Union Instruments CWD3000 EXP Operating Instructions Manual Download Page 42

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Transport, installation and acceptance

6.3.4 Opening and closing of the housing doors

DANGER

Risk of explosion!
Damaged seal/improper closing pose a hazard!
Explosion protection is no longer guaranteed if seals are damaged or doors are

closed improperly!

WARNING

Risk of severe injury – Housing is overpressurized!

•

Switch the device off first, then shut off the ignition gas supply and finally

open the doors!

•

Wait 5 minutes after switching off and allow thermal element to cool down!

Keep doors (one door per cell) closed during operation. Open only when switched

off, and observe safety provisions.

Close all hasps of all doors. Close with key/tool!

Summary of Contents for CWD3000 EXP

Page 1: ...Mrz 2019 V1 02 Translation of operating instructions Explosion Protected Combustion Calorimeter CWD3000 EXP ...

Page 2: ...nstruments com 02608199964 2019 Mrz 2019 V1 02 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: ...instructions 18 3 6 2 Information on specific hazards 18 3 7 Recurring operator training 18 3 7 1 Information on explosion protection 19 3 8 Owner safety precautions 19 3 8 1 Performing a workplace risk assessment 20 4 Protective equipment 21 4 1 Pressurized enclosure ignition protection type 21 4 2 Protective housing with doors 22 4 3 Monitoring of the flushing process and overpressure of flushin...

Page 4: ... 64 9 6 1 Main Menu Options 65 9 6 2 Main menu Trend 89 9 6 3 Main menu Event list 94 9 6 4 Main menu Device information 96 10 Decommissioning Switching off 97 11 Maintenance 99 11 1 Preparations 99 11 2 Maintenance Inspection 100 11 2 1 Cleaning the surface and display 101 12 Troubleshooting 105 12 1 Preparations for troubleshooting 106 12 2 Changing replacing fuses 107 12 3 Changing replacing th...

Page 5: ...5 1 Technical data 1 1 Name plate Fig 1 1 Name plate example 1 Device description and product code 2 Technical information 3 Approval information example 2 3 1 ...

Page 6: ...Technical data 6 1 2 Dimensions Fig 1 2 Housing dimensions Weight approx 140 kg ...

Page 7: ...on marking II 2G Ex pxb IIC T4 Gb EC type examination BVS 19 ATEX 012 X Ambient temperature 10 C Tamb 50 C 1 5 Marking as per the IECEx scheme IECEx marking and data provisional Explosion marking Ex pxb IIC T4 Gb IECEx certificate CoC BVS 19 0000X Ambient temperature 10 C Tamb 50 C 1 6 Voltage supply Voltage 230 volts or 115 volts 50 60 Hz alternating current Power consumption 185 VA max Protectio...

Page 8: ...ent upon combustion 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 Max 500 mbar Input pressure min 20 mbar dependent on the gas 1 11 Ignition protection gas Ignition protection gas Compressed air instrument air Input pressure max 5 bar Input pressure min 4 5 bar Te...

Page 9: ...ssible operating time without the compressor UNION recommends compressed air of class 533 as per ISO 8573 1 corresponding to solids of 40 μm class 5 dew point of 20 C class 3 oil quality of 1 mg m class 3 DANGER The calorimeter may not be operated outside the specified ambient temperature range 10 C Tamb 50 C The approval is void outside this temperature range ...

Page 10: ...ocess gas type Measuring range Wobbe index Measuring accuracy Wobbe index Series CWD2500 Series CWD3000 Industries producing and using natural gas 001 Natural gas and biomethane and gases associated with crude oil 30 60 MJ m3 I 8 0 16 0 kWh 7 000 14 000 kcal 750 1 500 BTU 1 FS 1 MV Refineries 004 Refinery gas 25 70 MJ m3 I 7 0 20 0 kWh 6 000 16 500 kcal 650 1 800 BTU 1 5 FS 1 5 MV Iron and steel 0...

Page 11: ...S 021 Flare gas 800 MJ m3 I 222 kWh 191 000 kcal 20 340 BTU ft3 3 FS 2 FS Synthesis gas 024 Synthesis gas 0 10 MJ m3 I 0 2 8 kWh 0 2 390 kcal 0 250 BTU ft3 3 FS 2 FS Metallurgy 025 Carbide gas low 8 4 12 4 MJ m3 I 2 3 3 4 kWh 2 010 2 960 kcal 210 320 BTU ft3 1 5 FS 1 5 MV 026 Carbide gas high 12 5 19 MJ m3 I 3 5 5 3 kWh 2 990 4 540 kcal 320 480 BTU ft3 1 5 FS 1 5 MV Testing and certification 027 M...

Page 12: ... of the approval Risk of serious accidents Installation location Protect against direct sunlight and ensure sufficient shade Temperature change 5 C per hour Air humidity 0 95 rel humidity Ambient pressure 800 1 100 hPa 0 8 1 1 bar Direct sunlight can cause changes in temperature temperature changes above 5 C h affect measurement results For other requirements see Section 6 3 ...

Page 13: ...EX Richtlinie 2014 34 EU ATEX directive 2014 30 EU Elektromagnetische Verträglichkeit 2014 30 EU Electromagnetic compatibility Angewandte harmonisierte Normen Harmonized standards used EN 60079 0 2012 Explosionsfähige Atmosphäre Teil 0 Betriebsmittel Allgemeine Anforderungen Explosive atmospheres Part 0 Equipment General requirements EN 60079 2 2014 Explosionsgefährdete Bereiche Teil 2 Geräteschut...

Page 14: ...EU Declaration of Conformity 14 ...

Page 15: ...n possible dangerous situations which could arise in hazardous areas is marked with the symbol shown here DANGER For an immediate danger that can lead to serious 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 prop...

Page 16: ...is intended for use in weather proof areas and for fixed mounting to a wall and fixed installation temperature range 10 C 50 C The calorimeter CWD3000 EXP is designed for continuous operation intervention is not required during operation The calorimeter CWD3000 EXP is suitable for operation in hazardous areas and is intended for use in explosion protection zone 1 group II category 2G in accordance...

Page 17: ...3 5 Personnel and qualification Gas connections and work on the electrical equipment of the combustion calorimeter may only be carried out by a professional in compliance with safety provisions especially for hazardous areas ...

Page 18: ...installation all gas conveying parts must be checked for proper seal according to national regulations Observe the national regulations on installation and setup e g IEC EN 60079 14 All repairs must be carried out by trained specialists regardless of the type of work 3 7 Recurring operator training NOTE Country specific regulations regarding the recurring instruction of operators must be observed ...

Page 19: ...t 4 5 5 bar You must wait for at least 5 minutes after separation of the power supply before any doors of the housing may be opened Static electricity discharge Warning plate may only be cleaned with a damp cloth 3 8 Owner safety precautions WARNING Toxic gases The owner must provide suitable protective equipment for the combustion calorimeter that can reliably prevent injuries to personnel e g fr...

Page 20: ...al safety equipment for different phases of operation Further technical developments may result in deviations from these operating instructions If you would like more information or if you encounter problems that are not covered in detail in this manual contact us at the following address UNION Instruments GmbH Zeppelinstraße 42 76185 Karlsruhe Germany 49 0 721 680381 0 49 0 721 680381 33 support ...

Page 21: ...ssed air as the ignition protection gas Before startup the the housing is flushed out with compressed air equaling several times its volume Overpressure is then generated These parameters are controlled and monitored with control unit FS870 S located outside The CWD3000 EXP is divided into containment areas In the inner containment area the combustible gas enters the combustion chamber for analysi...

Page 22: ...ps may only be opened with a tool 4 3 Monitoring of the flushing process and overpressure of flushing system Control unit for monitoring flush volume and overpressure of the ignition protection gas Prevents startup and operation of the device in case of insufficient characteristic values Fig 4 2 Depiction of control unit for pre flushing and overpressure example 4 4 Cable bushings Cable bushings f...

Page 23: ...The device is separated from the combustion gas Solenoid valves are closed in the current free state 4 6 Solenoid valve Should combustion malfunctions occur or the overpressure be insufficient the solenoid valves at the combustion gas inlet of the combustion calorimeter close A restart of the combustion calorimeter is necessary Fig 4 3 Depiction of combustion gas inlet solenoid valves example ...

Page 24: ...4 7 Pressure switches Monitor differential pressures of the media in the housing deenergize the device if limits are violated and solenoid valves at the combustion gas inlet close Fig 4 4 Depiction of pressure switches example ...

Page 25: ...ection in hazardous areas May be opened by specialists only The device must first be flushed after opening the housing and switching on again Minimum flow volume of 16 000 l h of compressed air at 4 5 5 bar You must wait for at least 5 minutes after separation of the power supply before any doors of the housing may be opened Static electricity discharge Warning plate may only be cleaned with a dam...

Page 26: ...arking Fig 4 7 Name plate with ATEX IECEX marking example NOTE Malfunction in case of interruption of ignition protection gas supply compressed air When a valve for shutting off the ignition protection gas supply is installed by the owner a sign is to be posted at that location In case of accidental unauthorized shut off the calorimeter switches off ...

Page 27: ...outlet 2 Wall mounting eyelet 4x 3 Door of cell 2 with 7 hasps 4 Ignition protection gas compressed air inlet 5 Signal line cable glands of cell 2 6 Display and operating unit door of cell 3 with 4 hasps 7 Control unit with electrical voltage supply connection 8 Gas inlets max 5 depending on the options 9 Door of cell 1 with 2 hasps 8 7 1 6 4 9 5 3 2 ...

Page 28: ...st air outlet 4 Pressure switches 3x 5 Thermal element with combustion chamber 6 Ignition transformer 7 Precision pressure controller with mixer block 8 Digital valve compressed air infeed with silencer 9 Proportional valve with pressure controller actuator for control unit and compressed air infeed with silencer 10 Voltage distribution power supply distribution rail 11 Electronics input and outpu...

Page 29: ...on approved accessories may cause damage and put persons at risk Such use will void the warranty The owner is then liable for any resulting damage Pay attention to the ATEX type examination IECEx certificate Only use genuine accessories or accessories approved by UNION Instruments GmbH ...

Page 30: ...Description and connections 30 ...

Page 31: ...g means may cause injuries Use suitable load carrying means when unpacking and transporting Check slings if applicable for adequate load bearing capacity and sound condition and fasten them carefully Never walk or stand under suspended loads NOTE If strong shocks occur during transport these may damage the housing Therefore check the transport container for damage before opening In case of transpo...

Page 32: ...ceptance 32 WARNING Risk of injury damage The protective function of the housing can be adversely affected by transport damage In case of damage to the transport packaging or signs of improper transport closely inspect the housing ...

Page 33: ...alorimeter is stored for longer than 3 months or must be operated or stored outside the prescribed ambient conditions 6 2 1 Storage conditions NOTE Ensure that the combustion calorimeter is free of gas moisture residue Frozen condensate water in the combustion calorimeter may cause damage Ambient temperature 0 60 C Air humidity 0 95 relative humidity Ambient pressure 700 1 400 hPa 0 7 1 4 bar ...

Page 34: ...oints are used explosion protection is no longer guaranteed Use only cable entry points approved for the required ignition protection type When selecting replacing cable and line entry points comply with the technical data Open holes and unused cable entry points pose a hazard Explosion protection is no longer guaranteed if there are open holes or unused cable entry points Always close up open hol...

Page 35: ... temperature changes above 5 C h affect measurement results Provided with clean and adequate compressed air ignition protection gas for unbiased measurement result combustion calorimeter requires max 30 000 l h air see technical data Off gases must be discharged protected from air draft using a suitable pipe tube Connection points must be checked for proper seal WARNING Risk of injury due to tempe...

Page 36: ...The combustion calorimeter is intended for mounting to a solid wall There are four 11 mm fastening eyelets on the housing The wall used for mounting must be sufficiently sturdy to bear the weight of the combustion calorimeter Adequate distance must be provided between the side wall of the installation location and the combustion calorimeter for service and maintenance left side approx 60 cm right ...

Page 37: ...t the system draws air and indicates false measured values Do not use sealant for sealing the gas connections Sealant components may falsify the measurement result Only suitable lines may be used 6 3 3 1 Ignition protection gas supply Compressed air Compressed air is required as the ignition protection gas for operation of the combustion calorimeter Ensure sufficient supply and seal of the connect...

Page 38: ...ompressed air pressure controllers external and in device Set external controller to no higher than 5 bar Do not change setting of internal pressure controller 6 3 3 2 Combustion gas WARNING Off gases must be discharged by the owner to a safe environment Check connections for proper seal NOTE Gas input pressure depending on the gas maximal 500 mbar minimum 20 mbar Chapter 1 9 Combustion gas must b...

Page 39: ...rier gas supply Contact the manufacturer regarding this 6 3 3 4 Calibration gas WARNING If a pressure reducer is not installed escaping calibration gas must be discharged by the owner to a safe environment NOTE Calibration gas must be free of contaminants and condensate The calibration gas quality must be similar to the combustion gas quality see Section 1 10 For device versions with two measuring...

Page 40: ...ases 6 mm screw fitting Number of connections optional 1 shows input of gas from the top down 1 Carrier gas I5 2 Input support gas 2 Test gas I5 1 Input test gas 3 Calibration gas 2 I2 3 Input calibration gas 2 4 Calibration gas 1 I 2 2 Input calibration gas 1 5 Combustion gas I1 1 Input process gas 1 1 ...

Page 41: ...scharged safely For flue gases containing CO H2 and H2S a safe environment must be ensured NOTE Flue gases residual heat must be discharged protected from air draft and without interruption through a vent An accumulation of residual heat leads to false measurement results Fig 6 4 Flue gas exhaust air connection 1 Flue gas exhaust air connection 1 ...

Page 42: ...aged or doors are closed improperly WARNING Risk of severe injury Housing is overpressurized Switch the device off first then shut off the ignition gas supply and finally open the doors Wait 5 minutes after switching off and allow thermal element to cool down Keep doors one door per cell closed during operation Open only when switched off and observe safety provisions Close all hasps of all doors ...

Page 43: ...er marked with the adjacent symbol may still carry voltage even when the main switch is switched off If required separate the combustion calorimeter from the supply network DANGER Risk of explosion Non approved cable bushings pose a hazard Cable bushings which are not suitable for the cable cross section pose a hazard Use only cable bushings with ATEX IECEx approval which fit the cable cross secti...

Page 44: ...operating instructions When making connection in terminal box of the control unit observe the following Tightening torques min max min 0 3 Nm max 0 4 Nm Wire cross section min max rigid 0 2 2 5 mm flexible 0 2 2 5 mm Use external protective conductor terminal grounding bolt on left side of housing Connect protective conductor firmly secure against loosening Protect connecting parts effectively aga...

Page 45: ...ecifications of the VDE the local and regional safety regulations and the factory internal safety rules must be complied with at all times during work on the combustion calorimeter NOTE Check whether the line voltage present is consistent with the device voltage of the combustion calorimeter The combustion calorimeter may only be operated with effective protective conductor connection in accordanc...

Page 46: ...ted personnel Allow only instructed trained service technicians to carry out commissioning DANGER Risk of explosion Electrical interfaces only connect analog signals and relays using the disconnector unit supplied Fig 6 6 Disconnector unit Gönnheimer FS852 example The disconnector unit SR852 could be placed in hazardous area It is certified on its own in protection type Ex e ...

Page 47: ...6 3 7 Connector assignment for input output signals Fig 6 7 Connector assignment of input output IO external type 06 WARNING Do not connect to line voltage Only operate outputs relay analog and digital and inputs with safety extra low voltage ...

Page 48: ...ction optionally assigned if applicable D 8 7 19 Common 20 Normally open 21 Normally closed Function optionally assigned if applicable D 9 8 22 Common 23 Normally open 24 Normally closed Function optionally assigned if applicable D 10 Connector X5 mA outputs 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 49: ...ction optionally assigned if applicable D 21 6 11 12 Function optionally assigned if applicable D 20 7 13 14 Function optionally assigned if applicable D 19 8 15 16 Function optionally assigned if applicable 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 ass...

Page 50: ...ring devices are removed attached The following transport securing devices must be removed attached within the combustion calorimeter Fig 6 8 Transport securing devices example shown Item No Component Type of securing device 1 Transport securing device for density measuring cell 4x cable ties 1x screw 5x16 2 Transport securing device of pressure controller 2x retaining belts 1x bubble wrap inside ...

Page 51: ... Remove the transport securing device bubble wrap Reclose the protective 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 white cable ties around the density measuring cell Loosen...

Page 52: ...ents for hazardous areas Exhaust discharged flue gas off gas to a safe environment In case of toxic gases mark outlet location of discharged flue gas off gas with a warning Tripping hazard from improperly routed supply lines 6 5 Documentation NOTE UNION Instruments GmbH recommends keeping a maintenance log and documenting all work and tests ...

Page 53: ...l commissioning or before an extended operating shutdown back up the device configuration Have the backup made by service technicians or in response to a special service instruction NOTE The following table contains significantly shortened steps for commissioning after an extended downtime To switch on the combustion calorimeter again after a short shutdown some steps can be omitted Right column ...

Page 54: ...ustion gas X Check whether the combustion gas is correct X Check whether the calibration gas and carrier test gas if applicable is correct X Check whether the gas connections are correct and sealed X Check whether the compressed air supply is correct X Furnish switch on owner side energy supplies and media supply X Ensure voltage X Ensure that the doors are closed and that all hasps are closed X X...

Page 55: ...chapter contains only elements for operation of the combustion calorimeter by the normal operator Fig 8 1 Work stations example Item No Designation Function Activity 1 Display Status display and calorimeter operation 2 Control unit Status display and operate control unit 2 1 ...

Page 56: ...Description of the work stations operator control elements 56 ...

Page 57: ...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 a key press 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 3 2 1 8 5 1 9 4 1 4 3 4 4 6 5 7 ...

Page 58: ... operation regardless of the menu level 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 USB memory stick For service purposes only 6 LED status display Power Device switched on Operation Process calibration Service Service required Fault Major fault Flame Flame...

Page 59: ...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 described in the corresponding screens 9 3 Available displays The available displays and their function are described...

Page 60: ...s Current status of the device e g START STOP Process Cal 26 02 2019 09 24 46 Current date time T1 Temperature of cooling air at thermoelectric battery input T2 Temperature of cooling air at thermoelectric battery output T2 T1 Temperature differential NOTE STD During a calibration 0 015 is typically achieved The calibration is concluded after that ...

Page 61: ...ifferential pressure Display example values Information dp air Pressure at thermal pipe aperture housing overpressure to combustion air pressure differential dp wobbe Pressure at density cell housing overpressure to combustion gas pressure differential ...

Page 62: ...Operation 62 ...

Page 63: ...limits 77 Main menu Options System 78 Main menu Options System General 79 Main menu Options System Ignition 81 Main menu Options System Update 81 Main menu Options System Load factory settings 82 Main menu Options System CSV Export 82 Main menu Options System Hold signal On Off 82 Main menu Options System Settings 83 Main menu Options System Settings Date Time 83 Main menu Options System Settings ...

Page 64: ...Operation 64 9 6 Main Menu The main menu is the standard display during active operation The following submenus are accessed from the main menu Options Trend Eventlist Device Info ...

Page 65: ... following parameters Configuration of calibration gas Automatic calibration Automatic calibration 2 Calibration Save base calibration Calibration limits System Configuration option for the following parameters General Ignition Update Load factory settings CSV export Hold signal On Off Settings e g date language and password Disable system Service For service technician only Activate serial interf...

Page 66: ...Operation 66 Main Menu Options I O Options for configuration for the following parameters Analog outputs Digital outputs mA display Digital inputs Display ...

Page 67: ...rved for this Units xxx m correspond to a gas temperature of 0 C and a barometric pressure of 1 013 mbar xxx Sm corresponds to a gas temperature of 15 C 60 F and a barometric pressure of 1 013 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 1 013 mbar ...

Page 68: ...flame is burning Calibration The calibration gas solenoid valve is open and the flame is burning Maintenance The device must be checked in the foreseeable future but is still ready for operation The reason for maintenance can be obtained from the General information field Examples reasons include Filter change air filter No calibration gas calibration canceled Room temperature too high air inlet t...

Page 69: ...the 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 du...

Page 70: ...ions I O mA display The mA values for the currently active outputs are displayed in this menu With the mA display key all channels can be displayed one after the other The value can be obtained from the General information field ...

Page 71: ...en 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 cancellation low open No calibr...

Page 72: ...Operation 72 Main Menu Options I O Display The display of measured values is configured in this menu A signal and a unit are assigned to each of the four display windows ...

Page 73: ...Operation 73 Main Menu Options Calibration In this menu the calibration values are configured and calibration can be started manually Calibrate ...

Page 74: ...ve density These values are calculated from the gas components of the calibration gas The manufacturer always uses dry gas as the basis Units xxx m correspond to a gas temperature of 0 C and a barometric pressure of 1 013 mbar xxx Sm corresponds to a gas temperature of 15 C 60 F and a barometric pressure of 1 013 mbar xxx stands for MJ kcal or kWh BTU ft corresponds to a gas temperature of 15 C 60...

Page 75: ... 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 With a restart of the device or 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 76: ...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 77: ...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 78: ...Operation 78 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 79: ...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 Flushing time after cooling air or device start 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 r...

Page 80: ...time elapses Minimum internal pressure When the minimum internal pressure is undershot 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 81: ...nition threshold is reached before the ignition duration elapses If the ignition threshold is not reached within the specified time the combustion calorimeter goes to the STOP state Interval ignition After device start and the flushing time period 10 s 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 ign...

Page 82: ...d 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 e g with a conventional spreadsheet 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 ...

Page 83: ...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 84: ...s for inserting copying and correcting various languages even those that have to be represented by bitmaps e g Chinese Languages can be downloaded onto a memory stick corrected and then re imported to the combustion calorimeter The language can be changed and your own bitmaps configured in this menu ...

Page 85: ...e observed here Factory password The combustion calorimeter is delivered with factory password of 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 no longer be unlocked ...

Page 86: ...Operation 86 Main menu Options System Settings Change color The display colors can be changed here ...

Page 87: ...Operation 87 Main menu Options System Settings Hardware 1 NOTE Only change this menu in consultation with the manufacturer The parameters for a multi range measuring device are configured in this menu ...

Page 88: ...ling The menu is password protected Setting for service only The device is provided with a default password 0721 with which the owner must specify handling The serial interface can be activated with OK and Enter using the menu sequence Options Service entry of the service password and other customer specific data For activation the menu button of the keyboard must be pressed calorimeter must be sw...

Page 89: ... configured in this menu The following must be observed here 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 90: ... obtain a resolution for this purpose 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 91: ...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 92: ...signal Signals for the curves can be selected in this menu Example 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 93: ...Operation 93 Main menu Graphic Select curve Individual curves can be selected in this menu in order to change parameters ...

Page 94: ...Operation 94 9 6 3 Main menu Event list NOTE The event list stores all events that are of interest for operation and service of the device A total of 1 000 events can be stored Show all All events ...

Page 95: ...Operation 95 Show startup Selection of the start events Show calibration Selection of the calibration events ...

Page 96: ... memory stick and sent to the manufacturer by email e g using a screenshot see CSV keyword 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 97: ...emporarily some steps can be omitted Switching off column Steps Switching off Decommi ssioning Set calorimeter to Stop End measurement STOP button on control panel X X Disconnect the device from the process professionally shut off the gas carrying lines X X Bring linked system components to a standstill X X Shut off air supply X X Disconnect voltage supply X X If the combustion calorimeter is to b...

Page 98: ...Decommissioning Switching off 98 ...

Page 99: ... voltage supply 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 Valve of the ignition pro...

Page 100: ...lose combustion gas shut off valve to combustion calorimeter and carry out leak testing The nature and amount of wear depends greatly on the individual use and operating conditions All specified intervals are therefore guide values To guarantee operational reliability use only genuine spare parts of the manufacturer DANGER The calorimeter can be operated with a door open for maintenance purposes I...

Page 101: ... observed through the viewing window of the thermal element and functions of the calorimeter can be checked using the display and control panel DANGER Risk of serious injury from electricity Ignition transformer generates high voltage during ignition Calorimeter is supplied with 230 V 115 V Cell 3 voltage supply power supply 11 2 1 Cleaning the surface and display Clean only with a damp cloth to a...

Page 102: ...ousing and inside the device for firm seating and proper seal Annually Gas inlet solenoid valves check connections for intactness check functioning switching Annually Check pressure switches and seal Annually If necessary use load from environment Check seal of housing for functioning and damage Each time the doors are opened Check compressed air filter for soiling blockage condensate optionally i...

Page 103: ...Maintenance 103 ...

Page 104: ...Maintenance 104 ...

Page 105: ...ltage supply 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 separate the...

Page 106: ...n event list with up to 1 000 events in chronological order specification of date The event list provides information about abnormal behavior see 9 6 3 The export of event data to portable external memory USB stick is possible upon consultation with UNION service The exported data can be sent to the manufacturer for fault analysis CSV export Section 9 6 1 Events include Start Stop Ignition Insuffi...

Page 107: ...alue The measured value drifts upward in one direction The calibration no longer achieves the required point The frequency controller is at its maximum value Strong compressed air supply fluctuation which can no longer be corrected 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 clean...

Page 108: ...ult Gas pressure is too low Fault in the thermoelectric battery Defective PT 100 temperature sensor Service Air inlet temperature 52 C Operation Flame is burning and calorimeter is running on combustion or calibration gas Operation delay Flame is burning calorimeter is running on combustion or calibration gas Delay time has elapsed after which the analog signals are enabled Process Flame is burnin...

Page 109: ...Troubleshooting 109 Calibration Flame is burning and solenoid valve for calibration gas is open Calibration is active and no mA signals are output they are on hold The last current value is retained ...

Page 110: ...Troubleshooting 110 ...

Page 111: ... 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 112: ...Service 112 ...

Page 113: ...e UNION Instruments GmbH dispose of your combustion calorimeter WARNING Risk of explosion and risk of injury from electricity and if applicable gases in the combustion calorimeter NOTE Observe national regulations for disposal of machines and working materials Sort parts by groups and have them recycled professionally ...

Page 114: ...Disposal 114 ...

Page 115: ...dard components use only identical components from the original manufacturer In the event that components are discontinued or components of other manufacturers are used request approval from 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 note the order number if neces...

Page 116: ...Spare parts 116 ...

Page 117: ...Air min Min air requirement unit m air m gas only with customer specific CWDs CWD 11 FLOAT 4 76 Reserve CWD 20 FLOAT 4 80 Fixer test value Sent 12345 6789 CWD 21 BYTE 1 81 Operating state Current CWD operating state 0 Stop 1 Process 2 Ignition 3 Ignition break 4 Fault 5 Overtemperature 6 Measurement range 1 calibration 7 Measurement range 2 calibration 8 Measurement range 3 calibration 9 Test gas ...

Page 118: ... selected in the I O Analog Outputs menu The interface must be activated in the Service menu Data transmission Transmission rate 9 600 baud Parity bit no Stop bit 1 Data bit 8 Output format 111111 111 222222 222 333333 333 777777 777 111111 111 Data 1 output 222222 222 Data 2 output 777777 777 Data 7 output Assignment of the plug pins 6 3 7 ...

Page 119: ... IECEx marking 7 Inspection 100 Installation location 35 Installing 34 Intended use 16 M Maintenance 99 100 O Operation 57 Operator control elements 55 P Personnel and qualification 17 Profibus Data structure 117 Protective equipment 21 Control unit 22 Pressure switches 24 Pressurized enclosure 21 Protective housing 22 Solenoid valve 23 Thermal cutoff 23 S Safety instructions 15 18 Serial interfac...

Page 120: ...iew 27 Fig 5 2 Housing with no doors example showing carrier gas option 28 Fig 6 1 Wall mounting 36 Fig 6 2 Ignition protection gas connection compressed air 6 mm screw fitting 38 Fig 6 3 Connections for process calibration carrier and test gases 6 mm screw fitting 40 Fig 6 4 Flue gas exhaust air connection 41 Fig 6 5 Electrical connection control unit example 44 Fig 6 6 Disconnector unit Gönnheim...

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Union Instruments CWD3000 EXP, Operating Instructions Manual

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Summary of Contents for CWD3000 EXP

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