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Union Instruments CWD2005 SPC, Original Operating Instructions, Page: 95 / 110

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Union Instruments CWD2005 SPC Original Operating Instructions Download Page 95

 

Troubleshooting 

 

 

 

 95 

 

12 Troubleshooting 

 

 

 

 

 

 

 

WARNING

 

Risk of serious injury from electricity and escaping gases! 

•

 

Before carrying out maintenance work on the combustion calorimeter and 
whenever necessary, also bring the the linked system components to a 
standstill. 

•

 

Switch off the main switch, and disconnect the device from the voltage sup-
ply if necessary, and take steps to prevent the main switch from being 
switched on again and the voltage supply from being reconnected! 

•

 

Only skilled electricians are permitted to work on the electrical equipment of 
the combustion calorimeter! 

•

 

Parts of the combustion calorimeter with the adjacent symbol may still carry 
voltage even when the main switch is switched off!  

•

 

If required, disconnect the combustion calorimeter from the supply network! 

 
 

 

NOTE

 

Troubleshooting is broken down into the following categories: 

•

 

Unstable measured value 

•

 

Drift of measured value 

•

 

Incorrect ignition behavior 

 

Summary of Contents for CWD2005 SPC

Page 1: ...Apr 2016 V1 06 Original Operating Instructions Combustion Calorimeter CWD2005 CWD2005 Plus ...

Page 2: ... com http www union instruments com 2016 This documentation is protected by copyright All rights in particular the rights of translation reprint extraction of figures radio transmission and duplication by photomechanical or other means and of storage in data processing systems in whole or in part are reserved Technical data subject to change ...

Page 3: ...5 3 4 3 Note on explosion protection 16 3 5 Safety precautions on the owner side 16 3 5 1 Recurring operator training 17 3 5 2 Performing a workplace hazard analysis 17 4 Protective equipment 19 4 1 Main switch 19 4 2 Safety switch 19 4 3 Thermal cutoff 20 4 4 Solenoid valve 20 4 5 Fan 20 4 6 Door enclosure 20 4 7 Markings and warning information 21 5 Description and connections 23 5 1 Enclosure c...

Page 4: ...ation 52 9 5 Menu structure 53 9 6 Main menu 54 9 6 1 Main menu Options 55 9 6 2 Main menu Trend 80 9 6 3 Main menu Event list 85 9 6 4 Main menu Device information 86 10 Decommissioning Switching off 89 11 Maintenance 91 11 1 Preparations 91 11 2 Maintenance work Inspection 92 12 Troubleshooting 95 12 1 Preparations for troubleshooting 96 12 2 Changing replacing fuses 97 12 3 Unstable measured va...

Page 5: ...Technical data 5 1 Technical data 1 1 Dimensions Fig 1 1 Housing dimensions Weight approx 54 kg ...

Page 6: ... Name plate 1 3 Voltage supply Voltage 230 Volt or 115 Volt 50 60 Hz alternating current Power consumption 185 VA max Protection class I Degree of protection IP50 1 4 Interfaces Interfaces RS232 Profibus Fieldbus Industr Ethernet Analog outputs 3 4 20 mA for heating value Wobbe and density Digital outputs 3 relays 1 2 ...

Page 7: ... Fast loop optional Gas connections Compression fitting 6 mm 1 7 Calibration gas Test gas Calibration gas Dependent on the process gas Calibration interval Dependent on the process gas Calibration duration Process lasts up to 20 minutes gas flow approx 10 minutes Gas consumption Approx 7 l gas per calibration dependent on the calibration gas Input pressure max 40 mbar Input pressure min 20 mbar de...

Page 8: ...g range span Inert gases such as N2 O2 or CO2 reduce the measuring range span CWD device series CWD2005 CWD2005 CT CWD2005 PLUS CWD2005 DPC CWD2005 SPC CWD2000 Ex Flare gas 0 15 3 0 0 15 0 15 Blast furnace gas 3 5 6 3 0 3 5 6 3 0 3 5 6 3 0 3 5 6 3 0 Converter gas 4 5 9 1 5 4 5 9 1 5 4 5 9 1 5 Mixed gas 5 10 2 0 5 10 2 0 5 10 2 0 5 10 2 0 Coke oven gas 15 30 1 5 15 30 1 5 15 30 1 5 15 30 1 5 Biogas...

Page 9: ...ntal conditions additional measures air conditioning of the combustion calorimeter etc must be agreed on with UNION Instruments GmbH Installation location Installation room required Chapter 4 Room temperature 5 40 C Temperature change 5 C per hour Air humidity 0 95 rel humidity Ambient pressure 800 1100 hPa 0 8 1 1 bar ...

Page 10: ...Technical data 10 ...

Page 11: ...certain voltage limits Angewandte harmonisierte Normen Used harmonized standards EN 61010 1 2010 Sicherheitsbestimmungen für elektrische Mess Steuer Regel und Laborge räte Teil 1 Allgemeine Anforderungen Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements EN 61326 1 2013 Elektrische Mess Steuer Regel und Laborgeräte EMV Anforderungen ...

Page 12: ...EU Declaration of Conformity 12 ...

Page 13: ...ger that can lead to serious physical injury or death WARNING For a potentially dangerous situation that can lead to serious physical injury or death NOTICE For a potentially dangerous situation that can lead to minor physical injury This may also be used for warnings of property damage NOTE For information that can improve the operation of the combustion calorimeter or contribute to prevention of...

Page 14: ...t process gases The analysis serves the process control The combustion calorimeter is intended for use in weather proof areas and for fixed mounting and installation The combustion calorimeter is not suitable for operation in hazardous areas In the case of toxic or explosive gases the safety provisions applicable at the in stallation location must be complied with Any use beyond this is regarded a...

Page 15: ...e sent and operational Further safety information Before the corresponding chapters 3 4 2 Information on specific hazards DANGER After installation all gas conveying parts must be checked for leak tightness according to national regulations Any type of repair that requires opening of the protective cover may only be carried out by instructed qualified personnel ...

Page 16: ...nically leak proof on a con tinuing basis compression fittings or through a systematically recurring testing of tubes and membranes described in the operating instructions All gas inputs in the combustion calorimeter are provided with solenoid valves The solenoid valves close automatically in the event of a fault during combus tion or ignition of the gas mixture The solenoid valves are closed in c...

Page 17: ...g of this combustion calorimeter the owner must prepare a workplace hazard analysis and specify personal safety equipment for different phases of operation Deviations from these operating instructions may occur due to further technical developments If you desire additional information or if specific problems arise that are not covered in detail in this manual you will receive information by contac...

Page 18: ...Safety information 18 ...

Page 19: ...Protective equipment 4 1 Main switch Fig 4 1 Main switch example 4 2 Safety switch The safety switch disconnects the ignition transformer from the voltage supply when the upper door is opened Fig 4 2 Figure Safety switch example ...

Page 20: ... solenoid valves of the combustion calorimeter close automatically A restart of the combustion calorimeter is necessary 4 5 Fan The fan mixes exhaust gases produced during combustion with fresh air and en sures an appropriate volume flow The fan is speed monitored If the fan fails the combustion calorimeter goes to a safe state 4 6 Door enclosure Protective covers of the housing separate electrica...

Page 21: ...arning information Fig 4 3 Markings and warning information example Item No Description 1 Warning information hot surface internal 2 Warming information electricity external Fig 4 4 Warning information on electrical connection plate example 1 2 ...

Page 22: ...Protective equipment 22 ...

Page 23: ... Description and connections 5 1 Enclosure connections outside Fig 5 1 Housing connections Item No Description 1 Cable glands for power supply 2 Cable glands for signals 3 Main switch 4 Filter cover 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 24: ...s 6 Display 7 Flue exhaust 8 Cover for analog signals 4 pieces 9 Fast Loop output optional 10 Carrier gas input 11 Calibration gas input SV X14 3 4 12 Calibration gas input SV X14 1 2 13 Process gas input SV X11 1 2 14 Cover for interface connections 2 pieces 15 USB connection ...

Page 25: ...mple Item No Description 1 Thermal cutoff behind the exhaust gas pipe on the rear wall 2 Thermal element 3 Density measuring cell 4 Precision pressure controller 5 Electronic input and output signals 6 Safety switch for ignition transformer 7 Power supply distribution rail example 8 Fan 1 2 3 4 6 5 7 8 ...

Page 26: ...isk of injury damage The use of non approved accessories may cause damage and endanger per sons Any warranty is voided in this case The owner is then liable for damage that occurs Only use genuine accessories or accessories approved by UNION Instruments GmbH ...

Page 27: ...let or load carrying means may cause injuries Use suitable load carrying means when unpacking and transporting Check slings if applicable for adequate load bearing capacity and sound condi tion and fasten them carefully Never walk or stand under suspended loads NOTE If strong shocks occur during transport these may damage the housing There fore check the transport container for damage before openi...

Page 28: ...imeter is stored for longer than 3 months or must be operated or stored outside the prescribed environ mental conditions 6 2 1 Storage conditions NOTE Ensure that the combustion calorimeter is free of gas moisture residues Frozen condensate water in the combustion calorimeter may cause damage Ambient temperature 0 60 C Air humidity 0 95 relative humidity Ambient pressure 700 1400 hPa 0 7 1 4 bar ...

Page 29: ...y for purposes of gas analysis and measure ments At least 50 cm working space on the left side Lockable windows Protected from direct influence by the weather and direct solar radiation Stable room temperature Provided with clean and adequate ambient air for unbiased measurement re sult combustion calorimeter requires approximately 30 m h air Adequate load bearing capacity of the wall is ensured M...

Page 30: ...avorable circulation installation conditions appropriate deflect ing sheets must be provided that prevent fresh air from flowing directly onto the combustion calorimeter The following conditions must be met No direct fresh air introduction in the combustion calorimeter Exhaust gases must be discharged to the environment protected from air draft using a suitable pipe tube and with the help of corre...

Page 31: ...rovided between the side wall of the installation lo cation and the combustion calorimeter for service and maintenance The combustion calorimeter is intended to be wall mounted The wall brackets are provided and must be secured to the wall The wall used for mounting must be sufficiently sturdy to bear the weight of the combustion calorimeter Cross struts are installed in a fixed manner on the back...

Page 32: ...Transport installation and acceptance 32 Fig 6 1 Wall mounting Fig 6 2 Dimensions wall mounting ...

Page 33: ...fitting on side of combustion calorim eter Gas input pressure depending on gas between 20 40 mbar Chapter 1 Technical data The input pressure for the gas connections must not exceed the specifica tions of the technical data of the combustion calorimeter Process gas must be free of contaminants and condensate Each connection point must be carefully checked for leak tightness When leaks are present ...

Page 34: ... can be subsequently converted to a carrier gas supply Contact the manufacturer regarding this For process gases that do not have stable combustion a carrier gas can be added Carrier gases maintain the combustion and exert no increased contribution toward the combustion value of the process gas ...

Page 35: ...essure for the gas connections must not exceed the specifica tions of the technical data of the combustion calorimeter Calibration gas must be free of contaminants and condensate The calibration gas quality must be similar to the process gas quality Each connection point must be carefully checked for leak tightness When leaks are present the system draws air and indicates false measured values Do ...

Page 36: ...gases must be discharged to the outside For flue gases containing CO H2 and H2S adequate room ventilation must be ensured NOTE Flue gases residual heat must be discharged to the outside protected from air draft and without interruption through a vent An accumulation of residual heat leads to false measurement results ...

Page 37: ...accordance with electrotechnical rules Parts of the open combustion calorimeter marked with the adjacent symbol may still carry voltage even when the main switch is switched off If required discon nect the combustion calorimeter from the supply network Fig 6 3 Electrical connection plate example Connect the combustion calorimeter to the voltage supply using connections L1 N PE in accordance with n...

Page 38: ...e combustion calorimeter The combustion calorimeter may only be operated with effective protective earth connection in accordance with local requirements for high operating currents 6 3 9 Electrical interfaces WARNING Endangerment of people and equipment when the combustion calorimeter is com missioned by non instructed personnel Allow only instructed trained service technicians to carry out commi...

Page 39: ...t Input Output IOexternal Fig 6 5 Connector assignment Input Output IO type 06 WARNING Do not connect to line voltage Only operate outputs relay analog digital and inputs with safety extra low volt age Only connect serial interface RS232 to an electrically safe device ...

Page 40: ...on if applica ble optionally assigned D 8 7 19 Common 20 Normally open 21 Normally closed Function if applica ble optionally assigned D 9 8 22 Common 23 Normally open 24 Normally closed Function if applica ble optionally assigned D 10 mA outputs Connector X5 Analog output Pin Connector X5 Function Disconnecting module no Jumper no open 1 1 mA 2 mA Wobbe TR 1 JP 5 2 3 mA 4 mA Density TR 2 JP 6 3 5 ...

Page 41: ...tion if applica ble optionally assigned D 21 6 11 12 Function if applica ble optionally assigned D 20 7 13 14 Function if applica ble optionally assigned D 19 8 15 16 Function if applica ble optionally assigned D 18 Serial interface RS232 Pin Connector X11 Signal 1 mA analog input 1 2 mA analog input 1 3 mA analog input 2 4 mA analog input 2 5 PT 100 air conditioner 6 PT 100 air conditioner 7 Not ...

Page 42: ... 42 6 4 Commissioning after installation WARNING Endangerment of people and equipment when the combustion calorimeter is commissioned by non instructed personnel Allow only instructed trained service technicians to carry out commissioning ...

Page 43: ...ring devices are removed attached The following transport securing devices must be removed attached within the combustion calorimeter Fig 6 6 Transport securing devices Item no Component Type of securing device 1 Transport securing device for density measuring cell 4x cable ties 1x hexagon socket screw 5x16 2 Transport securing device of pressure controller 2x retaining belt 1x bubble wrap inside ...

Page 44: ...e flap Proceed in reverse order to reattach the transport securing device Transport securing device of density measuring cell Transport securing device Order of removal attachment of transport securing device Transport securing device of density measuring cell Remove the black cable ties from the center eyebolt Remove the white cable ties around the density measuring cell Loosen the eyebolt Densit...

Page 45: ...own some steps can be omitted Right column Steps Com mis sioning Switch ingon Check whether the transport securing device has been removed The density cell must be able to swing freely at the springs X Check whether the transport securing device of the gas pressure controller has been removed The foam material within the controller must be removed X Check whether environmental conditions Technical...

Page 46: ...emoved The density cell must be able to swing freely at the springs X Ensure voltage X Ensure that the door is closed safety switch X X Switch on the main switch X X Establish start readiness of linked system components X X When the combustion calorimeter has been switched off only temporarily production can be resumed ...

Page 47: ...stations operator control elements NOTE This chapter contains only elements for operation of the combustion calorimeter by the normal operator Fig 8 1 Work stations Item No Description Function Activity 1 Display Displaying status and operation 2 Main switch Switching the device On Off 2 1 ...

Page 48: ...Description of the work stations operator control elements 48 ...

Page 49: ...ecific regulations 9 1 Operation of membrane keyboard Description of display The software controller is operated using a membrane keyboard The buttons shown can be selected by pressing them NOTE Damage to membrane keyboard Operation with pointed or sharp objects may damage the membrane keyboard Fig 9 1 Operator control elements Structure of display 4 2 6 3 2 1 9 5 1 10 4 1 4 3 4 4 7 5 8 ...

Page 50: ...l 5 Input Input keys are used to input numeric data A value field on the screen must be active for this 5 1 Screenshot This key creates and automatically saves a screenshot on the inserted memory stick 6 Inspection window Inspection window for monitoring the ignition or combus tion process 7 LED status display Power Device switched on Operation only in the process or during calibration Service Ser...

Page 51: ...anner over and over from the start Selection Enables a selection from a list Plus Minus Causes the selected numbers fields to be summed or unsummed Arrow Causes a jump to the next digit of a numeric input NOTE Other symbols not described above refer to the different menus These are de scribed in the corresponding screens 9 3 Available displays The available displays and their function are describe...

Page 52: ...f methane mV 24 56 mV signal of the thermal battery V 1 071 Voltage signal of the density measuring cell T1 29 04 0 24 Inlet temperature into the thermal body heating of the air p 4 00 Air differential pressure Fr 51 13 Controlled fan frequency Stabi 0 011 Standard deviation of the measurement value over 2 minutes NOTE STD During a calibration 0 015 is typically achieved The calibration is conclud...

Page 53: ...imits 67 Main menu Options System 68 Main menu Options System General 69 Main menu Options System Ignition 71 Main menu Options System Ignition 71 Main menu Options System Load factory settings 72 Main menu Options System CSV Export 72 Main menu Options System Hold signal On Off 72 Main menu Options System Settings 73 Main menu Options System Settings Date Time 73 Main menu Options System Settings...

Page 54: ...Operation 54 9 6 Main menu The main menu is the standard display during active operation The following menus are accessed from the main menu Options Trend Eventlist Device info ...

Page 55: ...ossibility for the following parameters Configuration of calibration gas Automatic calibration Automatic calibration 2 Calibration Save base calibration Calibration limits System Configuration possibility for the following parameters General Ignition Update Load factory settings CSV export Hold signal On Off Settings e g date language password Disable system Service For service technician only ...

Page 56: ...Operation 56 Main menu Options I O Options for configuration for the following parameters Analog outputs Relay outputs Disp mA Digital inputs Display ...

Page 57: ...e MB from MB to value fields for numeric input The following must be observed for this Units xxx m and BTU ft correspond to a gas temperature of 0 C and a barometric pressure of 1013 mbar xxx Sm corresponds to a gas temperature of 15 C 60 F and a barometric pressure of 1013 mbar xxx stands for MJ kcal or kWh BTU ft corresponds to a gas temperature of 15 C 60 F and a barometric pressure of 1013 mba...

Page 58: ...lame is burning Calibration The calibration gas solenoid valve is open and the flame is burning Maintenance The device must be checked in a foreseeable time but is still ready for operation The reason for maintenance can be obtained from the General information field Examples of reasons include Filter change air filter No calibration gas calibration canceled Room temperature too high air inlet tem...

Page 59: ... ignition threshold Operation delayed The flame is burning Thermoelectric voltage of process or calibration gas is greater than the ignition threshold and the delay time has elapsed Overtemperature The flame is too hot The Wobbe signal is greater than 76 mV i e the temperature rise in the inner tube of the thermoelectric battery is greater than 50 C Calibration deviation The value determined durin...

Page 60: ...tions I O mA display The mA values for the currently active outputs are displayed in this menu With the Disp mA key all channels can be displayed one after the other The value can be obtained from the General information field ...

Page 61: ...Start calibration high open Calibration starts closed No calibration low open No calibration closed Calibration starts Start measurement high open Measuring starts closed Measuring stops low open Measuring stops closed Measuring starts Hold signals high open Hold mA closed mA online low open mA online closed Hold mA Cancel calibration high open Calibration cancellation closed No calibration cancel...

Page 62: ...Operation 62 Main menu Options I O Display The display of measured values is configured in this display A signal and a unit is assigned to each of the 4 display windows ...

Page 63: ...Operation 63 Main menu Options Calibration Calibration values are configured in this menu ...

Page 64: ...density These values are calculated from the gas components of the cali bration gas The manufacturer always uses dry gas as the basis Units xxx m and BTU ft correspond to a gas temperature of 0 C and a barometric pressure of 1013 mbar xxx Sm corresponds to a gas temperature of 15 C 60 F and a barometric pressure of 1013 mbar xxx stands for MJ kcal or kWh BTU ft corresponds to a gas temperature of ...

Page 65: ...a list field Su Mo Tu We etc Time and Cycle are value fields Duration of calibration Depending on the device type the calibration duration is 10 20 min NOTE At a restart of the device or at a change of calibration gas the calibration may have to be started multiple times until the pulse line is sufficiently flushed with calibration gas and the stability criterion is met ...

Page 66: ...ed change in ambient temperature compared to the last calibration Main menu Options Calibration Calibration The calibration is started with this key This stops the automatic calibrations Main menu Options Calibration Save base calibration The measured values are saved with this key These values are reference values for additional calculations during the next calibration Any deviations from these r...

Page 67: ...alibration limits The calibration tolerances are set and the deviations from the base calibration are displayed in this menu If the calibration values exceed the defined tolerances this is indicated as a calibration deviation for digital outputs ...

Page 68: ...Operation 68 Main menu Options System The basic configurations of the device such as ignition time of day language and code key are specified in this menu ...

Page 69: ...ange signals after holding When the Hold signals mA function is ended an adjustment of the old and new measured values is made over a time ramp Purge time after cooling Specifies the length of time after the device start that the solenoid valve is open until ignition starts Screen switch off time Specifies the time after which the screen will be switched off if no input is made Display speed Refer...

Page 70: ...me elapses Minimum internal pressure When the minimum internal pressure is fallen below the device goes to STOP state default value is 8 mbar Internal pressure warning threshold Below the warning threshold insufficient gas is signaled for internal pressure and Service Default value is 14 mbar ...

Page 71: ... ignition thresh old is reached before the ignition duration elapses If the ignition threshold is not reached within the specified time the combustion calorimeter goes to STOP state Interval ignition After device start and the flushing time period 10 sec the ignition starts for a maximum set ignition duration and is repeated after a pause equal to the ignition duration This is repeated until the i...

Page 72: ...s and 5 days at 1 minute intervals The values are separated by TAB All possible 25 curves are written at once to a CSV file This file can be processed for example with MS Excel Main menu Options System Hold signal On Off The Hold signal function is switched on and off with this key Hold signal Storage of the mA values is activated with this function After the function is ended an adjustment of the...

Page 73: ...Main menu Options System Settings Main menu Options System Settings Date Time The date and time are set in this menu Increments selected numbers Decrements selected numbers Moves one field left Moves one field right ...

Page 74: ...us for inserting copying and cor recting various languages even those that have to be represented by bitmaps e g Chinese Download languages onto a memory stick correct them and then re import them to the combustion calorimeter The language is changed or your own bitmaps are configured in this menu ...

Page 75: ...served for this Factory password The combustion calorimeter is delivered with factory password 0 This can be changed if necessary Unlock time This time specifies when the system will be locked and the password must be re entered NOTE The time must be greater than 0 Otherwise the system can then no longer be un locked ...

Page 76: ...Operation 76 Main menu Options System Settings Change color The display colors can be changed here ...

Page 77: ...d in this menu The screen shows all possible configurations Range No indicates the number of installed measuring ranges A maximum of 3 measuring ranges are possible In this example 3 measuring ranges are config ured Dia WJet indicates the nozzle diameter in mm of the measuring range nozzle This specification is information only and is meant to help later in calculating the gas volumes ...

Page 78: ...indicates the physical unit of the measurement value Unit indicates the switchover point in the specified dimension between the meas uring ranges In the example the first measuring range is switched over at 650 5 kcal m3 Switch indicates the overlap of the measuring ranges in In the example the hysteresis is 5 Measuring range switchover can be done automatically or manually If manual measuring ran...

Page 79: ...Operation 79 Main menu Options Service NOTE Only change this menu in consultation with the manufacturer The menu is password protected Setting for Service only ...

Page 80: ...onfigured in this menu The following must be observed for this Up to three different curves in various colors can be displayed Selection A selection can be made from the following parameters Select time Select value Select signal Select unit Select curve ...

Page 81: ...ed in order to obtain a resolution The diagram is subdivided into 10 segments on the x axis The segment time and the total displayed time can be set as follows Increase segment time Reduce segment time Minimum segment time 1 s Maximum segment time 12 h The time values can be viewed as follows Shift to later values Shift to earlier values ...

Page 82: ...nu Graphic Select value Values for the curves can be set in this menu The curves can be viewed as follows Ref y value linearly toy axis Ref y value linearly from y axis dy value compressed y axis dy value stretched y axis ...

Page 83: ...gnal Signals for the curves can be selected in this menu Examples of signals Wobbe i Heating value mVSA Frequency T amb Wobbe s Combustion value mV p Wobbe T in Main menu Graphic Select unit Units for the signals can be selected in this menu ...

Page 84: ...Operation 84 Main menu Graphic Select curve Individual curves can be selected in this menu in order to change parameters ...

Page 85: ...event list stores all events that are of interest for operation and service of the device A total of 1000 events can be stored Show startup Selection of the different events Show calibration Selection of the different events Show all Cancel selection ...

Page 86: ...onto the memory stick and sent to the manufacturer by email refer to CSV Export Index 1 Device data Type Gas type Carrier gas Device number 2 Measuring ranges Wobbe Density 3 Equipment Nozzle MR1 Nozzle MR2 Burner 4 Additional options Installed additional options are listed here if applicable 5 Analog outputs Wobbe i Density Heating value 1 2 3 4 5 ...

Page 87: ...Operation 87 ...

Page 88: ...Operation 88 ...

Page 89: ...xtended down time To switch off the combustion calorimeter only temporarily some steps can be omitted Switching off column Steps Switching off Decom mission ing Disconnect the device from the process professionally close the line X X Bring linked system components to a standstill X X Switch off the main switch X X If the combustion calorimeter is to be taken out of service only temporarily the pro...

Page 90: ...Decommissioning Switching off 90 ...

Page 91: ...ply if necessary and take steps to prevent reconnection Only skilled electricians are permitted to work on the electrical equipment of the combustion calorimeter WARNING Risk of serious injury from escaping gases Before carrying out maintenance work on the combustion calorimeter and whenever necessary also bring the the linked system components to a standstill Gas connections may only be made by q...

Page 92: ...on calorimeter Wobbe i s Heating value combustion value Density mV signals mA signals Internal pressure Differential pressure Wobbe Differential pressure air Frequency of the fan control 2 Notify the control room 3 If no default values via PLC are possible activate Hold signal on the combus tion calorimeter 4 Close the shut off valve on the combustion calorimeter after a leak test The nature and a...

Page 93: ...hanger Every 6 months Check the fan Every 6 months Check the air intake filter ambient air inlet fan filter mat Every 6 months Clean4 the gas and air nozzles Change O rings if necessary Every 6 months Annual check Replace air filter Annually Replace neoprene tubes inside the combustion calorimeter Annually Clean the complete system Annually Additional information Included documents 2 Flow plates a...

Page 94: ...Maintenance 94 ...

Page 95: ...steps to prevent the main switch from being switched on again and the voltage supply from being reconnected Only skilled electricians are permitted to work on the electrical equipment of the combustion calorimeter Parts of the combustion calorimeter with the adjacent symbol may still carry voltage even when the main switch is switched off If required disconnect the combustion calorimeter from the ...

Page 96: ...eeps an event list with up to 1000 events in chronological order specification of date The event list provides information about incorrect be havior refer to 9 6 3 The export of event data to a special data carrier memory stick is possible after consultation with Service The exported data can be sent to the manufacturer for fault analysis refer to CSV Export 9 6 1 Events are Start Stop Ignition In...

Page 97: ... the required point The frequency con troller is at its maximum value Heavy filter contamination that can no longer be corrected The filter must be replaced The measured value drifts downward The heat exchanger is contaminated with soot when propane or butane is combusted with too little air The heat exchanger must be cleaned hot water and then dried with com pressed air The thermal battery is con...

Page 98: ...r change of air filter the frequency of the frequency converter is than the set threshold value Gas pressure is too low Fault in the thermoelectric battery Defective PT 100 temperature sensor Service Filter change of air filter Frequency threshold value Air inlet temperature 41 C Operation Flame is burning analyzer is running on process or calibration gas Operation delay Flame is burning analyzer ...

Page 99: ...Troubleshooting 99 Calibration Flame is burning solenoid valve for calibration gas is open Calibration is active no mA signals are output these are on hold the last current value is retained ...

Page 100: ...Troubleshooting 100 ...

Page 101: ...ustomer number phone number where you can be reached the combustion calorimeter type and number see name plate and required spare parts bills of material numbers if applicable UNION Instruments GmbH Service Maria Goeppert Straße 22 23562 Lübeck Germany 49 0 721 680381 30 49 0 721 680381 33 support union instruments com http www union instruments com ...

Page 102: ...Service 102 ...

Page 103: ...uggestion Have UNION Instruments GmbH dispose of your combustion calorim eter WARNING Risk of injury from electricity and if applicable gases in the combustion calo rimeter NOTE Observe national regulations for disposal of machines and working materials Sort parts by groups and supply them to professional recyclers ...

Page 104: ...Disposal 104 ...

Page 105: ...ponents of the original manufacturer In the event that components are discontinued or compo nents of other manufacturers are used this requires manufacturer s approval by UNION Instruments GmbH Spare parts can be ordered from UNION Instruments GmbH Chapter 11 Service Make a note of the combustion calorimeter type and number Name plate Identify and make a note of the order number if applicable Incl...

Page 106: ...Spare parts 106 ...

Page 107: ...WD 10 FLOAT 4 40 Air min Min Luftbedarf Einheit m Luft m Gas nur bei Kundenspezifischen CWDs CWD 11 FLOAT 4 76 Reserve CWD 20 FLOAT 4 80 Fixed test value send 12345 6789 CWD 21 BYTE 1 81 Operating condi tion Operating condition CWD 0 Stop 1 Proces 2 Ignition 3 Ignition pause 4 Error 5 over temperature 6 calibration measuring range 1 7 calibration measuring range 2 8 calibration measuring range 3 9...

Page 108: ...ted Parameters are selected in the I O Analog outputs The interface has to be activated in the menu service Data transmission Transmission rate 9600 baud Parity bit no Stop bit 1 Data bit 8 Output format 111111 111 222222 222 333333 333 777777 777 111111 111 Output data 1 222222 222 Output data 2 777777 777 Output data 7 Assignment of the plugs oins 6 3 10 ...

Page 109: ...onditions 28 F Fault correction 95 I Inspection 92 Installation location 29 Installing 29 Intended use 14 M Main switch 19 Maintenance 91 Maintenance work 92 O Operation 49 Operator control elements 47 P Personnel and qualification 14 Profibus Data structure 107 Protective equipment 19 S Safety information 13 15 serial interface data struture 108 Service 101 Spare parts 105 Symbols 13 T Transport ...

Page 110: ... 23 Fig 5 2 Housing without doors example 25 Fig 6 1 Wall mounting 32 Fig 6 2 Dimensions wall mounting 32 Fig 6 3 Electrical connection plate example 37 Fig 6 4 USB interface on the left side of the housing 38 Fig 6 5 Connector assignment Input Output IO type 06 39 Fig 6 6 Transport securing devices 43 Fig 6 7 Transport securing devices of pressure controller 44 Fig 8 1 Work stations 47 Fig 9 1 Op...

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