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Union Instruments CWD 2005 User Manual Download Page 18

Analyzer Overview 

 

Manual CWD 2005 

___________________________________________________________________ 

18 

Manual CWD2005.doc

 

 

 

Figure 2: Rear inside view of main door 

1 

Power supply 

2 

Port for connections 

3 

Blower power supply 

4 

Main Board 

5 

ETX Board 

6 

Blower ETX Board 

7 

Keypad back side 

Summary of Contents for CWD 2005

Page 1: ...Users Manual CWD 2005 Combustion Calorimeter For high speed measurement of fuel gases ...

Page 2: ...om Web http www union instruments com Represented in China by Anshan Union Industry and Commerce Company Ltd c3 311 Luse Zhihui Cheng Lishan District Anshan Liaoning 11404 China Tel 0086 412 5814665 0086 412 5921396 Fax 0086 412 5824215 Email uts_wang yahoo com cn Represented in North America by Delta Instrument LLC 148 Veterans Drive Northvale NJ 07647 Phone 201 768 7200 Fax 201 768 5020 Web Delt...

Page 3: ...nual CWD 2005 ___________________________________________________________________ Manual CWD2005 doc 3 Attention Please read all safety instructions before you connect the CWD 2005 See section 1 1 page 6 ...

Page 4: ...Manual CWD 2005 ___________________________________________________________________ 4 Manual CWD2005 doc ...

Page 5: ... 1 Shelter requirements 27 4 2 Room ventilation 27 4 3 Exhaust gas discharge 27 4 4 Electrical power connection 28 4 5 Gas connections 29 4 5 1 Process gas filters 29 4 5 2 Pressure Regulators 30 4 5 3 Sample gas pump 31 4 5 4 Carrier gas Support 32 4 5 5 Fast Loop connection 32 4 6 Interfaces 33 5 Commissioning 35 6 Software 38 6 1 Screen and Keypad layout 38 6 1 1 Menu keypad 39 6 1 2 Trend disp...

Page 6: ...eneral 54 6 2 1 3 2 Ignition 55 6 2 1 3 3 Update 55 6 2 1 3 4 Load factory configuration 56 6 2 1 3 5 Curve Data to CSV File 56 6 2 1 3 6 Hold Signal on off 56 6 2 1 3 7 Settings 57 6 2 1 3 7 1 Time Date 57 6 2 1 3 7 2 Language 58 6 2 1 3 7 2 1 Change language 59 6 2 1 3 7 2 2 Bit maps on off 59 6 2 1 3 7 2 3 Transfer W D C 60 6 2 1 3 7 2 4 Transfer W C D 60 6 2 1 3 7 2 5 Read PCX files 60 6 2 1 3...

Page 7: ...plete ignition 81 8 5 Software troubleshooting 81 9 Measurement principle 84 9 1 Heating Value measurement an overview 84 9 2 Thermopile measuring system 85 9 2 1 Specific Gravity measuring cell 87 9 2 2 Operational overview of the measuring cell 87 9 2 3 Functional diagram 88 9 2 4 Output signals 88 9 2 5 Commissioning 88 9 2 6 Testing and calibration 89 9 2 7 Maintenance 89 9 2 8 Technical speci...

Page 8: ... 101 11 5 2 Calibration gas connection 101 11 5 3 Process gas connection 102 11 6 Double Range 104 11 7 Carrier Gas 105 11 8 Fast loop 106 11 9 Air Consumption Option 106 11 9 1 Calculated Air Consumption 106 11 9 2 Air Consumption with CO measurement 107 12 Spare parts 110 12 1 Spares electronics 110 12 2 Spares Electric 111 12 3 Spares gas 114 12 4 Spares measurement system 116 12 5 Spares burne...

Page 9: ...ng transit If there is any sign of visible damage to the crate or hidden damage inside the shipment notify the carrier and the factory immediately as the equipment warranty does not cover damage in shipping In the event of trouble during start up please contact a factory representative and inform them of the model and serial number of the unit plus a fully description of the problem Note The facto...

Page 10: ...ditions not 100 burnt gas there is a danger of bad components in the burnt gases of the outlet of the system If process gas has toxic components please consider that all actual safety rules have to be abode Non toxic gases are without problems They are very high diluted with cooling air All electrical connections to line power must be carried out by a qualified electrician The analyzers internal e...

Page 11: ...r closed In the event of failure of gas or cooling air supply the gas solenoid valve will close and after a short interval the solenoid will reopen and the instrument will enter an ignition cycle If the ignition cycle or online measurement function is aborted due to flame out or power failure the gas supply solenoid reverts to its normally closed position and the small amount of sample gas flow is...

Page 12: ...Introduction Manual CWD 2005 ___________________________________________________________________ 12 Manual CWD2005 doc ...

Page 13: ...ured continuously and the temperature rise from heat of combustion is transferred from the burner to the thermopile via the cooling air supply and is measured by its thermopile sensor as heat rise Measurement is based on the real time Wobbe Index and Specific Gravity values of the gas a specific gravity sensor is built into the calorimeter The PC based microprocessor calculates Calorific Value usi...

Page 14: ...ual range option If one calibration gas is in the transition zone from one measuring range to the next a single calibration gas can be sufficient for both measuring ranges This must be tested on an application basis by the factory Measuring ranges that are too far apart or contain vastly different components can only be combined into a single measuring range under very specific circumstances Anoth...

Page 15: ...Manual CWD 2005 Analyzer Overview ___________________________________________________________________ Manual CWD2005 doc 15 ...

Page 16: ...______________ 16 Manual CWD2005 doc 3 Analyzer Overview All major components are shown below and can be replaced if necessary as a spare part Items marked with an are not visible on this drawing see following drawings Figure 1 CWD 2005 components shown above but without doors for clarity ...

Page 17: ...er ignition transformer 14 Air fan 15 Power supply for fan air 16 Line filter power supply fan air 17 Terminal block power supply 18 Cable gland signals 19 Cable gland signals 20 Cable gland signals 21 Cable gland signals 22 Cable gland line power 23 Cable gland signals 24 Electronic extern output signals digital and analog 25 Safety switch ignition transformer 26 PT 100 sensor box inlet temperatu...

Page 18: ...___________________________________________________________ 18 Manual CWD2005 doc Figure 2 Rear inside view of main door 1 Power supply 2 Port for connections 3 Blower power supply 4 Main Board 5 ETX Board 6 Blower ETX Board 7 Keypad back side ...

Page 19: ..._________________________ Manual CWD2005 doc 19 Figure 3 Front view 1 Cable gland signals 2 Cable gland signals 3 Cable gland signals 4 Cable gland signals PS M20 5 Cable gland ground M16 6 Filter cover 7 Switch on off 8 Door lock 9 Discharge 10 Display 11 Cover analog signals ...

Page 20: ...Interface connections 8 Fast loop 9 Carrier gas SV X11 3 4 10 Calibration gas 2 SV X14 3 4 11 Calibration gas SV X14 1 2 12 Process gas SV X11 1 2 The above drawing shows a standard instrument or instruments equipped with one or two calibration gases or carrier gas Instruments with the option of two process gases have a different inlet arrangement and this will be labeled on the instrument The ite...

Page 21: ...dimensions Height 1020 mm 40 2 inches Width 720 mm 28 3 inches Depth 337 mm 13 2 inches Weight 50 5 kg 111 lbs Protection IP 54 NEMA 12 The analyzer is supplied for wall mounting brackets are included All gas connections are located on the left hand side of the unit Allow enough space for the doors to swing open and other accessibility issues when mounting the unit ...

Page 22: ...ty gases such as Blast Furnace gas and Coke Oven gas The volume of the filter will effect the response time and the filter element should have a large active face retention area and a small dead volume If the process gas is at a much higher temperature than ambient and the humidity of the process gas is high water can condense in the lower temperature sample tubing runs and this must be avoided Th...

Page 23: ... feet 0 1450 Wobbe Btu ft 0 64 ft hour Example 2 Wobbe jet Size 0 85 S G Coke gas 0 422 The Coke gas consumption corresponds to a range of Wobbe Index of 6000 Wobbe kcal Nm or 25000 Wobbe to kj Nm 53 22 liter h In BTU and cubic feet 0 630 Wobbe Btu ft 1 89 ft hour Example 3 Wobbe jet Size 1 85 S G Blast Furnace gas 1 032 The Blast Furnace gas Coke gas consumption corresponds to a range of Wobbe In...

Page 24: ...e computer calculates the transition between the first and second range so that one continuous 4 20 mA DC output signal and display is available over the entire range 3 6 Ambient temperature limits The CWD 2005 should be installed in a room that does not exceed minimum and maximum temperature requirements A typical temperature range is 10 C to 38 C 50 F to 100 F Higher 100 F or more or lower tempe...

Page 25: ...005 doc 25 4 Installation Figure 6 Enclosure attachment Exhaust 1 Fixing element 2 Cover insulation 3 Draft brake 4 Discharge CWD 2005 5 Fixing barcket The analyzer is intended to be mounted on the wall 2 special fastening strips supplied from the manufacturer They are equipped with 8 mm pins attached to the ...

Page 26: ...les in the struts affixed according to figure A distance of 840mm must be available between the mounting strips see Figure 7 to meet exactly the holes vertical distance on the back of the analyzer Figure 7 Mounting the Analyzer The unit can also be installed on a freestanding rack and a stainless steel support bracket is available which must be ordered separately ...

Page 27: ...uced or eliminated completely Note Sections 4 1 4 2 and parts of 4 3 are for customer guidance if a shelter has not been purchased from the factory as part of the original order 4 3 Exhaust gas discharge The small quantity of flue gas is mixed with 25 m of air after combustion and is heavily diluted with an exhaust temperature around 8 10 C 15 F above ambient Flue gases must be discharged from a f...

Page 28: ... wired to the terminal block in the bottom section of the enclosure see drawing figures 1 and 8 Check whether the available voltage supply matches the analyzers rated voltage Figure 8 Connector block assembly 1 Power supply customer 2 Main switch instrument on off 3 Door safety switch 4 Line filter 5 Power supply 6 Ignition transformer 7 Door switch signal 8 Ignition impulse 9 Fan with power suppl...

Page 29: ...l volume Filter elements need to be changed occasionally and a pressure gauge can be used to check filter back pressure The mA hold function can be activated before the filter change to provide a continuous output signal during filter maintenance Be sure to cancel memory hold after use Figure 9 Small filter 1 Input 6 mm Gyrolok 2 Output 6 mm Gyrolok 3 Removable element cap 4 Filter body 316 SS 5 F...

Page 30: ...one calibration gas inlet and both inlet ports require a pre pressure regulator All connectors are mm or inch Adjust the process gas and calibration gas regulator outlet pressures to read the same pressure when gases are switched this is important for measurement stability The first pre pressure regulator 6 bar 90 PSI has a zinc die cast body and internal parts are made of steel and elastomers Two...

Page 31: ...DIN 477 Nr 1 or CGA sized fittings Mixed gas M19 x 1 5 LH DIN 477 Nr 14 or CGA sized fittings A pre pressure regulator is still required after the high pressure calibration gas cylinder regulator for two stage inlet pressure control Figure 13 High pressure regulator GO PR1 250 bar 3600 PSI 1 Inlet connection to suit gas cylinder 2 Outlet 6 mm Gyrolok tube 3 Gauge high pressure 4 Gauge low pressure...

Page 32: ...non flammable carrier gas that supports combustion without adding calorific value Typical flow of carrier gas is 3 5 Liter h The software is configured at the factory See Section 6 2 1 3 8 For mechanical installation see section 11 5 3 The carrier gas support option needs to be installed at the factory as it is difficult to retrofit the system after delivery 4 5 5 Fast Loop connection For a more r...

Page 33: ...erfaces A range of electronic devices can be connected to the CWD 2005 The analyzer can be operated using a plug in mouse and a standard PC keyboard with PS2 connector Figure 14 Interface connection on the left hand side of the main door 1 USB Interface 2 VGA Display 3 mouse Interface 4 Keyboard interface 5 Parallel interface ...

Page 34: ...Commissioning Manual CWD 2005 ___________________________________________________________________ 34 Manual CWD2005 doc ...

Page 35: ...dy to be powered up The following work must be carried out when commissioning the unit Remove the transport tie wraps and transport screws from the specific gravity cell The body of the cell must hang free on the springs and may not come into contact with the sides of the bracket The screw should be removed and stored and the following diagram illustrates the process Figure 15 Specific Gravity cel...

Page 36: ...weight loaded regulator The air pressure should need no adjustment by the user as control is by the variable speed air fan Check the specific gravity differential pressure indication on the screen reads 4 mbar and adjust if necessary see section 9 2 4 for more details After the warm up period the instrument will show the Calorific Value Wobbe Index Value and Specific Gravity numerically in the dis...

Page 37: ...Manual CWD 2005 Software ___________________________________________________________________ Manual CWD2005 doc 37 ...

Page 38: ...ng the bottom edge of the display adapts to the changing requirements of all the corresponding menus and redefines keypad function The menu buttons 1 always leads to the next higher menu level The menu button 5 always returns the user to the start menu regardless of menu level When addressing the software interface please allow one second between keypad commands 6 1 Screen and Keypad layout Figure...

Page 39: ...rom the thermopile V is the signal in Volts from the specific gravity cell T1 is the air temperature in C at the thermopile entrance The next value is the differential temperature of any change in incoming air temperature The next value is p for differential air pressure Fr is the current frequency of the fan speed controller and this value is helpful to monitor the condition of the air filter Sta...

Page 40: ...it of the frequency controller has been reached Disturbance Indicates a fault alarm condition 6 1 10 Arrow and data entry keypad Move the cursor in the different menu screens and the yellow center key enters data 6 1 11 Data input There are value fields and list fields which can also appear in each dialog box 6 1 11 1 Value fields In the value field the numerical values can be entered with the num...

Page 41: ...nd pressing the button faster than one second will receive no system response 6 1 13 Menu Navigation The block diagram shows three different shaped menu areas The simple square areas indicate that there are more menu levels The rectangle with the rounded corner indicates that menu is at the lowest menu level The double square indicates the location of an interactive input screen for value or data ...

Page 42: ...play 6 2 1 1 3 Disp mA 6 2 1 3 4 Load fact conf 6 2 1 4 Service 6 2 1 2 4 Store basic calib 6 2 4 Device info menue kurz engl CWD2005_2007_03_30 6 2 1 2 5 Calib limits 6 2 1 3 7 1 Date and time 6 2 1 3 7 3 Password 6 2 1 3 7 5 Hardware 1 6 2 1 3 6 Hold signals on off 6 2 1 3 5 Export CSV file 6 2 1 3 7 Settings 6 2 1 3 7 4 Color settings 6 2 2 1 Change time 6 2 2 5 Move cursor 6 2 2 4 Change units...

Page 43: ...ividual screen different information are available The description is made in the special section in this manual V 2 07 version number of soft ware R02 Instrument runs on process gas During a calibration the indication switches to calibration Actual date and time 19 00 mV signal of the thermopile 1 016 volt signal specific gravity cell T1 24 61 12 82 input Temperature in the thermopile in relation...

Page 44: ... 015 Under this value calibration is finished The free area of the info field is filled up with useful information in different menus for example filter changing over temperature etc 6 2 1 Options The Options menu contains all of the following menus Button leads back to the main menu The free area of the info field is reserved for important information The information belongs to the actual menu le...

Page 45: ...r example 3 outputs for Wobbe Index or 2 outputs for Specific Gravity etc 3 remote contact inputs and 4 numeric screen displays are provided 6 2 1 1 1 Analog outputs The symbols and move the marked value right or left The symbol leads back to the main menu The following items listed below can be selected from a series of multiple choice lists and the user can define the allocation order of the ana...

Page 46: ...e to are value fields for numerical inputs 6 2 1 1 2 Relay output The relay output configuration menu consists of signals in combination with threshold values or operating status messages If an alarm is triggered a message will appear in the information field and the fault LED on the door will light Signal is a list field Wobbe Calorific Value and alarm messages can be selected Operation will show...

Page 47: ...ital inputs Signal and zero position are multiple choice list fields These inputs can start a calibration cycle or switch on and off an output hold module The inputs are polled once a second and any change of status must apply for at least one second to be recognized by the system Signal Zero position Contact CWD 2005 Start measurement high open CWD2005 measurement closed CWD2005 measurement stop ...

Page 48: ... contact inputs Start measurement Start calibration and Start hold are connected to terminal block number X3 on terminals 1 to 6 See Chapter 10 for wiring details 6 2 1 1 5 Display Physical value and Unit are list fields They determine the numerical display on the user configurable display screen In the example Wobbe Index Calorific Value Specific Gravity and pressures are displayed on screen ...

Page 49: ... again using both carrier gas and process gas to establish correct calibration in all modes against calibration gases Dual sample stream analyzers usually use a single calibration gas Calibration for W 2005 The W 2005 is supplied without a density cell and does not require a specific gravity input Enter 0 in the density field display because if there is a number entered the software will try to ca...

Page 50: ...he user must calculate and enter these three calibration gas values from the components of the calibration gas A small software program excel file can be obtained from the factory which can also be downloaded from the Internet homepage Also the memory stick which is delivered with the instrument obtains this program This includes most of the gases found in many common process gas streams and this ...

Page 51: ...s A failed calibration will be recorded in the event list and may indicate a maintenance condition has occurred Warning Air can become trapped in the gas supply tubing during installation Purge the lines before first calibration or after changing the calibration gas cylinder The Start calibration command may need to be executed several times 6 2 1 2 3 Calibrate This menu starts the manual calibrat...

Page 52: ...on stores the last calibration to get a fix point for the calibrations The point is important to see the deviation at the next calibration and to have a deviation limit for a signal if the limit hits a programmed limit 6 2 1 2 5 Calibration Limits Here it is possible to program limits for each value after a calibration to give a signal if a deviation reaches this limit ...

Page 53: ...______________________ Manual CWD2005 doc 53 6 2 1 3 System This menu item contains the following basic analyzer configuration parameters Two pages open the different items of the menu The button swiches from one page to the other page The next line with other three menus ...

Page 54: ...t from the system and the shutdown of the fan saves energy and filter life A value of 0 will run the cooling air fan continuously and the unit is ready for immediate use after a restart When selecting Delayed shutdown the air fan can be switched off after the time shown in seconds In the example the air fan will run for a further 30 seconds after process gas shutdown before the fan shuts down auto...

Page 55: ...temperatures are gas composition dependant so the factory will preset the optimum temperature for the specified measuring range In the example 3 C is the differential temperature of the incoming cooling air flue gas mix at the thermopile 6 2 1 3 3 Update If a new update is required a CWD 2005 software memory stick has to be inserted in the left side of the door Start by pressing the Update menu ke...

Page 56: ...unction with the instrument this key allows a return to factory default by running the standard configuration as supplied by the factory Note Without a memory stick in the slot an error message appears Unable to open file 6 2 1 3 5 Curve Data to CSV File In this menu all data are exported as ASCI files All 25 available data are exported in one session in a CSV file Excel can handle this file 6 2 1...

Page 57: ...ual CWD2005 doc 57 6 2 1 3 7 Settings Settings are all menu buttons which belong to basic configuration and are only seldom or only from time to time used 6 2 1 3 7 1 Time Date Set the system time and date the clock stops when the menu is open Use CANCEL to exit the menu without making any changes ...

Page 58: ...___________________________________________ 58 Manual CWD2005 doc 6 2 1 3 7 2 Language The menu language consists of 10 submenus With the button all the menus can be reached After the first 4 menus the next 4 menus appear and at least the last 2 ones ...

Page 59: ...English display capability Other languages can be included relatively easily A TXT file is available for translation by a customer from one language English into another and requires 1100 words 6 2 1 3 7 2 2 Bit maps on off This button switches bit maps on or off For example a complete set of chinese files can be activated for correction or for completing the language file ...

Page 60: ... the memory stick to the hard disk of the unit 6 2 1 3 7 2 6 Store PCX files This key starts the copy from the hard disk of the unit of PCX files bit maps to the memory stick 6 2 1 3 7 2 7 Delete PCX files This key deletes all PCX files bit maps on the hard disk C of the unit 6 2 1 3 7 2 8 PCX Info PCX info writes a txt file Every word has a number to identify the expression Under this number the ...

Page 61: ...ble for a floppy disc The switch can be made here 6 2 1 3 7 3 Password A password can be selected if required by the user If selected no system changes can be made without entering the pass code When unlocked system access is denied after 30 minutes and will ask for the password Entering 0 switches the password system off A default is available if the password is lost ...

Page 62: ...o the burner type range and configuration These parameters are application specific and it is strongly recommended that changes in this table should not be made without consultation with the factory The data values have been tested at the factory to match the process gas if the customer decides to change ranges or carrier gas type contact the factory for new data The previous screen shot shows all...

Page 63: ...utomatically If manual is chosen an additional menu appears see section 6 2 1 3 9 for more details A 2 point calibration is an additional function for 2 point calibration with 2 calibration gases In the screen page 58 in the line change range are 4 different indications possible non automatic manuel calculate Calculate calculates 2 calibration gases in one line Under Range No third line range cfg ...

Page 64: ...enus are only accessible to the technical staff of the manufacturer and contain specialized areas for data calculation compensation for various temperatures operating functions and internal system calibrations Access to this area may void the equipment warranty if data in this area is corrupted by the user A special service manual is required for work in any of the special service areas To enter t...

Page 65: ..._________________________________ Manual CWD2005 doc 65 6 2 1 5 Customer specific application Several different menus described below These options are pre programmed by the factory as required Restart power to the unit after an option is selected to enable it ...

Page 66: ...on with the manufacturer 6 2 1 5 2 Serial Printer The RS232 interface can be connected to a printer and the Star Micronics model TSP 600 is recommended by the factory The analyzers software supports this model of printer The paper empty or interrupt during paper reload function are programmed in the software and the necessary feed back signals come from the printer Other printers can be installed ...

Page 67: ... and printed afterwards The service LED on the screen flashes as a warning to change the printer roll During this procedure any data is stored and printed afterwards During the instrument start up the printer will be unavailable during the warm up period and the printer will start at the selected time cycle Configure the printer options from the table below and 5 different parameters are available...

Page 68: ...it code of the outputs 1 7 Output 1 1 Output 2 2 Output 3 4 Output 4 8 Output 5 16 Output 6 32 Output 7 64 For all outputs enter code 127 1 2 4 8 16 32 64 Example Sum of outputs 1 to 7 Output 1 and 2 is the code 3 1 2 Output 1 2 and 3 1 2 4 is code 7 Logging state is the output of all state changes These states are also available in the event list and stored Yes or no switches this function on or ...

Page 69: ...e new stream After a purge time of 1 minute the process gas shows the new stream value and this is a standard configuration In the example above the values for the two gases are shown the last measured gas stream is displayed as a fixed value in the left hand display screen and the right hand display is the online value The information window at the top right indicates process gas 2 is online Note...

Page 70: ... the screen After pressing the button trend in the main menu 5 different menus are available to display all important functions of the instrument After scrolling the five menus the first menu is again available and so on To handle the parameters there are two possibilities 1 Buttons on the bottom line with different symbols The symbols change with the menu accordingly 2 The arrows and the return o...

Page 71: ...lue Available values Cal Vi 2 Wobbe I 2 free Spec grav 2 Cal Vs 2 cal Vi Wobbe i Wobbe s Spec grav Cal Vs T sec T ein dT T amb T i T Res 3 p air p Wobbe p density p res 3 mV All three info windows are prepared for all physical values and can be displayed in the diagram 6 2 2 2 Change time To present the diagrams optimal tools are programmed which can show the graph in an optimal solution In the fo...

Page 72: ...__________________________________ 72 Manual CWD2005 doc Every touch of the button makes one step The meaning of the symbols are Value linear right 25 x axis Value linear left 25 x axis Value pressed 25 x axis Value stretched 25 x axis 6 2 2 3 Change y values ...

Page 73: ...pressed 25 y axis Value stretched 25 y axis Now the specific gravity window is selected The three lines Dif y delta from line to line 15 00 Off y Position of the offset 1177 441 value actual value 1221 266 are important to have a good most significant graph of the specific gravity 6 2 2 4 Change signals The handling of the menu change signals is the same as before described ...

Page 74: ...___________________________________________ 74 Manual CWD2005 doc 6 2 2 5 Change units The handling of the menu change signals is the same as before described Note The trend data is the only data that will be erased if power is lost to the instrument ...

Page 75: ...urrence The buttons Show start up and Show calibration select these specific events The button Show all displays all events The buttons Previous and Next scroll the screen up and down Status calibration gives deviation from the last calibration in with date and time During an update of the CWD 2005 sometimes a message can appear ADU error This message is also shown in the event list This message i...

Page 76: ...n case of questions or trouble please give these data to the manufacturer Every change in the screens which are important for the running is automatically stored in this screen device Data Also important service informations are stored in the screen After a service our service people will update this screen For example a change of the range is automatically stored also changes of output data ...

Page 77: ...Manual CWD 2005 Maintenance ___________________________________________________________________ Manual CWD2005 doc 77 ...

Page 78: ...rubber connection on the Wobbe jet and air jet for any leakage Both the thermopile and heat exchanger should be removed and cleaned Combustion by products can form crystals and these can be washed away with warm water and when these parts have been thoroughly dried they can be re installed Note The heat exchanger is mounted on a gasket that remains in place and the gasket should always be inspecte...

Page 79: ...tion 1 1 Blower power supply 2 2 Fuse to power supply 3 10 Quartz burners jets 4 2 m EMV door gasket 5 2 Paper filters 6 2 m Rubber tube NBR 4x2 mm 7 1 Diaphragm gas pressure regulator 8 1 Ignition electrode The 2 3 years operation pack contains the same parts as a 1 years operation pack but with an extended supply of consumables as well as electrical and electronic components which based on exper...

Page 80: ...is unable to maintain constant pressure Process pressure is insufficient This can be the case with Blast Furnace gas A sample gas pump must be installed 2 Direct sunlight results in rapid temperature fluctuations In unprotected installations direct sunlight on the analyzer should always be avoided 3 Rapid temperature fluctuations Air conditioning systems or heating units with large cooling capacit...

Page 81: ... ETX Board and several printed circuit boards which can only be operated with its own unique software configuration data file A configuration file is provided with each instrument and it is stored on a memory stick for safety If the memory stick is misplaced or the configuration is corrupted due to an incident the device cannot be reconfigured without this memory stick The service memory stick con...

Page 82: ...reen prompts will return to the screen shown below remove memory stick and turn the Power switch off then on again The software starts normally with a basic configuration or with individual configurations if the memory stick contains this data 1 2 3 4 5 6 Full Instrument EAintern EAextern Configuration Instrument update backup update update update Backup int ext to To To To cfg full par system upd...

Page 83: ...that is replaced in a CWD 2005 system with a new one The new data file is provided and delivered with the board by the manufacturer An operation error is impossible because the memory stick supplied in this case only executes program 4 Config update This program generates the configuration data in the CWD 2005 that can be saved to disk as a backup from program 6 Instrument backup This program copi...

Page 84: ...calorific value by measuring residual oxygen in exhaust gas and pass off the measurement of Combustion Air Requirement Index or CARI as being the same as heat release value Note Indirect measuring methods using Zirconia oxide sensors ZrO2 were only developed for applications where the gases are stable and remain in the same family usually Natural gas and may require many calibration gases to curve...

Page 85: ...s 5 Thermopile cold junctions 6 Output signal 7 Gas flow 8 Pressure regulator 9 Pressure sensor 10 Temperature sensor 11 Temperature sensor 12 Temperature sensor 13 Specific Gravity cell 14 Cooling air fan 15 Heat exchanger 16 Pressure sensor 17 Temperature sensor 16 Ignition transformer Sample gas is passed to the burner 2 via a wobbe range orifice 1 at very precisely regulated pressure and burne...

Page 86: ...Heat for the thermocouples is also lost The heat management of this process is monitored by a number of thermal elements 10 11 12 and the result is included in a calculation which ensures the Wobbe Index value is linear In addition the response time of the system can be considerably reduced by the use of a proximity equation and end point forecasting The output signal is not yet the Calorific Valu...

Page 87: ... in volts is generated The expansion of the sound waves in the measurement chamber is not only dependent on gas density but also other parameters such as viscosity and heat conductivity The selectivity of the measuring cell to gas density is a question of geometric shape dimensioning and a few other proprietary factors The key to stability is a reference chamber that compares the measurement with ...

Page 88: ...The specific gravity cell is supplied with a transport lock after installation remove the tie wraps The cell is fitted with tension springs that mechanically de couple the system Vibrations in the unit air fan etc cannot be transferred to the specific gravity cell if the cell can move freely The differential pressure across the specific gravity cell is shown on display 53 It should be approximatel...

Page 89: ...ity cell requires no regular maintenance From time to time the pressure drop across the density cell should be checked After installation the sensor housing must be able to move freely on the springs A defective specific gravity cell can be sent in for repair The output for calorific value can be turned off in the software and the unit will now measure Wobbe Index only 9 2 8 Technical specificatio...

Page 90: ...fidentiality terms and conditions 10 1 Input Output card E A internal 1 5 6 10 1 5 6 10 D9 D10 D11D12 D13 D16 D2 D7 D21 D22 D1 D3 D14 D15 X14 X11 X9 X8 X15 X16 X17 X2 X5 X10 X12 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 3 4 6 1 3 4 6 1 3 4 6 1 3 4 6 1 6 7 12 1 2 X6 X4 X3 X7 X1 CW2000EAintern 07_2007_02_26 Figure 21 Input output card E A internal showing module plug positions Note T...

Page 91: ...1 PE Screen Pin 2 GND S G cell supply Pin 3 15 V S G cell supply Pin 4 DI S G cell signal Pin 5 DI S G cell signal Pin 6 15V S G cell supply Pin 7 N C Pin 8 N C Pin 9 N C Pin10 PE Screen Pin11 Wobbe Signal 30 mV Pin12 Wobbe Signal Plug x 16 Pin 1 N C Solenoid valve gas upper side front side Pin 2 N C Solenoid valve gas upper side front side Pin 3 N C Solenoid valve air upper side back side Pin 4 N...

Page 92: ...n 3 PE Screen Pin 4 P2T5 TL2 Temperature air 2 Pin 5 IPT5 TL2 Temperature air 2 Pin 6 PE Screen Plug x 5 Pin 1 PE No Connection Pin 2 DP2 Signal differential gas pressure Pin 3 DP2 Signal differential gas pressure Pin 4 AGND Supply differential gas pressure Pin 5 15V Supply differential gas pressure Pin 6 PE No Connection Pin 7 DP1 Signal differential pressure air Pin 8 DP1 Signal differential pre...

Page 93: ...5 D4 D10 D9 D8 D2 D6 X5 1 8 9 16 X5 X3 1 12 13 24 D19 D18 D14 D15 D16 D17 D25 D24 D23 D22 D21 D20 X11 1 8 16 9 1 9 6 5 X1 L2 L5 L3 L6 L1 L7 L4 L8 L9 L10 L6 L1 L7 L4 L8 L9 L10 DC DC OPTION TR5 DC DC TR1 DC DC OPTION TR2 DC DC OPTION TR6 JP 9 JP10 JP 5 JP 6 JP 11 JP 7 X 16 DC DC OPTION TR3 DC DC OPTION TR7 DC DC OPTION TR4 DC DC OPTION TR10 DC DC OPTION TR8 DC DC OPTION TR9 X 15 JP 12 JP 8 JP 3 JP 4...

Page 94: ...s illuminated The functional position for the relay outputs can be user configured from the menu and the standard factory configuration is shown below Block X14 on I O Card EA External type_06 Position Terminals Function Alarm LED 1 1 COM Common Process D 2 2 NO norm open 3 NC norm closed 2 4 COM Maintenance D 4 5 NO 6 NC 3 7 COM Filter change D 5 8 NO 9 NC 4 10 COM Fault D 6 11 NO 12 NC 5 13 COM ...

Page 95: ...aximum of seven analog outputs are available up to three are supplied as standard The functional position of the current outputs can be user selected using the Analog output menu and the standard delivery configuration is shown below Block X5 Analog Terminals Function Isolator module Output Pin Jumper No open 1 1 mA Wobbe Index Value TR 1 JP 5 2 mA 2 3 mA Specific Gravity TR 2 JP 6 4 mA 3 5 mA Cal...

Page 96: ... the example shown below is the standard configuration as delivered from the factory Block X 3 Digital Terminals Function Alarm LED Pin 1 1 Start measurement D25 2 Start measurement 2 3 Start calibration D24 4 Start calibration 3 5 Hold output signal D23 6 Hold output signal 4 7 Not connected D22 8 Not connected 5 9 Not connected D21 10 Not connected 6 11 Not connected D20 12 Not connected 7 13 No...

Page 97: ...ay 2 GND 500mA Heating solid state relay OC X16 1 24V 500mA Compressor air conditioner solid state relay 2 GND 500mA Compressor air conditioner solid state relay OC X15 1 24V 500mA Valve hot gas solid state relay 2 GND 500mA Valve hot gas solid state relay OC X 4 1 24V 500mA 2 GND 500mA mA X 6 1 20mA 2 GND OC X 8 1 24V 500mA 24 Volt Relay ignition impulse internal signal 2 GND 500mA GND Relay igni...

Page 98: ...Transmission rate 9600 Baud Parity bit no Stop bit 1 Data bit 8 Data output format 111111 111 222222 222 333333 333 444444 444 555555 555 666666 666 777777 777 111111 111 value analog output 1 222222 222 value analog output 2 777777 777 value analog output 7 Block X 11 Pin Signal 1 Not connected 2 Not connected 3 Not connected 4 Not connected 5 PT100 air conditioner heating enclosure 6 PT100 air c...

Page 99: ...t 4 Byte inferior cal val Inferior calorific value unit kJ m 3 2 Float 4 Byte superior cal val Superior calorific value unit kJ m 3 3 Float 4 Byte Wobbe i Inferior wobbe index unit kJ m 3 4 Float 4 Byte Wobbe s Superior wobbe index unit kJ m 3 5 Float 4 Byte dv Relative specific gravity dimensionless 6 Float 4 Byte Reserve 7 Float 4 Byte Reserve 8 Float 4 Byte Tin Air temperature of the burning ch...

Page 100: ...annot always be expected to reach 30 mbar 12 H2O 60 mbar 24 H2O with low calorific gases then a sample gas pump is required The boosted pressure is then reduced to required inlet pressure The pump should be suitable for the volume gas type and area code requirements and gas consumption see Chapter 3 or details A flow of gas between 8 l h and 220 l h is required depending on measurement range and s...

Page 101: ... mbar in accordance with the factory specification 11 5 1 Adjust pressure regulator The pressure regulator 6 is adjustable by the user and a small adjustment may be necessary on the regulator s to allow the small specific gravity differential pressure regulator 23 to operate within its correct input range This facilitates any adjustment to differential pressure as this controls the specific gravit...

Page 102: ...nnection LPG gas or Natural gas is clean and a small filter can be used as protection against particles see section 4 5 1 fig 9 The use of a pressure gauge 0 25 H2O 0 60 mbar is recommended between the pre regulator and the input of the CWD 2005 Steel industry gases such as BF gas or Coke gas need a larger filter see section 4 5 1 fig 10 and a mounting plate complete with a filter and bypass valve...

Page 103: ...ressure regulator 3 Sample gas filter 4 Pre regulator Zn 6 18mbar 5 Pressure gauge 0 60 mbar 6 CWD 2005 Figure 26 Process Gas line maximum pressure 60 bar 1 Process gas supply line 2 High pressure regulator 60 bars 3 4 bar 3 Sample filter 4 Pre regulator ZN 6 18mbar 5 Pressure gauge 0 60 mbar 6 CWD 2005 The high pressure regulator 2 in figure 27 is not necessary if the process pressure is below 6 ...

Page 104: ...ferent from one gas to an other gas In this case it is switched the wobbe jet can be kept and the air jet can be changed In connection with carrier gas it is possible to measure if needed with and without carrier gas The change considers the calibration with or without carrier gas The system checks if carrier gas will be considered or not The decision if carrier gas is necessary or not can be made...

Page 105: ... H2 needs a carrier gas option The amount of CO and H2 in the process gas determines if Oxygen or CH4 is suitable as a carrier gas A wide ranged flare gas will usually use Methane as a carrier gas See section 6 2 3 8 for a list of carrier gas configuration details Figure 28 Carrier gas module 1 Mounting bracket S S 2 Difference pressure gauge 3 Pressure regulator 4 Orifice block 5 Orifice carrier ...

Page 106: ...e is sampled by the instrument with a 1 4 improvement in response time The flow meter control valve customer supplied allows the customer to adjust the by pass ratio Figure 29 Fast loop schematic 1 Gauge inlet pressure 2 Filter 3 Pressure regulator 4 Gauge instrument inlet 5 Fast loop outlet pressure 6 Flow controller 11 9 Air Consumption Option It is possible to measure air consumption with a cal...

Page 107: ...alibration gas combustible 0 Gas with the same Wobbe Index as the second calibration gas but without CO and adjusted to zero The second calibration gas contains a CO proportion to calibrate the span of the CO Module as well as the complete instrument in the described configuration The calibration procedure is full automatically At delivery the two calibration gases are defined by the factory and t...

Page 108: ...______________________________________ 108 Manual CWD2005 doc Figure 30 CO Module installed in the CWD 2005 1 CO Measuring cuvette 3 Gas inlet 2 CO Module 4 Gas outlet Gas inlet and gas outlet to the module may be inverted There is no flow direction dictated ...

Page 109: ...Manual CWD 2005 Spare parts ___________________________________________________________________ Manual CWD2005 doc 109 ...

Page 110: ...eight 1700 gram Order description Specific Gravity Sensor heated Order number 02402199978 Electronic with pressure sensor CWD2000 2005 for differential pressure air 4 mbar Type cw2000sensor 02 Weight 15 gram Order description Electronic with pressure sensor air 4 mbar air Order number 02402199995 Electronic with pressure sensor for differential pressure gas 4 mbar gas Wobbejet Weight 110 gram Orde...

Page 111: ...npigas 12 2 Spares Electric Power supply ACM92 03 V1 5V 3 0A V2 15V 0 5A V1 15V 0 5A V1 24V 0 5A V1 24V 2 0A V1 24V 0 1A Weight 740 gram Order description Power supply CWD 2000 2005 type ACM92A03 110 240VAC Order number 02402199994 Fan CWD2000 2005 type RDO 110 resp 190 VAC Weight 6000 gram Order description Fan CWD 2000 2005 type RDO 110 resp 190 VAC Order number 02402199988 Fan CWD 2005 type 24 ...

Page 112: ...60 Hz with ignition lead and plug Weight 1600 gram Order description Ignition transformer TZI5 100N 115V 50 60 Hz Order number 02402199986 Ignition electrode Type ZE 6 44 30 Weight 20 gram Order description Ignition electrode Order number 02402199987 Plug in relay 24 V serial 40 31 with 1 changer Weight 17gram Order description Plug in relay 24 V serial 40 31 with 1 changer Order number 9840219999...

Page 113: ...r 98402199993 plug in relay 230 V series 40 31 with 1 changer Weight 20 gram Order description plug in relay 230 V series 40 31 with 1 changer Order number 98402199981 LED with free wheeling diode 110 230 V Weight 3 gram Order description LED with free wheeling diode 110 230 V Order number 98402199992 Finder relay socket series 95 1 changer with clip Weight 35 gram Order description Finder relay s...

Page 114: ...alves 24V DC 9 VA Weight 2100 gram Order description Solenoid valve block with 2 valves Order number 02403199998 Solenoid valve CWD 2000 2005 type 24V DC M25 X 1 Solenoid valve valve seat Weight 365 gram Order description Solenoid valve CWD 2000 2005 Order number 02402199996 Precision gas regulator Compatible to Union instruments CWD2005 Pin max 50 mbar Pout 4 mbar Weight 950 gram Order descriptio...

Page 115: ...ion Diaphragm to precision gas regulator Order number CWXX S G PRECDIA 6 mm 2 mm Neoprene tube 6 x 2 mm black lenght1 m Weight 30 gram Order description Neoprene tube 6x2 1m Order number cwxx s g rutu6x2 Pressure regulator gas type RV12LM Pin max 100 mbar output 10 30 mbar Material zinc Inlet outlet G1 8 Weight 45 gram Order description Pressure regulator RV12LM 10 30mbar Order number cw00 s g prr...

Page 116: ...th 24 thermo elements diameter 1 0mm Order number 02403199997 Heat exchanger 0 2mm with clamp collar Weight 60 gram Order description Heat exchanger 0 2mm with clamp collar Order number 02401199994 Gasket to heat exchanger Material ISOPLAN 750 94x84x2mm Weight 3 gram Order description Gasket to heat exchanger Order number 02401199985 Screen for noise suppression Weight 85 gram Beschreibung Screen ...

Page 117: ...escription Orifice Order number cw05 s m origas x xx mm Orifice gas or air Material alu Perbunan NBR Diameter x xx mm Weight 5 gram Order description Orifice Order number cw05 s m origas x xx mm Rubber tube to orifice gas or air Material Perbunan NBR 7 mm x 11 mm x 23 mm D1xD2xL Weight 3 gram Order description Rubber tube to orifice gas or air instrum CW85 95 CWD2000 2005 Order number cw00 s m ori...

Page 118: ...s b hcalss Single quarz jet with threaded sleeve Weight 2 gram Order description Single quarz jet with threaded sleeve Order number cwxx s b sq Landfill gas burner to CWD2000 2005 Material Aluminium Stainless Steel Weight 110 gram Order description Landfill Gas Burner comple Mat Alu SS316 to CWD2000 2005 Order number cw00 s b mcalss Wire sieve for Landfill gas burner to CWD2000 2005 Material Brass...

Page 119: ...les diameter 1 9 mm Weight 17 gram Order description Burner head LM for low BTU ALU head for CW85 95 2000 2005 Order number cwxx s b lmbh Burner type L for low BTU gase with Aluminium head for CWD2000 2005 Material Aluminium SS316 Burner head 36 holes diameter 2 5 mm 1 hole diameter 4 2 mm Weight 115 gram Order description Burner type L for low BTU gas with ALU head for CWD2000 2005 Order number c...

Page 120: ...0 2005 200 x 200 x 95 mm Weight 510 gram Order description Air filter for CWD2000 2005 200 x 200 x 95 mm Order number 02401199996 12 7 Spares enclosure 11 5 4 5 Wire netting Foam EMV sealing to CWD2000 2005 case length 2 Meter Typ Laird BE 4011 1107 1 Weight 42 gram Order description EMV sealing to CWD2000 2005 case length 2 Meter Order number 02401199995 ...

Page 121: ...fic Gravity 0 8 F S Specific Gravity Linearity 0 2 Repeatability 0 5 Response Time 50 7 seconds 90 30 seconds 99 45 seconds Outputs 4 20 mA DC isolated 600 ohms max load Up to 7 mA outputs 1 or 3 normally supplied RS232 Relay output 8 relays Contact rating 1 0 amp at 100 volt Digital output 4 Open collector Digital Input 3 Contact closures Communication RS232 System Details Gas Pressure 6 to 15 H2...

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