diagram in relation to the upper measuring range limit.

NOTICE
If more than eight components are measured, an arrow button is displayed at the right
side of the screen. By clicking the arrow button the next screen page is selected.

By clicking the button “development” (2, Fig. 26) the display of concentration development for
the respective component is opened (see Fig. 27, page 53).

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 9 Operating

Concentration development

2
4
3

Fig. 27: Menu “measurement” – concentration development

1 Concentration development of the selected 3 Arrow buttons

component 4 Buttons for setting the displayed time period
2 Display of day and time

According to the selected component the respective time development of the concentration is
displayed on the screen.
As standard the last 24 hours are displayed. Alternatively, the time range can be changed to
1, 6 or 12 hours by clicking the respective button (4, Fig. 27). Thereby the scaling of the axes
is carried out automatically.
The arrow buttons (3) serve going forward/back within the time axis. By clicking the display
moves the half of the selected time range forward/back.

NOTICE
Through going forward/back within the time axis the automatic actualisation of the
diagram is deactivated.
To reactivate the automatic actualisation, a click into the diagram must be done.

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9 Operating

9.6 System control

NOTICE
The functions in the menu are only operative in connection with the complete system.

In the menu “system control” the maintenance switch of the complete system can be switched
on/off. Besides, the selection between measuring gas, zero gas and optionally test gas is set.

Fig. 28: Menu “system control”

1 Switching on/off the maintenance switch 2 Selection of measuring/zero/test gas

Maintenance switch
By clicking the respective selection field (1, Fig. 28) the maintenance mode is switched on/off.

System
By clicking the respective selection field (2, Fig. 28) the measuring/zero/test gas can be
provided. The selection is also possible in case of an automatic test gas provision.

54 Operation Manual MCA 10 HWIR Version 3.3

 9 Operating

9.7 Diagnostics
In the menu “diagnostics” general system information as well as calculation relevant
measuring values of IR components, oxygen sensor, heater circuits, pressure sensors and
flow calculation are displayed.

Fig. 29: Menu “diagnostics”

1 Display of all parameters 2 Second selection list

(example - depending on selection) (depending on pre-selection)
3 First selection list

The selection of the information displayed in the menu is done by the selection lists.
The following values can be reviewed for diagnostics:

 IR-components
(subordination of the second selection list: all components)
 O2-sensor
 Heater
(subordination of the second selection list: detector, cuvette, injector, O2-sensor and
external heater circuits (optional))
 Pressure
(subordination of the second selection list: cuvette, injector)
 Flow (analyser flow)
 General

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9 Operating

9.8 Messages
In the menu “messages” the current message list and the history storage can be reviewed.
The selection of the information displayed in the menu is done by a selection list.

Current messages

4
1

Fig. 30: Menu “messages” – current messages

1 Event characterisation 3 Generated status of event

2 Additional message display 4 Selection list

Messages are distinguished as follows:

 Info messages
 Maintenance requirement messages
 Maintenance messages
 Failure messages

In the menu all currently upcoming messages are listed. Therefor the generated status
(3, Fig. 30; not in case of info messages) as well as the characterisation of the event (1) are
displayed as clear text. The overview is actualised in the interval of one second.
Specific messages, e.g. an active zero point routine or a failure of the communication status,
are additionally displayed in the lower status bar (2).
Under normal operation conditions there are no entries in the overview.

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 9 Operating

History

Fig. 31: Menu “messages” – history

1 Button “update” 3 Time and date

2 Previous message with status 4 Selection list
characterisation

In the overview all previous messages are listed. Therefor time and date (3, Fig. 31) as well as
the characterisation of the event (2) with determination of the status characterisation
“start”/“end” are displayed.
The history storage provides the opportunity of up to 2000 entries.

NOTICE
 Date and time are only registered if the communication to the PLC with required
timestamp is ensured.
 The actualisation of the history must be carried out manually by clicking the button
“update” (1).

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9 Operating

9.9 Auto calibration

NOTICE
The functions in the menu are only operative in connection with the complete system.

In the menu “auto calibration” the start of the automatic zero point setting can be triggered.

Fig. 32: Menu “auto calibration”

1 Button “start”

Zero point automatically

By clicking the button “start” (1, Fig. 32) an automatic zero point setting is carried out. Thereby
the maintenance mode is activated. The complete system is purged and afterwards the zero
point of the IR components is set. After another run-in period the system is switched back into
operation mode.
Depending on configuration an additional calibration of the span point of the oxygen sensor is
set to 20.95 vol. %.

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 9 Operating

9.10 Calibration

NOTICE
The screen is accessible only from password level 2.

In the menu “calibration” the settings for the calibration of IR components, oxygen sensor and
flow measurement can be defined.

2
1

Fig. 33: Menu “calibration”

1 Display of menu content 2 Second selection list

(example - depending on selection) (depending on pre-selection)
3 First selection list

The selection of the information displayed in the menu is done by the selection lists.
The following functions can be calibrated:
 IR zero point
 IR span point manually
(subordination of the second selection list: all measurable components)
 IR span point automatically (optional)
 O2-sensor
 Flow (analyser flow)
 Drift correction

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9 Operating

IR zero point

NOTICE
The analyser must be purged with zero gas and must be stabilised.

At executing the function the zero point of all IR components is set to the current absorption
value.

IR span point manually

NOTICE
The analyser must be purged with span gas and must be stabilised.

The calibration is carried out device-selective for the selected component (2, Fig. 33). At
executing the function the new calibration value is automatically calculated and transferred.

CAUTION
During data transfer the USB connection must not be interrupted.

IR span point automatically (optional)

NOTICE
The selection of the function is only available if the according test gas option is existent.

The span point can be calibrated component-selective. At executing the function of automatic
span point the control of the valves is carried out automatically. The time response can be set
in the menu “configuration – IR-components – component X – general” (see section 9.11,
page 62).

O2-sensor

NOTICE
For the calibration of the O2 sensor the following requirements apply:

 Zero point setting:

The analyser must be purged with nitrogen (oxygen 0.0 vol. %) and must be stabilised.
 Span point setting:
The analyser must be purged with zero gas and must be stabilised.

At executing the respective function the zero point respectively the span point of the O2-sensor
is calibrated.

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 9 Operating

Flow
At executing the respective function the zero point of the flow measurement is calibrated to the
pressure difference between cuvette and injector, respectively the analyser flow is calibrated
to the input span value.

Drift correction
At executing the function the drift value saved after a zero point setting is reset to zero.

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9 Operating

9.11 Configuration

CAUTION
Changes of configuration affect the function of the device and the complete system
seriously. Operating must solely be executed by specially trained qualified personnel.
The screen is accessible only from password level 3.

In the menu “configuration” all calculation-relevant and system-relevant parameters can be

reviewed and modified within their limits.
All parameter changes get active only at returning to the main menu.

CAUTION
During data transfer the USB connection must not be interrupted.

5
4
3 1

Fig. 34: Menu “configuration”

1 Display of menu content 3 Third selection list *

(example - depending on selection) 4 Second selection list *
2 Fourth selection list * 5 First selection list

* depending on pre-selection

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 9 Operating

The selection of the information displayed in the menu is done by the selection lists.
The following values can be configured:

 IR-components
(subordination of the second selection list: all measurable components)
 O2-sensor
 Heater
(subordination of the second selection list: detector, cuvette, injector, O2-sensor and
external heater circuits (optional))
 Pressure
(subordination of the second selection list: cuvette, injector)
 Flow (analyser flow)
 System
(subordination of the second selection list: general, password, back purging)

IR-components
Via the menu the parameters of all measurable components can be reviewed and modified.
For every component another selection list (3, Fig. 34) is available. By this the menu can be
adapted by the selection of the following possibilities:
 General
 Linearity
 Interference (add)
 Interference (mul)

In case of selecting interference the respective component, which shall be compared, can be
selected by a fourth selection list (2, Fig. 34). Then the table of cross sensitivity (interference)
is adaptable in the menu.

O2-sensor
Via the menu the parameters of the O2 sensor can be reviewed and modified.

Heater
Depending on the setting in the second selection list, parameters of the heaters of detector,
cuvette, injector, O2 sensor and external heater circuits (optional) can be reviewed and
modified via the menu.

Pressure
Depending on the setting in the second selection list, parameters of the pressure of cuvette
and injector can be reviewed and modified via the menu.

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9 Operating

Flow
Via the menu the parameters of the analyser flow can be reviewed and modified.

System

General
Via the menu the general settings, e.g. for date and time, zero point and service alarm, can be
made.

Password
Via the menu the passwords can be administered to restrict the access facilities to the
password levels.
1. Select password level 3.
2. Select menu “configuration”.
3. Select “system” in the first selection list.
4. Select “password” in the second selection list.
5. Click into the input field of the password which shall be changed.
› An input window opens.
6. Input the new password and acknowledge the input with “Enter”.
› The new password is adopted and immediately effective.

Back purging
Via the menu the parameters for back purging can be reviewed and modified.

9.12 Service mode

NOTICE
The service mode enables unlimited access which is exclusively reserved for authorised
service personnel of Dr. Födisch Umweltmesstechnik AG.
The screen is accessible only for password level 4.

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 10 Maintenance/Upkeep

10 Maintenance/Upkeep

NOTICE
The provision of guarantee items requires an execution of maintenance in due form.
Any work at the device must solely be executed by qualified personnel.
Executed maintenance/upkeep work must be documented according to the legal
regulations.

The maintenance work has the following target:

 Preservation of measurement precision
 Warranty of operational safety
 Increment of service life

The following maintenance/upkeep work must be executed:

Component Action Maintenance interval

Injector screwing-in Exchange 6 months
Sinter metal filter of cuvette Exchange 12 months
Gaskets at cuvette inlet Exchange 12 months
block
Screwing-in with nozzle at Exchange 24 months
gas distribution block

Tab. 4: Maintenance/upkeep work

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10 Maintenance/Upkeep

10.1 Exchange injector screwing-in

WARNING
Hot surface!
Several device parts can develop high temperatures.
Burn hazard!
Personal protective equipment according to the current legal accident prevention
regulations must be worn.

1. Purge the device with zero gas for 10 min.

2. Remove the exhaust pipe from the device (connection “exhaust”).
3. Unscrew the injector screwing-in with the aid of special tool and remove the gasket.
4. Attach the new gasket to the injector and screw it in.
5. Connect the exhaust pipe with the connection “exhaust” at the device.
6. Check the device for leak tightness.

10.2 Exchange sinter metal filter of cuvette / exchange gaskets at cuvette inlet
block

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.

WARNING
Hot surface!
Several device parts can develop high temperatures.
Burn hazard!
Personal protective equipment according to the current legal accident prevention
regulations must be worn.

1. Purge the device with zero gas for 10 min.

2. Disconnect the device from power supply.
3. Release the screws at the upper device cover and take the cover off.
4. Release the four hexagon socket-head screws at the cuvette isolation box and open it.
5. Release the four hexagon socket-head screws at the cuvette inlet block.
6. Disconnect the 4/6-type pipe from injector block.
7. Release the circlip with the aid of pincers.
8. Dismount the sinter metal filter and the gaskets.
9. Mount the new sinter metal filter and the new gaskets.
10. Replace the gaskets of the cuvette inlet block with new gaskets.
11. Fix the circlip.

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 10 Maintenance/Upkeep

12. Connect the 4/6-type pipe with the injector block.

13. Screw the four hexagon socket-head screws with the cuvette inlet block.
14. Close the cuvette isolation box and screw it with the four hexagon socket-head screws.
15. Put the upper device cover onto the device and screw it.
16. Check the device for leak tightness.
17. Connect the device to the power supply.

10.3 Exchange screwing-in with nozzle at gas distribution block

1. Purge the device with zero gas for 10 min.
2. Disconnect the device from power supply.
3. Release the screws at the upper device cover and take the cover off.
4. Release the four hexagon socket-head screws at the cuvette isolation box and open it.
5. Disconnect the PTFE hose from the screwing-in.
6. Dismount the screwing-in with nozzle.
7. Mount the new screwing-in with nozzle.
8. Connect the PTFE hose with the screwing-in.
9. Close the cuvette isolation box and screw it with the four hexagon socket-head screws.
10. Put the upper device cover onto the device and screw it.
11. Check the device for leak tightness.
12. Connect the device to the power supply.

Version 3.3 Operation Manual MCA 10 HWIR 67

11 Error search and failure clearance

11 Error search and failure clearance

11.1 Service qualification of the specialised personnel

CAUTION
Failure clearance must be executed by qualified personnel under strict observation of the
specified service qualification.
Persons without required service qualification are not authorised to carry out the
respective actions for clearance of error or failure causes and act illegally.
Non-observance can result in personal and/or material damage. The manufacturer
assumes no liability at all.

The levels of the service qualification for authorisation of error/failure clearance are as follows:

Level Service qualification

1 The executive personnel are specialised personnel of the system that possess
knowledge of the system and process measuring and control technology and that
have been instructed on location in operation with the device and the complete
system.
The here specified specialised personnel must solely execute actions which are
characterised in the sections 11.2.1 to 11.2.4 with the level 1.
2 The executive personnel are specialised personnel of the system that possess
knowledge and skills of the level 1 and additionally special knowledge of operation
with the device and the complete system which empowers to basic service
activities.
For service qualification the executive specialised personnel must have a
certificate of participation in the training “Basic service activity”.
The here specified specialised personnel must solely execute actions which are
characterised in the sections 11.2.1 to 11.2.4 with the levels 1 and 2.
3 The executive personnel are specialised personnel of the system that possess
knowledge and skills of the levels 1 and 2 and additionally special knowledge of
operation with the device and the complete system which empowers to advanced
service activities.
For service qualification the executive specialised personnel must have a
certificate of participation in the training “Advanced service activity”.
The here specified specialised personnel is allowed to execute all actions which
are specified in the sections 11.2.1 to 11.2.4.

Tab. 5: Service qualification of the specialised personnel

CAUTION
Actions for failure clearance which exceed the service qualification of the trained qualified
personnel of level 3 must solely be executed by service personnel of Dr. Födisch
Umweltmesstechnik AG.

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 11 Error search and failure clearance

11.2 Displaying of current messages and clearing of failures

Messages and alarms regarding error state can be displayed by a connected visualisation PC
with installed user software.
Upcoming failure and errors are signalised by the status information on operating surface
(“maint. req.”, “maintenance”, “failure”) and can be reviewed via menu (see section
9.8 “Messages”, page 56).
In case of a system application, current failure messages according to communication status
of MCA 10 HWIR and PLC are additionally displayed in the lower status bar on the screen.

1. Select menu “messages” on operating surface.

2. Select “current messages” in the selection list.
› On screen all currently upcoming messages are displayed.
3. Check all messages which are designated with “maint. req.”, “maintenance” or “failure” in
the column “generated status”.

NOTICE
Info messages, e.g. for failure of communication status, are only displayed in the lower
status bar. They are not signalised by any status information.
In the message list no generated status is defined.

4. Compare the respective message with the tables specified in the following sections:
› Failure (see section 11.2.1, page 70)
› Maintenance (see section 11.2.2, page 79)
› Maintenance requirement (see section 11.2.3, page 81)
› Info message (see section 11.2.4, page 88)

CAUTION
Failure clearance must be executed by qualified personnel.
Observe the required levels for service qualification (see section 11.1, page 68).

5. Depending on your service qualification, carry out the actions for failure clearance for the
respective message, if applicable.
› As soon as the cause of error/failure is eliminated, the corresponding message in the
menu disappears after approx. 2 min.
6. Check the error/failure message for disappearance.

NOTICE
In case of upcoming errors or failure which cannot be eliminated, please refer to
Dr. Födisch Umweltmesstechnik AG (contact details: see cover inside).

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11 Error search and failure clearance

11.2.1 Messages “failure”

Failure
Message Cause Action

air conditioner run-in phase is not finished 1 Close the cabinet door.
Wait until the system has thermally stabilised.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

failure at air conditioning unit 3 Check the message display at the air conditioning
unit.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

analyser several failure messages 1 Select the menu “messages” with the selection list
pertaining to the analyser “current messages” on the operating surface (see
are occurring (superordinate section 9.8 “Messages”, page 56).
message) Check all messages which are designated with
“failure” in the column “generated status” and
compare these with the quoted messages here in
this table.
Depending on your service qualification, carry out
the actions for failure clearance for the respective
messages, if applicable.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

analyser flow deposit respectively cross- 2 Exchange the probe filter. Check the connecting
underrun section constriction in the pieces.
region of the probe

deposit respectively cross- 2 Clean the exhaust pipe.

section constriction in the
region of the exhaust pipe

injector performance too low 2 Exchange the injector screwing-in (see section 10.1,
page 66).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

cuvette inlet filter is clogged 3 Exchange the cuvette inlet filter.

faulty flow measurement 3 Calibrate the flow measurement via the menu of the
operating surface (see section 9.10 “Calibration”,
page 59).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

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 11 Error search and failure clearance

Failure
Message Cause Action
cabinet ventilator run-in phase is not finished 1 Close the cabinet door.
Wait until the system has thermally stabilised.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

failure at air conditioning unit 1 Check the message display at the air conditioning
unit.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

chopper wheel failure miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

chopper wheel miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

initialization failed

communication miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

communication PLC in programming mode 2 Switch the DIP switch at the control unit in the
MCA - PLC (“PROG.”) system cabinet to “RUN”.

unconnected or defect 2 Check the connection cable between MCA 10 HWIR

connection cable between and PLC.
MCA 10 HWIR and PLC Exchange it, if necessary.

condensate tank full condensate tank 1 Empty the condensate tank.

defect level sensor 3 Check the function of the level sensor.

Exchange it, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

cuvette pressure limit parameters or limit values 3 Check the parameter settings in the menu of the
exceeded faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

detector ad-converter miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

limit exceeded

detector initialization miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

failed

external components failure at external measuring 1 Check the message display at the external
device measuring device.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

FID failure at FID 3 Select the menu “FID control” on the operating
surface of the MCA 10 HWIR.
Check the message display of the FID.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

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11 Error search and failure clearance

Failure
Message Cause Action
FID watchdog unconnected or defect 3 Check the connection cable between PLC and FID.
connection cable between Exchange it, if necessary.
PLC and FID

failure at internal 3 Carry out a reset of the FID and wait until the
communication of FID system has stabilised. For that purpose, read the
technical documentation of the supplier (see
appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

filter wheel failure miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

filter wheel miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

initialization failed

general PLC several failure messages 1 Select the menu “messages” with the selection list
pertaining to the PLC are “current messages” on the operating surface (see
occurring (superordinate section 9.8 “Messages”, page 56).
message) Check all messages which are designated with
“failure” in the column “generated status” and
compare these with the quoted messages here in
this table.
Depending on your service qualification, carry out
the actions for failure clearance for the respective
messages, if applicable.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

heating cuvette temporary occurring failure 1 Wait until the message has disappeared.
hardware failure message (without relevance)

permanently occurring failure Contact Dr. Födisch Umweltmesstechnik AG.

message

heating detector temporary occurring failure 1 Wait until the message has disappeared.
hardware failure message (without relevance)

permanently occurring failure Contact Dr. Födisch Umweltmesstechnik AG.

message

heating injector temporary occurring failure 1 Wait until the message has disappeared.
hardware failure message (without relevance)

permanently occurring failure Contact Dr. Födisch Umweltmesstechnik AG.

message

heating O2 sensor temporary occurring failure 1 Wait until the message has disappeared.
hardware failure message (without relevance)

permanently occurring failure Contact Dr. Födisch Umweltmesstechnik AG.

message

heating option intern temporary occurring failure 1 Wait until the message has disappeared.
hardware failure message (without relevance)

permanently occurring failure Contact Dr. Födisch Umweltmesstechnik AG.

message

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 11 Error search and failure clearance

Failure
Message Cause Action
initialisation chopper miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.
wheel

initialisation detector miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

initialisation filter miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

wheel

initialisation miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

mainboard flash

injector pressure limit parameters or limit values 3 Check the parameter settings in the menu of the
exceeded faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

O2 sensor limit heat-up phase is not finished 1 Wait until the current value of the cuvette
exceeded temperature has reached more than 80% of the
nominal value (see section 9.7 “Diagnostics”,
page 55).
As soon as the current value is more than 80%, wait
until the heat-up phase of the oxygen sensor is
finished.
Check the temperature at regular intervals.

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

controller error 3 Carry out a reset of the analyser (see section 12.1
“Shutdown”, page 89 and section 8.1
“Commissioning of MCA 10 HWIR”, page 38).
Wait until the heat-up phase is finished.

defect oxygen sensor 3 Exchange the oxygen sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

sample probe miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

software test miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature analyser several failure messages 1 Select the menu “messages” with the selection list
pertaining to the analyser “current messages” on the operating surface (see
temperatures are occurring section 9.8 “Messages”, page 56).
(superordinate message) Check all messages which are designated with
“failure” in the column “generated status” and
compare these with the quoted messages here in
this table.
Depending on your service qualification, carry out
the actions for failure clearance for the respective
messages, if applicable.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 73

11 Error search and failure clearance

Failure
Message Cause Action
temperature cabinet / heat-up phase is not finished 1 Wait until the heat-up phase of the analyser cabinet
option is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect cabinet heater 3 Exchange the cabinet heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature cuvette heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
overrun finished. Check the temperature at regular intervals
in the menu of the operating surface (see section
9.7 “Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect cuvette heater 3 Exchange the cuvette heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature cuvette heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect cuvette heater 3 Exchange the cuvette heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature detector faulty climatisation 2 Check the status display of the cabinet air
overrun conditioning.

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect detector heater 3 Exchange the detector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

74 Operation Manual MCA 10 HWIR Version 3.3

 11 Error search and failure clearance

Failure
Message Cause Action
temperature detector heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

ambient temperature is too 1 Close the cabinet door.

low Wait until the heat-up phase of the analyser is
finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect detector heater 3 Exchange the detector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature ambient temperature is 1 Close the cabinet door.

electronic/ cabinet instable Wait until the heat-up phase of the analyser is
overrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature ambient temperature is 1 Close the cabinet door.

electronic/ cabinet instable Wait until the heat-up phase of the analyser is
underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 75

11 Error search and failure clearance

Failure
Message Cause Action
temperature exhaust heat-up phase is not finished 1 Wait until the heat-up phase of the exhaust pipe is
line finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the exhaust 3 Exchange the exhaust pipe.

pipe

defect temperature sensor 3 Exchange the exhaust pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature external heat-up phase is not finished 1 Wait until the heat-up phase of the measuring gas
sample line pipe is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the 3 Exchange the measuring gas pipe.

measuring gas pipe

defect temperature sensor 3 Exchange the measuring gas pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature injector heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
overrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect injector heater 3 Exchange the injector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

76 Operation Manual MCA 10 HWIR Version 3.3

 11 Error search and failure clearance

Failure
Message Cause Action
temperature injector heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

deposit respectively cross- 2 Clean the exhaust pipe.

section constriction in the
region of the exhaust pipe

deposit respectively cross- 2 Exchange the injector.

section constriction in the
region of the injector

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

zero gas rate too high 3 Regulate the zero gas rate to the system-specific
nominal value (reviewable in the system-specific
supplementary sheet for MCA 10 HWIR).

defect injector heater 3 Exchange the injector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature internal heat-up phase is not finished 1 Wait until the heat-up phase of the measuring gas
sample line pipe is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the 3 Exchange the measuring gas pipe.

measuring gas pipe

defect temperature sensor 3 Exchange the measuring gas pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature O2 parameters or limit values 3 Check the parameter settings in the menu of the
sensor overrun faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect oxygen sensor 3 Exchange the oxygen sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 77

11 Error search and failure clearance

Failure
Message Cause Action
temperature O2 heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
sensor underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect oxygen sensor 3 Exchange the oxygen sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature sample heat-up phase is not finished 1 Wait until the heat-up phase of the measuring gas
line pipe is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the 3 Exchange the measuring gas pipe.

measuring gas pipe

defect temperature sensor 3 Exchange the measuring gas pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature sample heat-up phase is not finished 1 Wait until the heat-up phase of the probe is finished.
probe Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

faulty probe isolation 1 Check if the probe cover is correctly mounted.

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect probe heater 3 Exchange the probe heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Tab. 6: Error search and failure clearance – Messages “failure”

78 Operation Manual MCA 10 HWIR Version 3.3

 11 Error search and failure clearance

11.2.2 Messages “maintenance”

Maintenance
Message Cause Action

a/o testmode active simulation value of a 3 Check the simulation values of the components.
component is active If necessary, set these via the menu of the operating
surface to “0” (see section 9.11 “Configuration”,
page 62).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

analyser several maintenance 1 Select the menu “messages” with the selection list
messages pertaining to the “current messages” on the operating surface (see
analyser are occurring section 9.8 “Messages”, page 56).
(superordinate message) Check all messages which are designated with
“maintenance” in the column “generated status” and
compare these with the quoted messages here in
this table.
Depending on your service qualification, carry out
the actions for failure clearance for the respective
messages, if applicable.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

back purging / line back purging respectively 1 Wait until the back purging respectively the line
switching line switching is active switching after the changeover of the measuring
point is finished.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

external components maintenance at external 1 Check the message display at the external
measuring device measuring device.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

FID zero point routine or span 1 Wait until the zero point routine is finished.
point routine of the FID is
active

maintenance at FID 3 Select the menu “FID control” on the operating

surface of the MCA 10 HWIR.
Check the message display of the FID.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 79

11 Error search and failure clearance

Maintenance
Message Cause Action
general PLC several maintenance 1 Select the menu “messages” with the selection list
messages pertaining to the “current messages” on the operating surface (see
PLC are occurring section 9.8 “Messages”, page 56).
(superordinate message) Check all messages which are designated with
“maintenance” in the column “generated status” and
compare these with the quoted messages here in
this table.
Depending on your service qualification, carry out
the actions for failure clearance for the respective
messages, if applicable.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

maintenance switch maintenance switch of the 1 Set the maintenance switch via the menu of the
set system is set operating surface to “off” (see section 9.6 “System
control”, page 54).

testgas connected system is set to test gas 1 Set the system via the menu of the operating
surface to “measuring gas” (see section 9.6 “System
control”, page 54).

zero point routine zero point routine is active 1 Wait until the automatic zero point routine is
running finished.

zerogas connected system is set to zero gas 1 Set the system via the menu of the operating
surface to “measuring gas” (see section 9.6 “System
control”, page 54).

Tab. 7: Error search and failure clearance – Messages “maintenance”

80 Operation Manual MCA 10 HWIR Version 3.3

 11 Error search and failure clearance

11.2.3 Messages “maint. req.”

Maint. req.
Message Cause Action

analyser several maintenance 1 Select the menu “messages” with the selection list
requirement messages “current messages” on the operating surface (see
pertaining to the analyser section 9.8 “Messages”, page 56).
are occurring (superordinate Check all messages which are designated with
message) “maint. req.” in the column “generated status” and
compare these with the quoted messages here in
this table.
Depending on your service qualification, carry out
the actions for failure clearance for the respective
messages, if applicable.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

analyser flow deposit respectively cross- 2 Exchange the probe filter. Check the connecting
underrun section constriction in the pieces.
region of the probe

deposit respectively cross- 2 Clean the exhaust pipe.

section constriction in the
region of the exhaust pipe

injector performance too low 2 Exchange the injector screwing-in (see section 10.1,
page 66).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

cuvette inlet filter is clogged 3 Exchange the cuvette inlet filter.

faulty flow measurement 3 Calibrate the flow measurement via the menu of the
operating surface (see section 9.10 “Calibration”,
page 59).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

condensate tank full condensate tank 1 Empty the condensate tank.

defect level sensor 3 Check the function of the level sensor. Exchange it,
if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

external components maintenance requirement at 1 Check the message display at the external
external measuring device measuring device.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

FID maintenance requirement at 3 Select the menu “FID control” on the operating
FID surface of the MCA 10 HWIR.
Check the message display of the FID.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 81

11 Error search and failure clearance

Maint. req.
Message Cause Action
flow probe 1 flow at measuring point 1 is 1 Check and clean the measuring point 1.
under limit value

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

flow probe 2 flow at measuring point 2 is 1 Check and clean the measuring point 2.
under limit value

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

general PLC several maintenance 1 Select the menu “messages” with the selection list
requirement messages “current messages” on the operating surface (see
pertaining to the PLC are section 9.8 “Messages”, page 56).
occurring (superordinate Check all messages which are designated with
message) “maint. req.” in the column “generated status” and
compare these with the quoted messages here in
this table.
Depending on your service qualification, carry out
the actions for failure clearance for the respective
messages, if applicable.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

PLC battery empty flat or empty buffer battery of 3 Exchange the buffer battery of the control unit.
the control unit

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

pressure cuvette limit deposit respectively cross- 3 Check the exhaust pipe.
exceeded section constriction in the Clean the exhaust pipe respectively exchange it, if
region of the exhaust pipe necessary.

deposit respectively cross- 3 Check the injector.

section constriction in the Clean the injector respectively exchange it, if
region of the injector necessary.

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

pressure injector limit deposit respectively cross- 3 Check the exhaust pipe.
exceeded section constriction in the Clean the exhaust pipe respectively exchange it, if
region of the exhaust pipe necessary.

deposit respectively cross- 3 Check the injector.

section constriction in the Clean the injector respectively exchange it, if
region of the injector necessary.

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

82 Operation Manual MCA 10 HWIR Version 3.3

 11 Error search and failure clearance

Maint. req.
Message Cause Action
ratio flow P1/P2 high flow at measuring point 2 is 1 Check and clean the measuring point 2.
too low

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

ratio flow P1/P2 low flow at measuring point 1 is 1 Check and clean the measuring point 1.
too low

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

servicetime interval deadline of service date is Contact Dr. Födisch Umweltmesstechnik AG.
overrun exceeded

software test miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature cuvette heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
overrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect cuvette heater 3 Exchange the cuvette heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature cuvette heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect cuvette heater 3 Exchange the cuvette heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 83

11 Error search and failure clearance

Maint. req.
Message Cause Action
temperature detector faulty climatisation 2 Check the message display at the air conditioning
overrun unit.
If applicable, eliminate the respective cause of
error/failure. For that purpose, read the technical
documentation of the supplier (see appendix).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect detector heater 3 Exchange the detector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature detector heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

ambient temperature is too 1 Close the cabinet door. Wait until the heat-up phase
low of the analyser is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect detector heater 3 Exchange the detector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature ambient temperature is 1 Close the cabinet door. Wait until the heat-up phase
electronic/ cabinet instable of the analyser is finished.
overrun Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

84 Operation Manual MCA 10 HWIR Version 3.3

 11 Error search and failure clearance

Maint. req.
Message Cause Action
temperature ambient temperature is 1 Close the cabinet door. Wait until the heat-up phase
electronic/ cabinet instable of the analyser is finished.
underrun Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature exhaust heat-up phase is not finished 1 Wait until the heat-up phase of the exhaust pipe is
line finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the exhaust 3 Exchange the exhaust pipe.

pipe

defect temperature sensor 3 Exchange the exhaust pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature external heat-up phase is not finished 1 Wait until the heat-up phase of the measuring gas
sample line pipe is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the 3 Exchange the measuring gas pipe.

measuring gas pipe

defect temperature sensor 3 Exchange the measuring gas pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 85

11 Error search and failure clearance

Maint. req.
Message Cause Action
temperature injector heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
overrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect injector heater 3 Exchange the injector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature injector heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

deposit respectively cross- 2 Clean the exhaust pipe.

section constriction in the
region of the exhaust pipe

deposit respectively cross- 2 Exchange the injector.

section constriction in the
region of the injector

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

zero gas rate too high 3 Regulate the zero gas rate to the system-specific
nominal value (reviewable in the system-specific
supplementary sheet for MCA 10 HWIR).

defect injector heater 3 Exchange the injector heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature internal heat-up phase is not finished 1 Wait until the heat-up phase of the measuring gas
sample line pipe is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the 3 Exchange the measuring gas pipe.

measuring gas pipe

defect temperature sensor 3 Exchange the measuring gas pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

86 Operation Manual MCA 10 HWIR Version 3.3

 11 Error search and failure clearance

Maint. req.
Message Cause Action
temperature O2 parameters or limit values 3 Check the parameter settings in the menu of the
sensor overrun faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect oxygen sensor 3 Exchange the oxygen sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature O2 heat-up phase is not finished 1 Wait until the heat-up phase of the analyser is
sensor underrun finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect oxygen sensor 3 Exchange the oxygen sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature sample heat-up phase is not finished 1 Wait until the heat-up phase of the measuring gas
line option pipe is finished.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect heater of the 3 Exchange the measuring gas pipe.

measuring gas pipe

defect temperature sensor 3 Exchange the measuring gas pipe.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

temperature sample heat-up phase is not finished 1 Wait until the heat-up phase of the probe is finished.
probe Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

faulty probe isolation 1 Check if the probe cover is correctly mounted.

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect probe heater 3 Exchange the probe heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Version 3.3 Operation Manual MCA 10 HWIR 87

11 Error search and failure clearance

Maint. req.
Message Cause Action
temperature sample heat-up phase is not finished 1 Wait until the heat-up phase of the probe is finished.
probe option Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).

faulty probe isolation 1 Check if the probe cover is correctly mounted.

parameters or limit values 3 Check the parameter settings in the menu of the
faulty operating surface (see section 9.11 “Configuration”,
page 62). Correct these, if necessary.

defect electric connections 3 Check the electric connections of heater and

temperature sensor.

defect probe heater 3 Exchange the probe heater.

defect temperature sensor 3 Exchange the temperature sensor.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

zero drift component instability during zero point 1 Close the cabinet door. Wait until the system has
... setting thermally stabilised.
Check the temperature at regular intervals in the
menu of the operating surface (see section 9.7
“Diagnostics”, page 55).
Carry out an automatic zero point setting (see
section 9.9 “Auto calibration”, page 58). Wait until
this setting has finished.
After finishing the automatic zero point setting, wait
min. 1 h and repeat the process, if necessary.

pollution of instrument air 2 Clean respectively exchange the filters of the

compressed-air cleaning system.

water ingress in the 3 Check the pressured-air system for condensate

instrument air formation. Remove possibly existing condensate.

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Tab. 8: Error search and failure clearance – Messages “maint. req.”

11.2.4 Info message

Message Cause Action

MCA not connected temporary communication 1 Wait until the connection is re-connected
loss automatically and the message has disappeared.

unconnected or defect 2 Check the connection cable between visualisation

connection cable between PC and MCA 10 HWIR. Exchange it, if necessary.
visualisation PC and
MCA 10 HWIR

miscellaneous Contact Dr. Födisch Umweltmesstechnik AG.

Tab. 9: Error search and failure clearance – Info message

88 Operation Manual MCA 10 HWIR Version 3.3

 12 Shutdown and Disposal

12 Shutdown and Disposal

12.1 Shutdown

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.

WARNING
Corrosive substances!
Depending on the measuring gas incidental substances can be corrosive and/or
poisonous.
Contact can cause chemical burn of body tissue and serious eye injury.
Personal protective equipment according to the current legal accident prevention
regulations must be worn.

WARNING
Hot surface!
Several device parts can develop high temperatures.
Burn hazard!
Before working at the device it must be cooled down.

NOTICE
Please observe the procedure in combination with the analyser cabinet respectively with
optional additional devices if necessary.

1. Purge the device with zero gas for min. 30 min.

2. Disconnect the measuring gas pipe from gas sampling. Therefor shut the valves at the
gas bottles.
3. Disconnect the power plug from power supply.

Version 3.3 Operation Manual MCA 10 HWIR 89

12 Shutdown and Disposal

12.2 Disassembling

NOTICE
Please observe the procedure in combination with the analyser cabinet respectively with
optional additional devices if necessary.

1. Disconnect the power cord from the device.

2. Disconnect the communication cable of PC from the device.
3. Disconnect the forced air pipe from the device.
4. Disconnect the measuring gas pipe and the exhaust pipe from the device.
5. If necessary, disconnect optional additional devices from the connections at the device.
6. Release the screws at the mounting plate and remove the device from the mounting
place.
7. Store all pipes safe and care for correct storage of the device.

12.3 Storage
For correct storage of the multi component analyser MCA 10 HWIR the following ambient
conditions apply:
 Ambient temperature: 0 ... 50 °C
 Relative humidity: max. 90% (non-condensing)
 Storage in rooms (outdoor storage not permissible)
 Protection against wetness
 Location free of percussion

12.4 Disposal

NOTICE
The disposal must be executed according to the country-specific legal environmental
protection regulations. The device must be treated as hazardous waste.

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13 Technical data

13.1 Multi component analyser MCA 10 HWIR

Multi component analyser MCA 10 HWIR

Insulation protection class I according to
IEC 1010-1:1993
Insulation co-ordination overvoltage category II according to
IEC 1010-1:1993
Protection degree IP40
Pollution pollution degree 2 according to
IEC 1010-1:1993
Ambient conditions:
 Ambient temperature for operation 25...35 °C (temperature stability max. 2 K/h)
 Ambient temperature for storage 0 ... 50 °C
 Relative humidity max. 90% (non-condensing)
Power consumption 350 W
Power supply 110 V to 230 V, 50/60 Hz
Compressed-air supply 4...6 bar
Compressed-air consumption approx. 1 m³/h (dependent on application)
Calibration  zero point: automatically with instrument
air
 span point: with test gas, optional:
automatically
Measuring method bi-frequency measuring method, gas filter
correlation, oxygen measurement
Number of measuring components max. 12 infrared components (dependent on
application) and oxygen
Measuring ranges 2 per measuring component
Detection limit < 2% of the respective measuring range
Air pressure correction yes
Correction of cross sensitivity (interference) additive, multiplicative
Drift correction of zero point automatically
Sensitivity correction with test gas, once in 6 months
(sensitivity tests as standard with a
concentration of 80% of the measuring
range)
Standardisation dry, wet
Gas conveyance air-jet pump
Forced air supply 1...4 bar depending on flow rate

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Multi component analyser MCA 10 HWIR

Operating PC connection via USB
Interfaces 2 x RS 232, USB
Software versions [PC/MCA10/PLC] 4.00/3.61/3.62

Tab. 10: Technical data – Multi component analyser MCA 10 HWIR

Photometer
Spectral range 1 ... 16 µm
Supply voltage of emitter unit 10 V
Gas line, heated continuous to 200 °C, standard 185 °C,
higher possible
Path length of measuring cell adjustable 2...10 m
Dead volume of measuring cell 1l
Particle filter 2 µm

Tab. 11: Technical data – Photometer

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13.2 Measuring ranges of MCA 10 HWIR

For measurement of the various gas concentrations the MCA 10 HWIR is tested regarding the
following measuring ranges:

Component Certification range Measuring range 2 Measuring range 3

CO 0...75 mg/m³ 0...300 mg/m³ 0...5000 mg/m³
CO2 0...25 vol. % 0...50 vol. % -
NO 0...80 mg/m³ 0...400 mg/m³ 0...3000 mg/m³
NO2 0...50 mg/m³ 0...500 mg/m³ -
N2O 0...50 mg/m³ 0...3000 mg/m³ -
NH3 0...10 mg/m³ 0…50 mg/m³ 0…500 mg/m³
SO2 0...75 mg/m³ 0...300 mg/m³ 0...2500 mg/m³
HCl 0...15 mg/m³ 0...90 mg/m³ 0...5000 mg/m³
HF* - 0...20 mg/m³ -
H2O 0...40 vol. % - -
CH4 0...50 mg/m³ 0...500 mg/m³ -
TOC 0...15 mg/m³ 0...30 mg/m³ 0…500 mg/m³
O2 0...25 vol. % - -
* not suitability tested according to DIN EN 15267‑3; certified in compliance with MCERTS Performance Standards

Tab. 12: Measuring ranges of MCA 10 HWIR

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14 Spare and wear parts

14 Spare and wear parts

For placing a purchase order of spare and wear parts please refer to Dr. Födisch
Umweltmesstechnik AG (contact details: see cover inside).

Element/Component Item number

BaF2 window 15x2 mm ETLD 242
BaF2 window 20x1 mm ETLA 304
Blank plug ETLD 325
Bulkhead plug connector ETLA 1121
Bulkhead screwing ETLD 163
Cable for detector board power supply ETLD 27
Cable for mainboard power supply 10 V ETLD 261
Cable for mainboard power supply 24 V ETLD 265
Cable for PT100 detector box ETLD 210
Cable for PT100 heating cuvette ETLD 254
Cable for PT100 of gas distribution block ETLD 193
Cable loom for heating of cuvette ETLD 253
Cable loom for heating of detector box ETLD 208
Cable loom for heating of gas distribution block ETLD 192
Cable of signal transmission for detector box to mainboard ETLD 26
Chopper motor with intermediate plate for emitter box ETLD 200
Chopper wheel ETLA 276
Collet chuck ETLD 32
Connection board ETLD 81
Control cable for power supply unit of mainboard ETLD 266
Control cable for stepper motor of detector box ETLD 30
Control cable for stepper motor of emitter box ETLD 29
Cuvette ETLD 19
Detector board ETLD 118
Detector box ETLD 18
Elbow screwing ETLA 690
Elbow screwing of pressure sensor ETLD 154
Emitter box ETLD 17
Fan for power supply unit ETLD 467

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Element/Component Item number

Fuses T 10 A ETLD 152
Gas distribution block ETLD 7
Gas inlet ETLD 249
Gas outlet ETLD 250
Injector for gas distribution block ETLD 21
IR emitter ETLD 70
Isolation box of cuvette ETLD 15
Isolation boxes of gas distribution block ETLD 16
Light barrier of detector box ETLD 213
Light barrier of emitter box ETLD 199
Locking ring ETLD 240
Locking screw of gas distribution block ETLD 161
Mainboard ETLD 149
Mirror set of cuvette ETLA 934
Nozzle of gas distribution block ETLD 160
O-ring of gas outlet ETLD 252
O-rings of gas inlet ETLD 251
Over-temperature protection ETLA 113
Oxygen sensor ETLD 258
PE cable for board of housing ETLD 31
PE cable for top of main carrier ETLD 28
Power supply unit ETLD 185
Pressure sensor ETLD 159
PT100 for intermediate plate of detector box ETLD 219
PT100 for mainboard ETLD 227
PTFE hose 100 mm ETLD 328
PTFE hose 1200 mm ETLD 330
PTFE hose 146 mm ETLD 327
PTFE hose 240 mm ETLD 329
PTFE hose 4/6 ETLD 75
PTFE hose 46 mm ETLD 326
PTFE hose 560 mm ETLD 331
Screw-in connection with gasket ETLD 322

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Element/Component Item number

Screw-in connection with gasket for gas distribution block ETLD 139
Sealing set for cuvette ETLD 248
Side panel 1 of emitter with BaF2 window ETLD 346
Side panel 2 of detector with BaF2 window ETLD 211
Sinter metal filter ETLD 239
Sinter metal filter (set), gilded ETLD 540
Slot bracket ETLD 147
Spacer for cuvette ETLD 77
Stepper motor for chopper wheel ETLD 432
Stepper motor for filter wheel ETLD 359
Stepper motor with intermediate plate for detector box ETLD 215
Stud bolt for gas distribution block ETLD 43
Thermo switch ETLA 264
Touch pen ETLD 632
Window holder ETLD 80

Tab. 13: Spare and wear parts – Multi component analyser MCA 10 HWIR

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15 System application with analyser cabinet

NOTICE
This chapter describes the general system connection by the analyser cabinet.
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.
Application examples for system design: see section 5.11, page 31.

15.1 Design of analyser cabinet

The analyser cabinet is an air-conditioned steel sheet cabinet. The complete
electrics/electronics, feeding, voltage distribution, signal processing and PLC as well as a
pressured air distribution are located inside. The multi component analyser MCA 10 HWIR is
mounted rear at the mounting plate. In the steel sheet door the control panel with touch
surface is generally located. Optionally, a Thermo-FID can be mounted into the analyser
cabinet (see appendix).

1 2 3 4 5 6

8
10

Fig. 35: Design of analyser cabinet (Application example)

1 Air conditioners 6 Feedthrough for measuring gas pipe

2 Feedthrough for power supply 7 Control
3 Feedthrough for peripheral connections 8 MCA 10 HWIR
4 Control panel (touch screen) 9 Thermo-FID (optional)
5 Master switch 10 Service aperture

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15.2 Transport of analyser cabinet

The analyser cabinet is transported separately from the multi component analyser
MCA 10 HWIR.
The analyser cabinet is delivered upright-standing on a stillage. The transport can be carried
out in miscellaneous way:
 by lifting the stillage with the aid of a forklift
 by gibbeting at hoisting lugs at the top side of analyser cabinet

DANGER
Heavy load! At transport the analyser cabinet may topple or fall.
Risk of injury!
Remain aloof from floating load. Wear personal protective equipment.
Chose appropriate means of transport with sufficient load-bearing capacity.
Safeguard the analyser cabinet against toppling or falling.
Avoid heavy shocks and percussion at transport.

CAUTION
Risk of incorrect attaching.
The hoisting lugs mounted at the analyser cabinet are solely appropriate for vertical
forces. Gibbeting at only one load hook causes damage.
One vertical load-bearing rope/chain with load hook must be provided for every hoisting
lug.
Consider the barycentre of analyser cabinet when lifting.

1. Check the analyser cabinet as well as the packaging material for transport damage.
2. Document possibly existing damage.
3. Remove the packaging material.
4. Keep the packaging material for possible re-use.

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15.3 Placement and Mounting

15.3.1 Placement
For correct operation the following conditions apply:
 Ambience:
- Ambient temperature: 5 ... 40 °C
- Relative humidity: max. 90% (non-condensing)
- Operation in rooms (outdoor operation not permissible)
- Protection against wetness
 Bottom ground:
- solid and plane
- carrying capacity: min. 500 kg/m²
- securing of safe standing of the analyser cabinet including possible additional equipment
 Location free of percussion
 Distance between air conditioners and wall: min. 20 cm
(air inlets and air outlets must not be covered)

Placing of analyser cabinet

1. Lift the analyser cabinet to the installation location and put it down at the footprints
carefully.
2. Remove all means of transport (ropes, chains etc.) and hoisting lugs if necessary.
3. Align the analyser cabinet with the aid of a spirit level.
4. Tighten the analyser cabinet at the wall/ground.

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15.3.2 Mounting
1. Lay the measuring gas pipe.
2. Connect the heater of the measuring gas pipe and the temperature sensor to the power
supply (circuit diagrams: see appendix).
3. Mount the probe (circuit diagrams: see appendix).
4. Connect the probe heater to the power supply.
5. Connect the measuring gas pipe with the probe.
6. Lay the exhaust pipe.
7. If necessary, connect the heater of the exhaust pipe to the power supply (circuit diagrams:
see appendix).
8. Insert the MCA10 HWIR horizontally into the analyser cabinet and fix the device at the
mounting plate of the analyser cabinet.

CAUTION
Insufficient ventilation can cause damage at the device.
Take care that the ventilation slots are not covered.

9. Execute the following work at the MCA 10 HWIR:

a) Connect the measuring gas pipe, the exhaust pipe and if necessary additional devices
with the connections at the right device side (see Fig. 15, page 30).
Furnish possibly non-used connections with seal caps.
b) Connect the forced air pipe with connection C6 (6, Fig. 14, page 30) at the left device
side.
c) Connect the communication cable to PLC with connection C3 (3, Fig. 14).
d) Connect the communication cable to PC with connection C4 (4, Fig. 14).
e) Connect the power cord with connection C1 (1, Fig. 14) and with the terminal strip in
the analyser cabinet.
10. If necessary, connect optional additional devices of the system (circuit diagrams: see
appendix).

NOTICE
At locations with temperatures below 20 °C, an analyser cabinet heater must be installed
for temperature stabilisation, so that the analyser cabinet is tempered constantly to
min. 22 °C.

11. Connect the signal connection to the control system.

12. Connect the power plug of the analyser cabinet to the power supply.

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15.4 Commissioning

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.

NOTICE
If the MCA 10 HWIR shall be commissioned again after storage, before commissioning it
must stand unused at installation location at least one day under permissible ambient
conditions.
Requirements for location: see section 15.3.1 “Placement”, page 99.

1. Switch on the power supply by the master switch at the analyser cabinet.
2. Provide the relevant gases. Therefor open the valves at the gas bottles.
3. Adjust the forced air to 1 bar.

CAUTION
The measuring medium must have atmospheric pressure (1013 mbar absolute).

4. Purge the device with instrument air.

5. Check the temperatures and the instrument air during the heat-up phase at regular
intervals.
6. Wait until temperatures, pressures and regulation parameters are stable.
7. Carry out the zero point setting:
- Manual zero point setting (see section 9.10 “Calibration”, page 59).
- Automatic zero point setting (see section 15.5, page 102)

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15.5 Automatic zero point setting via “Thermocal”

NOTICE
In case of intensely fluctuating ambient temperature the zero point position must be
corrected. Via function “Thermocal” the new zero point setting is executed automatically
(max. once in 2 hours).

If the deviation of electronics temperature of the MCA 10 HWIR from the last automatic zero
point setting until the current time is larger than 2.0 K, the function “Thermocal” is triggered.
Thereby the MCA 10 HWIR is purged with instrument air with a delay of two hours and the
zero point is set. The function “Thermocal” happens in maintenance mode.

1 2 3
Temperature [°C]

Time [h]

Fig. 36: Function “Thermocal”

1 Automatic zero point 3 “Thermocal” zero point

2 Leaving of the limit of 2 K

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15.6 Test gas provision

The test gas provision can be carried out locally via the gas distribution block at the
MCA 10 HWIR or by overflow process via gas sample probe.

NOTICE
Generally, a test gas provision via gas sample probe is recommended.

Within the scope of QAL3 tests the provision method must be kept according to component
specification. Hence the method of test gas provision must be defined at the beginning of a
QAL3 examination and must be adopted unmodified during the series of tests.

CAUTION
 Before test gas provision a stable zero point setting must have been carried out
(control of drift correction values not more than 0.2 %/h).
 To keep the climatic conditions constant, the cabinet door must be closed during the
complete test gas provision.
 For zero point calibration of the oxygen sensor, solely nitrogen must be used.

CAUTION
Conversion-active components!
Interactions with probe parts and the filter element can be caused.
In case of dry test gas provision of HCl, NH3, HF and NO2 a local test gas provision is
recommended.

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15.6.1 Local test gas provision at MCA 10 HWIR

(See section 8.2 “Test gas provision”, page 39)

15.6.2 Test gas provision via gas sample probe (optional)

NOTICE
For operation with the gas sample probe please read the technical documentation of the
supplier (see appendix). The contents are at responsibility of the manufacturer.

WARNING
Hot surface!
The gas sample probe is standard heated to a temperature of 185 °C.
Burn hazard!
Personal protective equipment according to the current legal accident prevention
regulations must be worn.

Fig. 37: Test gas provision via gas sample probe

1 Test gas connection

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Provide test gas

1. Switch the system into maintenance mode by the maintenance switch at the analyser
cabinet.
2. Connect the pipes for test gas provision with the test gas connection (1, Fig. 37).
3. Open the test gas supply.
4. To open the throttle non-return valve safe, adjust the primary pressure to 3 bar.
5. To avoid damage at the measuring device, limit the flow rate of the medium to min. 600 l/h
and max. 1000l/h.
› Excessive medium is conducted into the canal.
6. Wait until the settling time is over.
7. Read the measuring result from the connected visualisation PC.

To change into normal measuring operation after test gas provision, please proceed as
follows:
1. Close the test gas supply.
2. Remove the pipes of test gas provision from the test gas connection (1, Fig. 37).
3. Switch the system into operation mode by the maintenance switch at the analyser cabinet.

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15.7 Maintenance/Upkeep

NOTICE
The provision of guarantee items requires an execution of maintenance in due form.

The maintenance work has the following target:

 Preservation of measurement precision
 Warranty of operational safety
 Increment of service life

The following maintenance/upkeep work must be executed:

Component Action Maintenance interval

MCA 10 HWIR see chapter 10, page 65
Exhaust pipe Cleaning as required
Air conditioning unit Cleaning as required
Gas sample probe:
 Internal filter Exchange 4 months
 Gaskets Exchange 4 months
 Flange gasket Exchange 12 months

Tab. 14: Maintenance/upkeep works – system

NOTICE
For maintenance and upkeep of optional additional devices please read the technical
documentations of the suppliers (see appendix).
The contents are at responsibility of the respective manufacturers.

15.8 Error search and failure clearance

NOTICE
Error search and failure clearance for the system are carried out according to the
MCA 10 HWIR (see chapter 11, page 68).

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15.9 Shutdown and disposal

15.9.1 Shutdown

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.

WARNING
Corrosive substances!
Depending on the measuring gas incidental substances can be corrosive and/or
poisonous.
Contact can cause chemical burn of body tissue and serious eye injury.
Personal protective equipment according to the current legal accident prevention
regulations must be worn.

WARNING
Hot surface!
Several device parts can develop high temperatures.
Burn hazard!
Before working at the device it must be cooled down.

1. Purge the MCA 10 HWIR with zero gas for min. 30 min.
2. Disconnect the measuring gas pipe from gas sampling. Therefor shut the valves at the
gas bottles.
3. Switch off the compressed-air supply of the analyser cabinet.
4. Switch off the power supply by the master switch at the analyser cabinet.
› The MCA 10 HWIR, the air conditioner of the analyser cabinet and if necessary
connected optional additional devices are switched off automatically.

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15.9.2 Disassembling
1. Disconnect the power plug of the analyser cabinet from power supply.
2. Disconnect the signal connection from the control system.
3. Execute the following work at the MCA 10 HWIR:
a) Disconnect the power cord of the MCA 10 HWIR from the terminal strip in the analyser
cabinet.
b) Disconnect the communication cables of PLC and PC from the device.
c) Disconnect the forced air pipe from the device.
d) Disconnect the measuring gas pipe and the exhaust pipe from the device.
4. If necessary, disconnect optional additional devices from the system.
5. Release the tightening of the analyser cabinet from the wall/ground.
6. Release the screws at the mounting plate of the MCA 10 HWIR and remove the device
from the analyser cabinet.
7. If necessary, disconnect the heater of the exhaust pipe from the power supply.
8. Disconnect the measuring gas pipe from the probe.
9. Disconnect the probe heater from the power supply.
10. Dismount the probe.
11. Disconnect the heater of the measuring gas pipe and the temperature sensor from the
power supply.
12. Store all pipes safe and care for correct storage of all system components.

15.9.3 Storage
For correct storage the following conditions apply:
 Ambience:
- Ambient temperature: 0 ... 50 °C
- Relative humidity: max. 90% (non-condensing)
- Storage in rooms (outdoor storage not permissible)
- Protection against wetness
 Solid and plane bottom ground
 Location free of percussion

15.9.4 Disposal

NOTICE
The disposal must be executed according to the country-specific legal environmental
protection regulations. The device must be treated as hazardous waste.

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15.10 Technical data

System
Insulation Protection class I acc. to IEC 1010-1:1993
Insulation co-ordination Overvoltage category II according to
IEC 1010-1:1993

Protection degree IP 54
Pollution Pollution degree 2 according to
IEC 1010-1:1993
Ambient conditions:
 Ambient temperature for operation 5 ... 40 °C
 Ambient temperature for storage 0 ... 50 °C
 Relative humidity max. 90% (non-condensing)
Power supply 400 V / 50 Hz, 4000 W (analyser cabinet,
air conditioner, probe)
+ 100 W/m measuring gas pipe
Compressed-air supply 4...6 bar
Compressed-air consumption Approx. 1 m³/h (dependent on application)
Calibration  Zero point: automatically with instrument
air
 Span point: with test gas, optional:
automatically
Interfaces Analogue outputs, Modbus, Profibus, further
on request
Remote control Ethernet
Analogue outputs Max. 24 x 4 ... 20 mA
Digital outputs Failure, maintenance, maintenance require-
ment, measuring range switch-over, other
Inputs For analogue and digital signals

Tab. 15: Technical data – System

Analyser cabinet
Dimensions 2100 mm x 800 mm x 600 mm (H x W x D)
Material Steel sheet
Weight Approx. 200 ... 300 kg (depending on
fitments)
Colour RAL 7035 (light grey)
Operating unit Control panel with touch surface

Tab. 16: Technical data – Analyser cabinet

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15.11 Spare and wear parts

For placing a purchase order of spare and wear parts please refer to Dr. Födisch
Umweltmesstechnik AG (contact details: see cover inside).

Element/Component Item number

2-way solenoid valve ETLD 608
2-way solenoid valve, normally closed ETLD 318
2-way solenoid valve, normally open ETLD 319
Air conditioner ETLA 469
Analogue extension module for PLC ETLA 1038
Analogue input for PT100 for PLC ETLA 1039
Battery for FP Sigma ETLA 1041
Bulkhead screwing, straight, stainless steel ETLA 1356
Bulkhead screwing, straight, stainless steel ETLA 482
Cabinet heating ETLD 264
Communication cassette COM4 ETLA 1037
Compressed-air station ETLD 138
Compressed-air station, common supply block ETLD 136
Compressed-air station, end block at left site ETLD 134
Compressed-air station, end block at right site ETLD 135
Condensate tank with level sensor ETLD 344
Connector block module PLC ETLA 1165
Coupling relay ETLA 437
CPU for PLC/cabinet ETLA 1036
Digital output expansion for PLC ETLA 1040
Elbow screwing with plug connector ETLD 321
Fine dosing valve ETLA 481
Locking screw M63x1.5 ETLA 187
Multiple-port plate ETLD 316
Null modem cable ETLD 349
Pass element ETLD 353
PLC ETLD 324
PLC programming cable for PC ETLA 598
Plug connector screwing with hexagon socket ETLD 315

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Element/Component Item number

Power supply unit 24 V, 120 W ETLA 1052
Power supply unit 24 V, 60 W ETLA 1051
Pressure regulator ETLD 133
Rack assembly set ETLD 137
Ribbon cable ETLA 1042
Screw-in adapter ETLA 713
Sealing set for solenoid valve station ETLD 465
Solenoid valve station ETLD 323
Throttle non-return valve ETLD 320
Thyristor power switch ETLA 634
Touch panel ETLD 498 /
ETLD 52
USB cable ETLD 350

Tab. 17: Spare and wear parts – System / Analyser cabinet

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16 Index

16 Index

A
Components ........................................15
Additional devices
Configuration ...........................50, 63
System design ............................... 31
Diagnostics ....................................55
Air-jet pump ......................................... 27
Interference....................................63
Ambient conditions for analyser cabinet
Linearity .........................................63
Operation ....................................... 99
Span point................................59, 60
Storage ........................................ 108
Zero point.................................59, 60
Ambient conditions MCA 10 HWIR
Compressed-gas cylinders ..................14
Operation ....................................... 37
Concentration development.................53
Storage .......................................... 90
Configuration .......................................62
Analyser cabinet.................................. 97
Safety instructions .........................15
Ambient conditions ................ 99, 108
Conformity .............................................7
Commissioning of system ............ 101
Connection assignment .......................30
Design ........................................... 97
Couple-in area / Couple-out area ........25
Disassembling ............................. 108
CPU components ................................34
Disposal ....................................... 108
Cross sensitivity ..................................20
Maintenance ................................ 106
Cuvette ................................................25
Mounting ...................................... 100
Placement ..................................... 99
Shutdown of system .................... 107 D
Spare parts .................................. 110
Data transfer........................................45
Storage ........................................ 108
Date .....................................................42
Technical data ............................. 109
Date of manufacture ............................50
Transport ....................................... 98
Design
Upkeep ........................................ 106
Analyser cabinet ............................97
Wear parts ................................... 110
CPU components...........................34
Analyser cabinet heater .................... 100
Cuvette ..........................................25
Application .................................... 21, 31
Detector unit ..................................26
Arrow button ........................................ 45
Emitter unit.....................................24
Auto calibration ................................... 58
Gas circuit diagram ........................32
Automatic zero point setting .............. 102
Gas distribution block ....................27
Interfaces .......................................29
B Mainboard ......................................28
MCA 10 HWIR ...............................23
Back (button) ....................................... 45
Oxygen sensor...............................27
Back purging ....................................... 64
Power supply unit ..........................29
Bi-frequency measuring method ......... 17
Signal plan .....................................35
System design ...............................31
C Detector board.....................................26
Calibration ........................................... 59 Detector unit ..................................23, 26
Auto calibration .............................. 58 Detector, pyroelectric ..........................26
CE label ................................................ 7 Device information ...............................50
Certification range ............................... 93 Diagnostics ..........................................55
Chopper wheel .................................... 24 Disassembling MCA 10 HWIR.............90
Commissioning MCA 10 HWIR ........... 38 Disassembling of analyser cabinet ....108
Software installation ...................... 40 Display and operating elements ..........42
Commissioning of system ................. 101 Disposal MCA 10 HWIR ......................90
Communication paths ......................... 35 Disposal of analyser cabinet..............108
Communication status............. 42, 56, 88 Drift correction ...............................59, 61
Compensation table ............................ 20

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 16 Index

E M
Electrical power supply ....................... 12 Main menu .......................................... 50
Electrical safety ................................... 13 Mainboard ........................................... 28
Electronic elements............................. 15 Maintenance MCA 10 HWIR ............... 65
Emitter unit .................................... 23, 24 Maintenance message ............ 42, 56, 79
Error search ........................................ 68 Maintenance of analyser cabinet....... 106
Exhaust connection............................. 30 Maintenance of system ..................... 106
Maintenance requirement
message ................................. 42, 56, 81
F Maintenance switch............................. 54
Failure clearance ................................ 68 Manufacture date ................................ 50
Failure message ..................... 42, 56, 70 MCA 10 HWIR
Filter wheel ......................................... 26 Ambient conditions .................. 37, 90
Flow Commissioning .............................. 38
Calibration ............................... 59, 61 Connection assignment ................. 30
Configuration ........................... 63, 64 Design ........................................... 23
Diagnostics .................................... 55 Device type .................................... 50
Flow measurement ............................. 27 Disassembling ............................... 90
Focussing mirror ........................... 24, 26 Disposal ......................................... 90
Function button ................................... 44 Maintenance .................................. 65
Functional description ......................... 21 Mounting ........................................ 37
Mounting in analyser cabinet ....... 100
G Operating ....................................... 41
Placement ..................................... 37
Gas circuit diagram ............................. 32 Scope of supply ............................. 36
Gas distribution block.................... 23, 27 Shutdown ...................................... 89
Gas filter correlation ............................ 18 Spare parts .................................... 94
Gas provision ...................................... 54 Storage .......................................... 90
Gas supply .......................................... 14 Technical data ......................... 91, 92
Transport ....................................... 36
H Upkeep .......................................... 65
Wear parts ..................................... 94
Heater ................................................. 27
Measurement ...................................... 52
Configuration ................................. 63
Concentration development ........... 53
Diagnostics .................................... 55
Measuring cell ..................................... 23
Heater control ..................................... 26
Measuring gas cell .............................. 27
History................................................. 57
Measuring gas connection .................. 30
Measuring gas provision ..................... 54
I Measuring principles ........................... 16
Info message ...................................... 88 Measuring ranges ............................... 93
Info text ............................................... 43 Menu ................................................... 50
Information ............................................ 6 Auto calibration .............................. 58
Infrared emitter ................................... 24 Calibration ..................................... 59
Input field ............................................ 44 Concentration development ........... 53
Input window ....................................... 44 Configuration ................................. 62
Intended use ......................................... 6 Diagnostics .................................... 55
Interfaces ............................................ 29 Main menu ..................................... 50
Interference ......................................... 63 Measurement ................................ 52
Messages ...................................... 56
Service mode ................................ 64
K System control ............................... 54
Key symbol ......................................... 50 Messages ...................................... 56, 69
History ........................................... 57
Mirror ................................................... 25
L
Mounting MCA 10 HWIR ..................... 37
Language Mounting of analyser cabinet ............ 100
Change.......................................... 51
Display .......................................... 50
Linearity .............................................. 63

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16 Index

O Q
O2-sensor Qualification for error/failure
Calibration ............................... 59, 60 clearance .............................................68
Configuration ................................. 63
Diagnostics .................................... 55
Operating ............................................ 41 R
Auto calibration .............................. 58 Regulations ...........................................7
Calibration ..................................... 59 RJ-45 interface ....................................29
Configuration ................................. 62 RS232 interface...................................29
Data transfer .................................. 45
Diagnostics .................................... 55
Display and operating elements .... 42 S
Main menu ..................................... 50 Safety instructions .................................8
Measurement ................................ 52 Scope of supply MCA 10 HWIR ..........36
Menu structure............................... 46 Selection field ......................................43
Messages ...................................... 56 Selection list ........................................43
Password levels............................. 49 Serial number ......................................50
Screen design ............................... 42 Service date ........................................50
Service mode ................................ 64 Service mode ......................................64
Software installation ...................... 40 Service qualification ............................68
Software uninstallation .................. 40 Shutdown MCA 10 HWIR ....................89
System control ............................... 54 Software uninstallation ...................40
Optional additional devices Shutdown of system ..........................107
System design ............................... 31 Signal plan...........................................35
Over-temperature protection ......... 26, 27 Software
Oxygen measurement ......................... 19 Installation......................................40
Oxygen sensor .............................. 23, 27 Uninstallation .................................40
Calibration ............................... 59, 60 Versions ...................................50, 92
Configuration ................................. 63 Span point .....................................59, 60
Diagnostics .................................... 55 Spare parts for analyser cabinet........110
Spare parts MCA 10 HWIR .................94
Spectral range .....................................92
P Standards ..............................................7
Parameter synchronisation ................. 34 Status information ...............................42
Particle filter ........................................ 92 Step motor ...........................................26
Password ...................................... 49, 50 Storage MCA 10 HWIR .......................90
Input password .............................. 51 Storage of analyser cabinet ...............108
Password administration ............... 64 Synchronisation ...................................34
Personal protective equipment ............ 10 System
Personnel, requirements ..................... 11 Commissioning ............................101
Photometer ......................................... 23 Configuration ...........................63, 64
Technical data ............................... 92 CPU components...........................34
Photometry .......................................... 16 Design ...........................................31
Placement MCA 10 HWIR ................... 37 Diagnostics ....................................55
Placement of analyser cabinet ............ 99 Gas circuit diagram ........................32
Pop-up window.................................... 44 Gas provision .................................54
Power supply....................................... 12 Maintenance/Upkeep ...................106
Power supply unit ................................ 29 Shutdown .....................................107
Pressure Signal plan .....................................35
Configuration ................................. 63 Technical data .............................109
Diagnostics .................................... 55 System application ..............................97
Pressure measurement ....................... 27 System control.....................................54
Pressure sensor ............................ 23, 27
Protective equipment .......................... 10
Purging (back purging) ........................ 64
Pyroelectric detector ........................... 26

114 Operation Manual MCA 10 HWIR Version 3.3

 16 Index

T V
Technical data MCA 10 HWIR ...... 91, 92 Value input .......................................... 44
Certification range and measuring
ranges ........................................... 93
Technical data of analyser cabinet ... 109 W
Technical data of system .................. 109 Warranty ............................................... 7
Temperature sensor............................ 27 Wear parts MCA 10 HWIR .................. 94
Test gas provision ............................... 54 Wear parts of analyser cabinet.......... 110
Local.............................................. 39
Via gas sample probe.................. 103
Thermocal ......................................... 102 Z
Time .................................................... 42 Zero gas provision............................... 54
Transport MCA 10 HWIR .................... 36 Zero point ............................................ 60
Transport of analyser cabinet ............. 98 Zero point automatically ...................... 58
Zero point setting, automatic ............. 102
Zirconium dioxide cell .......................... 19
U
Upkeep MCA 10 HWIR ....................... 65
Upkeep of analyser cabinet .............. 106
Upkeep of system ............................. 106
USB interface ...................................... 29
Use, intended ........................................ 6

Version 3.3 Operation Manual MCA 10 HWIR 115