Union CWD2005 DPC Page 102 Operating Instructions Manual Download

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CWD2005 DPC

chapter — page:

8—6

NOTE

The following overview only describes the checks / work in regard to the protec-
tive housing and the functions for explosion protection!

Inspection

Interval
(recommended)

Weekly inspection

Compressed air inlet free

weekly, or when
required

Pressure indicator at protective cabinet readable and plausible

weekly, or when
required

Flame arrester consistent and not soiled

weekly, or when
required

Exhaust system free

weekly, or when
required

Quarterly inspection

Process gas analyser calibrated according to manufacturer's speci-
fications

every 3 months, lat-
est annually or when
required

Summary of Contents for CWD2005 DPC

Page 1: ...Operating instructions Combustion calorimeter CWD2005 DPC Mai 2017 V2 01 ...

Page 2: ...om http www union instruments com 2017 This documentation is copyrighted The engendered rights are retained in particular the rights to translation reprinting taking pictures radio transmission reproduction by photomechanical or similar methods and storage in data processing systems including excerpts The right to technical changes is retained ...

Page 3: ...ch 4 3 4 8 Thermal fuse 4 3 4 9 Solenoid valve 4 3 4 10 Fan 4 3 4 11 Markings and warning system 4 4 5 Connections transport setting up 5 1 5 1 Description and connections 5 2 5 2 Transport 5 6 5 3 Ambient conditions 5 7 5 4 Installing and connecting 5 7 5 5 Startup after setup 5 23 5 6 Documentation 5 26 6 Commissioning operation removing from service 6 27 6 1 Commissioning start up 6 28 6 2 Desc...

Page 4: ...C II 8 4 Preparations for troubleshooting 8 12 8 5 Changing replacing fuses 8 13 8 6 Instable measured value 8 13 8 7 Service 8 16 9 Disposal 9 1 10 Spare parts 10 1 11 Annex 11 3 Index 11 3 List of figures 11 4 ...

Page 5: ...points 1 Calibration inlets 1 internal through gas bottle Gas connections Clamp ring connection 6 mm Relative gas humidity 95 condensate free Inlet temperature gas max 45 C Power supply Voltage 115 VAC 50Hz Power consumption 185 VA max Protection class I Degree of protection IP50 External circuit breaker required 240VAC 120VAC 10A Instrument air supply max input pressure 10 bar 145 psi min input p...

Page 6: ...8 mm additional 300 mm for flame arrestor Width 822 mm Depth 399 mm Weight Weight up to 85 kg DANGER The system must not be operated outside of the specified ambient temperature 5 C Tamb 40 C Outside of this temperature range the approval becomes void ...

Page 7: ...as 25 48 20 25 45 1 0 25 Refinery gas 25 50 40 25 50 1 5 25 LPG 40 90 20 40 90 1 5 15 1 Gas with a heating value 3 5 MJ m does not burn autothermic carrier gas needed The combus tibility always depends on the gas type 2 FS linearity error in relation to full scale value 1 1 2 Display times of calorific value measurement1 Dead time 3 seconds 50 time 7 seconds 90 time 15 seconds 99 time 45 seconds 1...

Page 8: ...2005 DPC chapter page 1 4 1 1 4 Linearity and measuring range The measuring ranges cannot be used from 0 to 100 The range depends on the gas composition Typical for a measuring range are 45 100 Wobbe index ...

Page 9: ... compressed air two terminal boxes a venting system of the protective housing a pressure manometer and pressure switch inside the housing a compressed air supply with controller and ball valve a combustion calorimeter List of the important assembly groups details according to drawing and parts list see overall drawing Fig 1 1 System overview ...

Page 10: ...CWD2005 DPC chapter page 1 6 1 3 Dimensions Fig 1 2 Dimensions of system Additional 300 mm height for flame arrestor ...

Page 11: ... EC Electromagnetic compatibility Angewandte harmonisierte Normen Used harmonized standards DIN EN 61010 1 2011 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 DIN EN 61326 1 2006 Elektrische Mess Steuer Regel und Laborgeräte...

Page 12: ...CWD2005 DPC chapter page 2 2 ...

Page 13: ...rsonnel and qualifications 3 4 3 4 Safety notes 3 5 3 4 1 General safety notes 3 5 3 4 2 Notes on specific hazards 3 5 3 4 3 Electrical connection 3 6 3 4 4 Process gas 3 7 3 4 5 Instrument air supply 3 8 3 4 6 Flue gas 3 9 3 5 Operator safety precautions 3 9 3 6 Regular operator training 3 10 3 7 Workplace hazard analysis 3 10 ...

Page 14: ...ury or death ATTENTION Potentially hazardous situations that can lead to minor physical injury This can also be used for property damage NOTE Denotes information that can make it easier to handle the system or help prevent property damage DANGER The system is approved according to the approval limited product certification for use in potentially explosive atmospheres Notices of possibly occurring ...

Page 15: ...is designed as a device with over pressure encapsulation and purging by compressed air The combustion calorimeter CWD2005 DPC is intended according to the marking for use in an EX zone acc to NEC Class I Division 2 Group B C and D Determining the calorific value of gas supports process control in industrial sys tems The system is intended for use inside closed rooms for stationary mounting and ins...

Page 16: ...gulations especially those regarding explosive areas NOTE Changes to the electric installation equipment or gas bearing modules by per sons without corresponding authorisation qualification and without consulting UNION Instruments GmbH cause loss of type test approval DANGER Changes to the installation or modules by persons without corresponding author isation qualification cause loss of type test...

Page 17: ... safety notes Before the corresponding chapters 3 4 2 Notes on specific hazards DANGER After installation all gas conducting parts must be checked for leaks accord ing to national internal regulations Observe national regulations for assembly and installation e g IEC EN 60079 14 NEC500 NFPA 496 All repairs that require the protective covering to be opened may only be per formed by trained personne...

Page 18: ...the system has been opened the parts identified by the adjacent symbol may still be live even when the master switch has been turned off If necessary disconnect system from the voltage mains NOTE Changes to the electric installation by persons without corresponding authorisa tion qualification cause loss of type test approval Only operate relay with functional extra low voltage Do not connect to t...

Page 19: ...lean and free of residue Impurities can en ter the combustion calorimeter and cause incorrect measurements and or damage The inlet pressure for the gas connections must not exceed the values speci fied in the technical data Each connection needs to be carefully checked for leaks If there are any leaks the system will draw air and the measurements will be incorrect Only use suitable pipes Use a sep...

Page 20: ...es the protective functions against explo sions by purging and creating an overpressure Establishing instrument air connections and working on the instrument air equip ment of the system may only be carried out by specialists adhering to the safety regulations especially those regarding explosive areas ...

Page 21: ...nt room ventilation NOTE Flue gases residual heat must be emitted to the open air through a suitable ex haust system 3 5 Operator safety precautions WARNING The operator needs to provide suitable safety equipment for the system to re liably prevent individuals from being injured from gas leaks Danger of stumbling over improperly laid supply lines Other safety precautions taken by the operator corr...

Page 22: ...e operator must perform a workplace risk analysis if applicable independent of the CE marking approval of this com bustion calorimeter Technical developments can give rise to deviations from these operating instruc tions If you require additional information or if particular problems arise that are not fully addressed in this manual please contact the following address UNION Instruments GmbH Zeppe...

Page 23: ...2 Instrument air purged and pressurised housing 4 2 4 3 Locks and doors of the housing 4 2 4 4 Flame arresters 4 2 4 5 Cable line glands 4 2 4 6 Pressure switch pressure too low 4 2 4 7 Safety switch 4 3 4 8 Thermal fuse 4 3 4 9 Solenoid valve 4 3 4 10 Fan 4 3 4 11 Markings and warning system 4 4 ...

Page 24: ...housing Openings of the housing are designed in such a way that transfer of a potential ignition hazard to the outside is prevented 4 3 Locks and doors of the housing The purged and pressurized housing is closed with three separated doors Each door is operated by two square box keys 4 4 Flame arresters Flame arresters prevent the propagation of a potential ignition hazard to other sys tem parts 4 ...

Page 25: ...nitiation the thermal fuse disconnects the 24 V voltage supply 4 9 Solenoid valve In case of faults the solenoid valves of the combustion calorimeter close automat ically The combustion calorimeter then needs to be restarted 4 10 Fan The fan mixes the exhaust gases generated in the combustion with fresh air and ensures an appropriate volume flow The rotational speed of the combustion calo rimeter ...

Page 26: ... 11 Markings and warning system Fig 4 3 Markings and warnings 1 Warnings purge duration switching on off 2 Type plate 3 Warning note disabling protective gas instrument air and connection supply 4 Warning note electricity 2 1 3 4 4 ...

Page 27: ...ce system chapter page 4 5 Fig 4 4 Markings and warnings inside the housing top compartment 1 Warning note hot surface Fig 4 5 Warning notes on the electric connection board example inside hous ing right bottom compartment 1 ...

Page 28: ...CWD2005 DPC chapter page 4 6 ...

Page 29: ...s and calibration gas 5 13 5 4 7 Carrier gas supply 5 14 5 4 8 Calibration gas 5 15 5 4 9 Flue gas 5 16 5 4 10 Instrument air connection 5 17 5 4 11 Electrical connection 5 18 5 4 12 Electrical interfaces 5 18 5 4 13 Operator safety precautions 5 23 5 5 Startup after setup 5 23 5 5 1 Removing attaching the transport safeguard 5 24 5 6 Documentation 5 26 NOTE Generally the system is started up by U...

Page 30: ...escription and connections Fig 5 1 Connections 1 Output flue gas and protective gas instrument air 2 Connection of power supply 3 Input compressed air 4 Connection of signal lines 5 Input process gas 6 Input calibration gas 1 6 4 3 2 5 ...

Page 31: ...dicator 5 Input protective gas instrument air 6 Mounting rack with fixation points 6 7 USB connection for service 8 Input process and calibration gas 9 Compartment combustion calorimeter 10 Compartment internal power supply 11 Compartment internal signal output 12 Terminal boxes with external power supply signal output 13 Power Switch main 8 2 1 7 3 4 5 6 9 10 11 12 13 ...

Page 32: ... doors 1 Thermal fuse behind the exhaust pipe at the rear wall 2 Thermal body 3 Density measuring cell 4 Precision pressure controller 5 Electronics input and output signals internal 6 Safety switch ignition transformer 7 Bus bar for power supply example 8 Fan 1 2 3 4 6 5 7 8 ...

Page 33: ...of injury defective Use of non approved accessories can cause defects and be hazardous This will render the warranty null and void The operator is liable for incurring damage Ob serve the Ex approval Only use original accessories or accessories that have been approved by UNION Instruments GmbH ...

Page 34: ...ling from pallets and load carry ing equipment Use suitable hoisting equipment for unpacking and transport Check the load bearing capacity and condition of the slinging equipment and carefully attach it Never stand under suspended loads NOTE Shocks during transport can impair the protective housing Therefore check sys tem protective housing after transport for damage In case of damage during trans...

Page 35: ...lative humidity Ambient pressure 700 1400 hPa 0 7 1 4 bar 5 4 Installing and connecting DANGER Risk of explosion Danger due to invalid cable glands If improper cable glands are used the explosion protection cannot be ensured an ymore Only use cable glands approved for the required ignition protection type Observe the technical data when selecting using cable and line glands Danger due to open dril...

Page 36: ...ficient amount of compressed ambient air for undistorted measurements Ensure that the load bearing capacity of the environment is sufficient Design sufficient space on the sides for mounting and connecting lines Install according to the requirements of explosion protection marking WARNING Leaking process gas needs to be discharged by the operator into a safe environment NOTE The compressed air mus...

Page 37: ... above housing temperature Use PPE against burns NOTE In case of adverse flow installation conditions appropriate deflector plates must be installed that prevent direct flow of fresh are onto the combustion calorimeter Exhaust gases must be emitted to the environment through a suitable pipe tube after being mixed with a sufficient amount of fresh air The connections must be checked for tightness ...

Page 38: ...lation on the wall ground Provide suitable means of attachment Ensure sufficient load bearing capacity of the environment and the means of at tachment WARNING Danger of injury due to the weight of the system Weight and dimensions see technical data Use measures against falling and suitable hoisting tools ...

Page 39: ...ling surfaces If seals are damaged seals and the doors closed improperly the explosion protection cannot be ensured anymore If the doors are improperly locked the explosion protection cannot be en sured anymore A repair must only be done according to the design specifications of the manufac turer Terminal boxes Loosen screws at the housing lid and remove lid carefully Make sure not to remove lose ...

Page 40: ...th approved sealing plugs Observe the technical data when selecting replacing suitable sealing plugs NOTE The connecting parts need to be clean and free of residue Impurities can en ter the calorimeter and cause incorrect measurements and or damage The inlet pressure for the gas connections must not exceed the values speci fied in the technical data of the combustion calorimeter Each connection ne...

Page 41: ...hnical data The input for process and calibration gas to the protective housing and combustion calorimeter is suited on the left side Fig 5 4 Terminal block inlet process and calibration gas 1 Calibration gas inlet 2 Process gas inlet 3 Nozzle block inlet gas Recommended material for connecting lines is stainless steel outer diameter Ø 6mm 3 2 1 ...

Page 42: ...ed with a car rier gas Non flammable gases are automatically mixed with flammable or not flamma ble carrier gases by the combustion calorimeter The carrier gas will be reck oned up in the combustion calorimeter Carrier gases maintain the combustion and do not increase the calorific value of the process gas carrier gas consumption Ø nozzle methane 10 l h 0 40 mm propane 6 0 l h 0 40 mm hydrogen 51 ...

Page 43: ...e combustion calorimeter The inlet pressure for the gas connections must not exceed the values speci fied in the technical data of the combustion calorimeter Calibration gas must be free from impurities and condensate The quality of the calibration gas should be similar to the process gas quality Each connection needs to be carefully checked for leaks If there are any leaks the system will draw ai...

Page 44: ...rious risk of injury from escaping flue gas Flue gas must be emitted to the open air For flue gases with the components CO H2 and H2S ensure sufficient room ventilation NOTE Flue gases residual heat must be emitted to the open air through an exhaust system ...

Page 45: ...ument air connection Maximum input pressure of instrument air see technical data and plate at pressure controller Fig 5 5 Purge air supply and distribution 1 Pressure controller overpressure in protective housing 2 Shut off valve for instrument air 3 Instrument air inlet 3 1 2 ...

Page 46: ...60079 14 as well as national reg ulations The cable gland must meet the requirements of EX zones and be matched to the cable and the threaded hole in the housing Observe the operating instructions of the cable glands Integrate all blank not energised metal parts independent of the operating voltage into the protective ground system The outer protective ground connection at the system is designed f...

Page 47: ... 60947 1 Install the circuit breaker in close proximity to the unit An assignment to the unit must be ensured Note additional requirements for operation the hazardous area 1 Terminal box for power supply 2 Connection power supply 3 Terminal box for electrical signals 4 Optional ports for connection electrical signals Fig 5 6 Electric connection system optional connections 1 3 3 4 4 2 ...

Page 48: ... plate und technical data Connection Pressure Switch via Relay X8 K2 connection to terminal X17 installed refer to Fig 5 9 X16 2 COM X16 4 NO X16 6 NC Terminal block X16 Terminal block X7 in terminal box Ex e for power supply in purge enclosure Customer Union Instr Cable Union Instr Relay X16 2 Relay X8 K2 COM X16 1 7G1 5 3 X7 K1 11 signal X16 4 NO X16 3 7G1 5 4 X7 K1 14 overpressure X16 6 NC X16 ...

Page 49: ...14 3 X17 8 Relay K2 COM X17 7 25G1 4 X14 4 Service request X17 10 NO X17 9 25G1 5 X14 5 X17 12 NC X17 11 25G1 6 X14 6 X17 14 Relay K3 COM X17 13 25G1 7 X14 7 Error X17 16 NO X17 15 25G1 8 X14 8 X17 18 NC X17 17 25G1 9 X14 9 4 20mA X17 50 IOut1 X17 49 25G1 5 10 X5 1 lower row Wobbe index outputs X17 52 X17 51 25G1 5 11 X5 2 30 60 MJ m X17 54 IOut2 X17 53 25G1 5 12 X5 3 Calorific value X17 56 X17 55...

Page 50: ...ta transfer the USB stick is provided with the device 4 20mA X17 66 IOut5 X17 65 25G1 5 18 X5 9 upper row not installed outputs X17 68 X17 67 25G1 5 19 X5 10 X17 70 IOut6 X17 69 25G1 5 20 X5 11 not installed X17 72 X17 71 25G1 5 21 X5 12 Digital X17 78 Dig In 1 DGNDE X17 77 25G1 5 22 X3 1 lower row customer specific use Inputs X17 80 E DI1 X17 79 25G1 5 23 X3 2 from X17 90 Relay COM X17 89 3G1 1 X...

Page 51: ...eeds to be diverted into a safe environment Identify the exit point of the diverted gas with a warning Danger of stumbling over improperly laid supply lines Install the supply lines in a suitable manner 5 5 Startup after setup NOTE Before commissioning transport of the combustion calorimeter make sure that all transport safeguards are removed attached See separate operating instructions for combus...

Page 52: ... all transport safeguards are removed attached The following transport safeguards must be removed attached in the combustion calorimeter Fig 5 12 Transport safeguards Item No Component Type of safeguard 1 Transport safeguard density measuring cell 4x cable strap 1x ring screw 2 Transport safeguard pressure controller 2x safety rubber 1x bubble wrap inside 2 1 ...

Page 53: ...n Remove the transport safeguard bubble wrap Close the protective flap again To re attach the transport safeguard proceed in reverse order 5 5 1 1 2 Transport safeguard density measuring cell Transport safeguard Order of removing attaching the transport safeguard Transport safeguard density measuring cell Remove the black cable straps of the centre eyebolt Remove the white cable straps around the ...

Page 54: ...CWD2005 DPC chapter page 5 26 5 6 Documentation NOTE UNION Instruments GmbH recommends keeping maintenance manual and documenting all jobs and tests ...

Page 55: ...rom service chapter page 6 27 6 Commissioning operation removing from service 6 1 Commissioning start up 6 28 6 2 Description of the workplaces operating elements 6 30 6 2 1 Workplaces 6 30 6 3 Operation 6 31 6 4 Decommissioning switching off 6 32 ...

Page 56: ...uirements X X Check if the system is attached safely X Check that the gas analysis device is suitable for the process gas X Check that the process gas is correct X Check that the calibration gas is correct X Check that the gas connections are correct and tight X X Check the filters water fine filter check for condensate dirt X X Establish switch on the operator energy and media supply X X Switch o...

Page 57: ...libration gas supply when combustion calorimeter is configured with auto matic calibration NOTE For first stating or starting up after a long downtime back up the configuration of the combustion calorimeter Let a service technician do the backup or ask Service for special instructions ...

Page 58: ...purging and overpressure 6 2 1 Workplaces Fig 6 1 Workplaces Item No Designation Function activity 1 Main switch Switch on off de energises the system 2 Pressure display manometer Displays overpressure in protective housing displays status 3 instrument air inlet Opens closes the instrument air supply regulator for pre pressure 4 Display Keyboard Operating the combustion calorimeter see following c...

Page 59: ...ed for leaks according to national regulations if an overpressure of 1 0 inWC is displayed In order to ensure the function of protection and automatic analysis operation check the pressure indicator display in the safety range green range 1 0 inch of water adjust the overpressure in the housing using the controller Operation of the combustion calorimeter is described in the following chapter ...

Page 60: ...sys tem gas analysis device Let a service technician do the backup or ask Service for special instructions Steps Turn off Decom mission ing Turn off the main switch X X Rinse system for 30 minutes let compressed air switched on until de vice has cooled down and no voltage is applied anymore X X Shut compressed air supply X X Disconnect the device from the process close the line professionally X Sh...

Page 61: ...of film keyboard description of display 7 34 7 2 Basics on operation 7 36 7 3 Available displays 7 36 7 4 General information on the start screen 7 37 7 5 Menu structure 7 38 7 6 Main menu 7 39 7 6 1 Main menu Options 7 40 7 6 2 Main menu Trend 7 62 7 6 3 Main menu Event list 7 67 7 6 4 Main menu Device info 7 68 ...

Page 62: ... software controls are operated using a membrane keypad The displayed but tons can be selected by pressing the key NOTE Damage to the membrane keypad Operation with pointed sharp objects can damage the film keyboard Fig 7 1 Operating elements layout of display 4 2 6 7 2 1 9 3 5 8 4 1 4 3 ...

Page 63: ...tion can be programmed The button also saves the input data in the memory 4 3 ESC button The ESC button cancels the current input process independ ent of the menu level 5 Input buttons Input buttons serve for input of numeric data For this pur pose a value field must be active on the screen 6 Burner window Check window to monitor the ignition or combustion process 7 LED status display Power lights...

Page 64: ... to move left or right Symbols Plus and Minus in the menu buttons Calculates the sum of the marked numbers fields or subtracts from that sum Symbol Arrow in the menu buttons Causes a jump to the adjacent field vertically horizontally In the position button field you can set the next lines NOTE Other symbols not described above refer to the different menus They are de scribed on the corresponding s...

Page 65: ...date time 3 Methane 95 01 Vol Volume share of methane 4 mV 24 56 mV signal of the thermal battery 5 V 1 071 Voltage signal of the density measuring cell 6 T1 29 04 0 24 Inlet temperature into the thermal body heating of the air 7 p 4 00 Air differential pressure 8 Fr 51 13 Controlled fan frequency 9 Stabi 0 011 Standard deviation of the measurement value over 2 minutes NOTE Sabi Typical result of ...

Page 66: ...ts 7 51 7 6 1 1 3 Main menu Options System 7 52 7 6 1 1 3 1 Main menu Options System General 7 53 7 6 1 1 3 2 Main menu Options System Ignition 7 54 7 6 1 1 3 3 Main menu Options System CSV export 7 54 7 6 1 1 3 4 Main menu Options System Signal hold on off 7 54 7 6 1 1 3 5 Main menu Options System Settings 7 55 7 6 1 1 3 6 Main menu Options System Settings Date and time 7 55 7 6 1 1 3 7 Main menu...

Page 67: ...eration combustion calorimeter chapter page 7 39 7 6 Main menu The main menu is the standard display in running operation From the main menu you can access the following sub menus Options Trend Event list Device info ...

Page 68: ...hange temperature too high I O Option to configure the following parameters Analogue and digital outputs Digital inputs mA display and display Calibration Option to configure the following parameters Calibration gas settings Calibration limits Calibration System Option to configure the following parameters General Update Hold signal Settings o Date language etc Database Service For service technic...

Page 69: ...CWD2005 DPC Operation combustion calorimeter chapter page 7 41 7 6 1 1 1 Main menu Options I O Option to configure the following parameters Analogue outputs Relay outputs Disp mA Digital input Display ...

Page 70: ...pter page 7 42 7 6 1 1 1 1Main menu Options I O Analogue outputs Signal list field Wobbe index density heating value Type list field 4 20 mA Unit list field kcal m relative MB from MB to value fields for numeric input ...

Page 71: ...e frequency converter is 48 Hz or air inlet temperature 41 C Filter change Filter change of air filter The frequency of the frequency con verter is 48 Hz Fault The air filter is heavily soiled The differential air pressure is thus 3 5 mbar Operation The flame is burning Operation delayed The flame is burning and the delay time has expired Over temperature The flame is too hot The Wobbe signal is l...

Page 72: ...1 1 3Main menu Options I O mA display In the menu item Disp mA you can display the mA values for all 7 outputs The display is located on the upper right below the date With the button Disp mA you can show all channels one after the other ...

Page 73: ...ected by the system Signals Zero position Contact CWD2005 Start calibration high open Calibration starts closed No calibration low open No calibration closed Calibration starts Start measurement high open Measurement starts closed Measurement stops low open Measurement stops closed Measurement starts Signals hold high open mA hold closed mA online low open mA online closed mA hold Calibration canc...

Page 74: ...display The numeric display in the display can be selected arbitrarily Any pre set value can be entered in the display on the upper left Size and unit are list fields they determine the numeric display on the device s screen The display can be selected arbitrarily ...

Page 75: ...nu Options Calibration Enter the calibration point numerically as Wobbe index and as relative density The density variation will be added as error into the measurement Relative density and heating value show the error the Wobbe index is measured physically and shown as exact value ...

Page 76: ...tion gas if the calibra tion gas producer only specified numbers of the gas components and not dv and heating value Take into account of the calorific value or the heating value is to be used for the calculation The literature values of the components refer to dry or humid gas The temperature reference point 0 C or 15 C also results in a difference in reference value The producer always bases the ...

Page 77: ...s criterion is reached after 6 to 10 min depending on the gas Afterwards the device automatically switches back to pro cess gas If the criterion is not reached the calibration is aborted after 10 min The abortion is documented in the events list Attention After a device restart or a change of calibration gas the calibration might need to be repeated 2 3 times Successful calibration is only possibl...

Page 78: ...The entered calibration time in the menu Automatic calibration is skipped but remains active for the next calibration 7 6 1 1 2 5Main menu Options Calibration Saving basic calibration The Basic calibration is done immediately after pressing the button It determines a calibration point which will serve as basis for further calibrations so that any de viation can be detected This deviation is entere...

Page 79: ...7 51 7 6 1 1 2 6Main menu Options Calibration Calibration limits In this screen you can specify the calibration limits If the value differs by a specific value or if the calibration thresholds are exceeded in either direction smaller higher an alarm is issued ...

Page 80: ...CWD2005 DPC chapter page 7 52 7 6 1 1 3 Main menu Options System In this menu item you specify the basis configuration of the device such as ignition time language and code key ...

Page 81: ...e The continuous transi tion is specified in seconds Purge time after cooling Specifies the time period after which the screen is switched off after no input has been given Screen switch off time Specifies the time period after which the screen is switched off after no input has been given Display speed Refers to a time constant in different burn ers This is pre set by the manufacturer and depends...

Page 82: ...mperature depends on the gas com position The settings are done accordingly The manufacturer pre sets the opti mum temperature for the ordered measuring range In this example it is 3 C differ ential temperature between cooling air and flue gas 7 6 1 1 3 3Main menu Options System CSV export Here you export the data as ASCII files The values are TAB separated In one go all possible 25 curves are wri...

Page 83: ...he basic settings which are used only rarely or once 7 6 1 1 3 6Main menu Options System Settings Date and time System time and date are set here With OK in the position button field you confirm the settings With Cancel you exit the screen mask without changes Counts up marked digits Counts down marked digits Next field to the left Next field to the right ...

Page 84: ... to a memory stick corrected and uploaded onto the hard drive of the combustion calorimeter again 7 6 1 1 3 8Main menu Options System Settings Password Input of the password numbers can be confirmed with OK or quit with Cancel Without entering the password digits nothing on the system can be changed After release the system locks again automatically after 30 seconds Then the system prompts for the...

Page 85: ...CWD2005 DPC Operation combustion calorimeter chapter page 7 57 7 6 1 1 3 9Main menu Options System Settings Change colour Here you can change the display colours ...

Page 86: ... and the time of connection is determined In case of changing the carrier gas the manufacturer can provide the new data They are entered in the screen mask shown below All values are tested according to customer s specifications before delivery The screen shows all possible configurations Range No indicates the number of installed measuring ranges A maximum of 3 measuring ranges are possible In th...

Page 87: ...ver point 1 and 2 Signal 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 manuall...

Page 88: ...t data switched off The last measurement data and the last three calibration data are also shown The menu items Options is divided into the following sub menus MV Thermal voltage of the thermal battery mV MV K Jump response of the thermal voltage MV KB Wobbe index calibration constant V DV Relative density V DVB Relative density calibration constant T0 Thermal battery outer temperature C TS Ambien...

Page 89: ... chapter page 7 61 7 6 1 1 4 Main menu Options Service Service menus are only accessible by technicians of the manufacturer and are required for adjusting the compensation data for different temperatures and the internal calibration of the system ...

Page 90: ...election you can select the parameters Time Value selections Signal selection Unit selection and Curve selection The parameters can be varied in 2 ways Buttons on the bottom of the screen with different symbols that change with the menu Arrow buttons and Return in the right hand side of the screen with identical and additional functions If you press the button Trend the following menus are availab...

Page 91: ...olu tion are already programmed The diagram shows a window over 5 seconds with a distance of 30 minutes from line to line In the centre of the X axis the distance line to line is always specified Every time the button is pressed it moves one step forward The symbols mean value linear right 25 X axis value linear left 25 X axis value compressed 25 X axis value stretched 25 X axis ...

Page 92: ...ear down 25 Y axis value compressed 25 Y axis value stretched 25 Y axis The calorific value is selected The three lines Dif y distance line to line 4 800 Off y position from offset 0 145 Value current value 10 988 are important for an unambiguous analysis of the graphical presentation of the cal orific value ...

Page 93: ...chapter page 7 65 7 6 2 1 3 Main menu Trend Signal selection This menu corresponds to the menus described above in terms of operation 7 6 2 1 4 Main menu Trend Unit selection This menu corresponds to the menus described above in terms of operation ...

Page 94: ...ect the physical value the arrow buttons and Return are also active Pressing any button causes a jump to the next unit The units are 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 on dT T amb T i T Res 3 p air p Wobbe p density p res 3 All three screens are prepared for all units and can be displayed arbitrarily ...

Page 95: ... 3 Main menu Event list NOTE The events list saves all events that are relevant for operation and service of the device 1000 events can be saved Show startup Selection of the different events Show calibration Selection of the different events Show all Cancel selection ...

Page 96: ...rors they can be saved on the memory stick and then sent to the manufacturer per e mail 1 Device data Type Gas type Carrier gas Device number 2 Measurement ranges Wobbe Density 3 Configuration Jet MB1 Jet MB2 Burner 4 Additional options Here any installed additional options are listed 5 Analogue outputs Wobbe i Density Heating value 1 2 3 4 5 ...

Page 97: ...housing 8 8 8 2 1 Preparations 8 9 8 2 2 Changing replacing fuses 8 9 8 2 3 Messages malfunctions 8 10 8 3 Troubleshooting Combustion Calorimeter 8 11 8 4 Preparations for troubleshooting 8 12 8 5 Changing replacing fuses 8 13 8 6 Instable measured value 8 13 8 6 1 Drift of the measured value 8 13 8 6 2 Faulty ignition 8 13 8 6 3 Fault status messages with description 8 14 8 7 Service 8 16 ...

Page 98: ... The feed lines to linked system components can be closed for servicing purposes Once operation has been resumed they need to be reopened DANGER Serious risk of injury from electricity The parts of the combustion calorimeter identified by the adjacent symbol may still be live even when the main switch has been turned off If necessary disconnect combustion calorimeter from the voltage mains Turn of...

Page 99: ...g and over pressure There is no protection against explosions Bridging only for service and maintenance work Bridging only by authorised trained staff Use suitable measures warnings to prevent permanent operation Fig 8 1 Top hat rail X9 Service bridge Item No Designation Function activity 1 Service bridge bridge pressure monitoring system combustion calorimeter can be used without protection syste...

Page 100: ...ponents Observe the cool down time of 15 min before servicing the burner system 8 1 2 Maintenance work Inspection NOTE The maintenance work must be carried out in accordance with the inspection and maintenance schedule The type and extent of the wear depends on the individual application and operating conditions Thus all maintenance intervals specified are guide values only Maintenance work at the...

Page 101: ...ential pressure air Frequency of fan control 2 Notify the control room 3 If no standard values are possible via PLC activate Signal hold at the com bustion calorimeter 4 Close the shut off valve at the combustion calorimeter after testing for tight ness The type and extent of the wear depends on the individual application and operat ing conditions Thus all maintenance intervals specified are guide...

Page 102: ...n Compressed air inlet free weekly or when required Pressure indicator at protective cabinet readable and plausible weekly or when required Flame arrester consistent and not soiled weekly or when required Exhaust system free weekly or when required weekly or when required Quarterly inspection Process gas analyser calibrated according to manufacturer s speci fications every 3 months lat est annuall...

Page 103: ...emove2 clean3 thermal battery and heat exchanger every 6 months Replace the seal at the heat exchanger every 6 months Check fan every 6 months Check inlet filter inlet ambient air filter mat ventilator every 6 months Clean4 gas and air nozzles If necessary replace O rings every 6 months Yearly inspection Replace air filter yearly Replace neoprene tubes in the combustion calorimeter yearly Clean th...

Page 104: ...ore After resetting replacing the thermal fuse in the process gas analyser check the device for proper function In case of housing damage protective housing terminal boxes check their protective functions and replace Replace the flame arresters After fire or explosion at the flame arrester Visible mechanical damage at housing lid or retaining ring of flame arrester Strong soiling or corrosion of t...

Page 105: ...ng EX area Before maintenance works shut down the combustion calorimeter and if nec essary any connected system components Turn off main switch disconnect from power supply if necessary and secure against connecting turning on again After turning off the main switch purge for at least 30 minutes with com pressed air Only a trained electrician may work on the electrical equipment of the process gas...

Page 106: ...ggers required overpressure not reached Check instrument air supply for free flow dirt Check inlet pressure of instrument air supply see technical data Check function of the pressure switch Check function of the faceplate in the exhaust air duct system Check free flow of instrument air in all concerned lines connections ...

Page 107: ...ategories Instable measured value Drift of the measured value Incorrect ignition behaviour The system keeps a results list Events are registered in the order of occurrence and saved with the respective date You can download the results list to a special data medium included in the scope of delivery and send it to UNION Instruments for fault analysis ...

Page 108: ...ened NOTE Events list The software keeps an event list with up to 1000 events in the order of occurrence tracked date The events list provides information about faults You can export the event data to a special data medium USB stick after consult ing Service Then you can send the exported data to the manufacturer for fault analysis Events are start stop ignition lack of cooling air and calibration...

Page 109: ...d value drifts up in one direction The calibration does not reach the required point anymore The frequency control ler has reached its maximum value Heavy filter soiling which cannot be compensated by controller anymore Replace the filter The measured value drifts down The heat exchanger is sooty in case of propane butane combustion with insuffi cient air Clean the heat exchanger warm water Then d...

Page 110: ... 4 Fault Filter change of air filter The frequency of the frequency converter is the set threshold Gas pressure to low Fault in thermal battery Defective PT 100 temperature sensor 8 6 3 1 5 Service Filter change of air filter Frequency threshold value Air inlet temperature 41 C 8 6 3 1 6 Operation Flame is burning analyser is running with process or calibration gas 8 6 3 1 7 Operation delay Flame ...

Page 111: ...aintenance and service chapter page 8 15 8 6 3 1 9 Calibration Flame is burning solenoid valve of calibration gas is open Calibration active no mA signals are issued these are on hold the last current value is held ...

Page 112: ...tions please have the customer number tele phone number for return calls the type and number of the process gas analyser see the type plate and the required spare parts and parts list numbers to hand UNION Instruments GmbH Service Maria Goeppert Straße 22 23562 Lübeck Germany 49 0 721 680381 30 support UNION instruments com http www UNION instruments com ...

Page 113: ...lorimeter WARNING Risk of injury from electricity and exiting gases in the combustion calorimeter if applicable If necessary purge the gases e g by running a calibration with ambient air Before disassembly separate combustion calorimeter from energy supplies NOTE Observe the national regulations on disposing machines and operating materials Sort the parts according to group and recycle properly ...

Page 114: ...CWD2005 DPC chapter page 9 2 ...

Page 115: ...ns replicas of used and wear parts can cause de fects and be hazardous This will render the warranty null and void The operator is liable for incurring damage When replacing standard components only use identical components by the orig inal manufacturer If components are discontinued or components by different manufacturers are used request the manufacturer approval by UNION Instru ments GmbH Spar...

Page 116: ...CWD2005 DPC chapter page 10 2 ...

Page 117: ...eter 8 11 Error elimination Ex 8 8 Ex characteristic 1 1 F Fuses 8 13 Changing 8 13 G Gas connection 5 13 I Inspection 8 4 Installing the system 5 7 Instrument air 3 8 connection 5 17 M Maintenance work 8 4 O Operating elements 6 30 Operation 6 31 7 33 P Personnel and qualifications 3 4 Process gas 3 7 5 12 Proper use 3 3 S Safety notes 3 5 Service 8 2 8 16 Service bridge 8 3 Setup site 5 8 Spare ...

Page 118: ...rminal block inlet process and calibration gas 5 13 Fig 5 5 Purge air supply and distribution 5 17 Fig 5 6 Electric connection system optional connections 5 19 Fig 5 7 Electric connection system power supply X16 5 20 Fig 5 8 Electric connection system signal lines X17 5 21 Fig 5 9 Electric connection X17 Relay K1 K3 analogue output 5 21 Fig 5 10 Electric connection X17 analogue and digital output ...

Page 119: ...CWD2005 DPC Annex chapter page 11 5 ...

Page 120: ...CWD2005 DPC Annex February 2015 V2 00 chapter page 11 6 ...

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