Union CWD2005 DPC Operating Instructions Manual
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Union CWD2005 DPC Operating Instructions Manual

Combustion calorimeter
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Operating instructions
Combustion calorimeter
CWD2005 DPC
Mai-2017 V2.01

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  • Page 1 Operating instructions Combustion calorimeter CWD2005 DPC Mai-2017 V2.01...
  • Page 2 CWD2005 DPC UNION Instruments GmbH Zeppelinstraße 42 76185 Karlsruhe Germany  +49 (0)721-680381-0  +49 (0)721-680381-33  support@union-instruments.com  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.

  • Page 3: Table Of Contents

    CWD2005 DPC Table of contents Technical Data CWD2005 DPC ................1—1 Technical Data Combustion calorimeter ............1—3 System limits and overview ................1—5 Dimensions ....................... 1—6 EC declaration of conformity ................. 2—1 Safety notes ......................3—1 Warnings and symbols ..................3—2 Fundamentals of proper use ................
  • Page 4 CWD2005 DPC Preparations for troubleshooting ..............8—12 Changing / replacing fuses ................8—13 Instable measured value .................. 8—13 Service ......................8—16 Disposal ........................9—1 Spare parts ......................10—1 Annex ........................11—3 Index ........................11—3 List of figures ........................11—4...

  • Page 5: Technical Data Cwd2005 Dpc

    CWD2005 DPC Technical Data CWD2005 DPC Technical Data CWD2005 DPC Technical Data Combustion calorimeter ............1—3 1.1.1 Specifications .................... 1—3 1.1.2 Display times of calorific value measurement ..........1—3 1.1.3 Calibration gas ................... 1—3 1.1.4 Linearity and measuring range ..............1—4 System limits and overview ................
  • Page 6 CWD2005 DPC Dimensions Height: 1798 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 ≤ T ≤...
  • Page 7 Calculated gas properties: Higher Wobbe-index, lower heating value (calorific value), higher heating value (higher calorific value) Calculated gas properties combustion air requirement index (CARI), combus- options: tion air requirement Gas type, inlet pressure, typical consumption CWD2005 DPC Range Range Pressure Accuracy [ ± %FS] Gas Flow Gas type [MJ / m³]...
  • Page 8 CWD2005 DPC 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). chapter — page: 1—4...

  • Page 9: System Limits And Overview

    CWD2005 DPC Technical Data CWD2005 DPC 1.2 System limits and overview The system comprises: • a protective enclosure purged with compressed air • two terminal boxes • a venting system of the protective housing • a pressure manometer and pressure switch inside the housing •...

  • Page 10: Dimensions

    CWD2005 DPC 1.3 Dimensions Fig. 1.2: Dimensions of system Additional 300 mm height for flame arrestor. chapter — page: 1—6...

  • Page 11: Ec Declaration Of Conformity

    CWD2005 DPC EC declaration of conformity 2 EC declaration of conformity Der Hersteller / The manufacturer UNION Instruments GmbH Zeppelinstraße 42 G-76185 Karlsruhe erklärt hiermit, dass folgend bezeichnete Produkte / hereby declares, that following named products: Produktbezeichnung: Verbrennungskalorimeter Gerätegruppe: CWD2005...
  • Page 12 CWD2005 DPC chapter — page: 2—2...

  • Page 13: Safety Notes

    CWD2005 DPC Safety notes 3 Safety notes Warnings and symbols ..................3—2 Fundamentals of proper use ................3—3 Personnel and qualifications ................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...

  • Page 14: Warnings And Symbols

    CWD2005 DPC 3.1 Warnings and symbols In the operating instructions, the following names and symbols are used to denote particularly important information: DANGER Immediate danger that can lead to serious physical injury or death. WARNING Potentially hazardous situations that can lead to serious injury or death.

  • Page 15: Fundamentals Of Proper Use

    – calorimeter and protective housing, 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.

  • Page 16: Personnel And Qualifications

    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 approval.

  • Page 17: Safety Notes

    CWD2005 DPC Safety notes 3.4 Safety notes 3.4.1 General safety notes WARNING The system may only be operated when all of the protective equipment is availa- ble and operable. Additional safety notes:  Before the corresponding chapters! 3.4.2 Notes on specific hazards DANGER •...

  • Page 18: Electrical Connection

    CWD2005 DPC 3.4.3 Electrical connection DANGER Danger from electrical shock! Only a trained electrician may modify the electrical equipment of the system in ac- cordance with the relevant guidelines! When 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.

  • Page 19: Process Gas

    CWD2005 DPC Safety notes 3.4.4 Process gas WARNING Establishing gas connections and working on the gas-bearing equipment of the system may only be carried out by specialists adhering to the safety regulations, especially those regarding explosive areas. No gas warning system is installed in the system! NOTE •...

  • Page 20: Instrument Air Supply

    CWD2005 DPC 3.4.5 Instrument air supply WARNING Protective gas - instrument air generates 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: Operator Safety Precautions

    CWD2005 DPC Safety notes 3.4.6 Flue gas WARNING Serious risk of injury from escaping flue gas. • Flue gas must be emitted to the open air! • For flue gases with the components CO, H and H S ensure sufficient room ventilation.

  • Page 22: Regular Operator Training

    CWD2005 DPC 3.6 Regular operator training NOTE Country-specific or company-internal regulations about regular user training by the operator must be observed, in particular training on handling explosive areas, gases, and electrical equipment! 3.7 Workplace hazard analysis NOTE Depending on the national regulations, the operator must perform a workplace risk analysis, if applicable, independent of the CE marking / approval of this com- bustion calorimeter.

  • Page 23: Safety Device System

    CWD2005 DPC Safety device system 4 Safety device system Main switch ....................... 4—2 Instrument air purged and pressurised housing ..........4—2 Locks and doors of the housing ................. 4—2 Flame arresters ....................4—2 Cable / line glands ..................... 4—2 Pressure switch, pressure too low ..............4—2 Safety switch .....................

  • Page 24: Main Switch

    CWD2005 DPC 4.1 Main switch Switches the power supply for the device, refer to terminal box on bottom. Fig. 4.1: Main switch (example) 4.2 Instrument air purged and pressurised housing Components that can cause ignition are installed in a housing that is purged with instrument air.

  • Page 25: Safety Switch

    CWD2005 DPC Safety device system 4.7 Safety switch The safety switch switches the ignition transformer voltage-free upon opening the top door. Fig. 4.2: Figure of safety switch (example) 4.8 Thermal fuse NOTE The initiation temperature of the thermal fuse is 72°C.

  • Page 26: Markings And Warning System

    CWD2005 DPC 4.11 Markings and warning system Fig. 4.3: Markings and warnings Warnings, purge duration, switching on/off Type plate Warning note disabling protective gas (instrument air) and connection / supply Warning note electricity chapter — page: 4—4...

  • Page 27: Fig. 4.4: Markings And Warnings, Inside The Housing, Top Compartment

    CWD2005 DPC Safety device system Fig. 4.4: Markings and warnings, inside the housing, top compartment Warning note hot surface Fig. 4.5: Warning notes on the electric connection board (example, inside hous- ing, right bottom compartment) chapter — page: 4—5...
  • Page 28 CWD2005 DPC chapter — page: 4—6...

  • Page 29: Connections, Transport, Setting Up

    Generally, the system is started up by UNION Instruments GmbH or service tech- nicians. If it is not transported, set up and started up by UNION Instruments GmbH (for ex- ample in-house transportation and resale), coordinate the appropriate procedure with UNION Instruments GmbH ( Chapter 12 Service).

  • Page 30: Description And Connections

    CWD2005 DPC 5.1 Description and connections Fig. 5.1: Connections Output flue gas and protective gas (instrument air) Connection of power supply Input compressed air Connection of signal lines Input process gas Input calibration gas chapter — page: 5—2...

  • Page 31: Fig. 5.2: Description

    CWD2005 DPC Connections, transport, setting up Fig. 5.2: Description Output flue gas and compressed air Display Door lock, 2 for each door Pressure indicator Input protective gas (instrument air Mounting rack with fixation points (6) USB connection for service Input process and calibration gas Compartment combustion calorimeter 10.

  • Page 32: Fig. 5.3: Combustion Calorimeter, Housing Without Doors

    CWD2005 DPC Fig. 5.3: Combustion calorimeter, Housing without doors Thermal fuse (behind the exhaust pipe, at the rear wall) Thermal body Density measuring cell Precision pressure controller Electronics - input and output signals, internal Safety switch ignition transformer Bus bar for power supply, example chapter —...

  • Page 33: Accessories

    CWD2005 DPC Connections, transport, setting up 5.1.1 Accessories WARNING Risk 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-...

  • Page 34: Transport

    CWD2005 DPC 5.2 Transport WARNING Risk of injury / defective! Transport damage can impede the protective function of the protective housing. In case of damage to the transport packaging or indications for improper transport, check the housing thoroughly! WARNING Possible injury from the system tipping over or falling from pallets and load carry- ing equipment.

  • Page 35: Ambient Conditions

    ATTENTION Ambient conditions during storage and set up. Observe the ambient conditions! Contact UNION Instruments GmbH if the system has been stored for more than three months or needs to be operated or stored un- der ambient conditions other than those specified! 5.3.1 Storage conditions...

  • Page 36: Setup Site

    CWD2005 DPC 5.4.1 Setup site The installation location of the system must meet the following requirements: • Observe the requirements acc. to the technical data, especially the ambient conditions and the IP protection type. • Clean, closed room • Protected from direct sunlight •...

  • Page 37: Room Ventilation

    CWD2005 DPC Connections, transport, setting up 5.4.2 Room ventilation WARNING Risk of injury due to the temperature of exhausts / housing! The exhaust gas temperature is between 8 - 20°C 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.

  • Page 38: Wall / Ground Attachment

    CWD2005 DPC 5.4.3 Wall / Ground Attachment The CWD2005 DPC is designed for fixed installation 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!

  • Page 39: Opening And Closing The Housing Lids/Doors

    CWD2005 DPC Connections, transport, setting up 5.4.4 Opening and closing the housing lids/doors DANGER Risk of explosion! Terminal boxes See operating instructions of the terminal boxes • Danger due to damaged seals and sealing surfaces, danger due to improper screw connections!

  • Page 40: Process Gas

    CWD2005 DPC 5.4.5 Process gas DANGER Risk of explosion! Danger due to invalid line glands! If improper line glands are used, the explosion protection cannot be ensured any- more! • Only use line glands approved for the required ignition protection type! •...

  • Page 41: Connection Of Process And Calibration Gas

    CWD2005 DPC Connections, transport, setting up 5.4.6 Connection of process and calibration gas Maximum gas input pressure see technical data. The input for process and calibration gas to the protective housing and combustion calorimeter is suited on the left side.

  • Page 42: Carrier Gas Supply

    CWD2005 DPC 5.4.7 Carrier gas supply NOTE • Combustion calorimeters can later be refit to carrier gas supply. Contact the manufacturer. • Process gases without stable combustion properties can be mixed with a car- rier gas. • Non-flammable gases are automatically mixed with flammable or not flamma- ble carrier gases by the combustion calorimeter.

  • Page 43: Calibration Gas

    CWD2005 DPC Connections, transport, setting up 5.4.8 Calibration gas WARNING Only qualified trained staff must install the gas connections! If no pressure reducers are installed, the operator must make sure that escaping calibration gas is emitted to a safe environment! NOTE •...

  • Page 44: Flue Gas

    CWD2005 DPC 5.4.9 Flue gas WARNING Serious risk of injury from escaping flue gas. • Flue gas must be emitted to the open air! • For flue gases with the components CO, H and H S ensure sufficient room ventilation.

  • Page 45: Instrument Air Connection

    CWD2005 DPC Connections, transport, setting up 5.4.10 Instrument air connection Maximum input pressure of instrument air, see technical data and plate at pressure controller. Fig. 5.5: Purge air, supply and distribution Pressure controller, overpressure in protective housing Shut-off valve for instrument air Instrument air inlet chapter —...

  • Page 46: Electrical Connection

    CWD2005 DPC 5.4.11 Electrical connection DANGER Danger from electrical shock! Only a trained electrician shall connect the power supply and electrical signal wires! Only a trained electrician may modify the electrical equipment of the system in accordance with the relevant guidelines! When 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.

  • Page 47: Fig. 5.6: Electric Connection System - Optional Connections

    CWD2005 DPC Connections, transport, setting up WARNING Standard safety requirement An external circuit breaker is required in accordance to national requirements and IEC 60947-1. Install the circuit breaker in close proximity to the unit. An assignment to the unit must be ensured.
  • Page 48 CWD2005 DPC Terminal box for power supply 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...

  • Page 49: Fig. 5.9: Electric Connection X17 - Relay K1 - K3, Analogue Output

    CWD2005 DPC Connections, transport, setting up Fig. 5.8: Electric connection system – signal lines X17 Terminal box for signals Assignment see provided wiring diagram. Customer Union Instr. Cable Union Instr. Relay X17.2 Relay K1 X17.1 25G1.1 X14.1 lower row Process X17.4...

  • Page 50: Fig. 5.10: Electric Connection X17 - Analogue And Digital Output, Digital Input

    CWD2005 DPC 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 IOut6 not installed X17.70 X17.69 25G1,5.20 X5.11 X17.72 X17.71 25G1,5.21 X5.12 [...] [...] [...] Dig.In 1 DGNDE lower row customer specific use Digital X17.78...

  • Page 51: Startup After Setup

    CWD2005 DPC Connections, transport, setting up 5.4.13 Operator safety precautions WARNING • Operate the system according to the requirements for potentially explosive atmospheres. • The operator needs to provide suitable safety equipment for the system to re- liably prevent individuals from being injured from gas leaks.

  • Page 52: Removing / Attaching The Transport Safeguard

    CWD2005 DPC 5.5.1 Removing / attaching the transport safeguard NOTE Before commissioning / transport of the combustion calorimeter, make sure that all transport safeguards are removed / attached. The following transport safeguards must be removed / attached in the combustion calorimeter: Fig.

  • Page 53: Fig. 5.13: Transport Safeguards In The Pressure Controller

    CWD2005 DPC Connections, transport, setting up 5.5.1.1.1 Transport safeguard in the pressure controller Fig. 5.13: Transport safeguards in the pressure controller Order of removing/attaching the Transport safeguard transport safeguard • Remove the rubber. • Open the protective flap (screw connection).

  • Page 54: Documentation

    CWD2005 DPC 5.6 Documentation NOTE UNION Instruments GmbH recommends keeping maintenance manual and documenting all jobs and tests. chapter — page: 5—26...

  • Page 55: Commissioning, Operation, Removing From Service

    CWD2005 DPC Commissioning, operation, removing from service 6 Commissioning, operation, removing from service Commissioning / start-up ................. 6—28 Description of the workplaces / operating elements ......... 6—30 6.2.1 Workplaces ....................6—30 Operation ......................6—31 Decommissioning / switching off ..............6—32 chapter —...

  • Page 56: Commissioning / Start-Up

    CWD2005 DPC 6.1 Commissioning / start-up ATTENTION To establish operational readiness, including of the linked system components, according to the corresponding operating instructions. NOTE The following table includes abridged instructions for commissioning the system after a longer standstill. To turn on the system after a short downtime, a few steps can be omitted: ...
  • Page 57 CWD2005 DPC Commissioning, operation, removing from service Open calibration 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: Description Of The Workplaces / Operating Elements

    CWD2005 DPC 6.2 Description of the workplaces / operating elements NOTE This chapter only discusses the elements normal operators use to operate the system to establish the protective function by purging and overpressure. 6.2.1 Workplaces Fig. 6.1: Workplaces Item Designation...

  • Page 59: Operation

    CWD2005 DPC Commissioning, operation, removing from service 6.3 Operation WARNING Danger of injury! Only operate combustion calorimeter • if all lines have been installed and checked 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, •...

  • Page 60: Decommissioning / Switching Off

    CWD2005 DPC 6.4 Decommissioning / switching off ATTENTION To remove the system from service, the linked system components must also be removed from service according to their operating instructions. NOTE The following table contains the steps for decommissioning the analyser for a long period.

  • Page 61: Operation Combustion Calorimeter

    CWD2005 DPC Operation combustion calorimeter 7 Operation combustion calorimeter Operation of film keyboard / description of display ........... 7—34 Basics on operation ..................7—36 Available displays .................... 7—36 General information on the start screen ............7—37 Menu structure ....................7—38 Main menu ......................

  • Page 62: Operation Of Film Keyboard / Description Of Display

    CWD2005 DPC 7.1 Operation of film keyboard / description of display The 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.
  • Page 63 CWD2005 DPC Operation combustion calorimeter Item Designation Function Numeric display Output of current measurement values after reaching the op- erating mode. Display field Information field, start screen. Position buttons Position buttons move the cursor in a current input field to the input position.

  • Page 64: Basics On Operation

    CWD2005 DPC 7.2 Basics on operation The buttons described in the following serve for operation via the software of the combustion calorimeter. Symbol Function Symbol "Back" in the menu buttons: • Cause a jump to one menu level up at a time until the main menu is reached.

  • Page 65: General Information On The Start Screen

    CWD2005 DPC Operation combustion calorimeter 7.4 General information on the start screen Fig. 7.2: Information field, start screen Indication (screen) Information V 4.39R09 Version number of the software 04.02.2015 10:05:09 Current date / time Methane: 95.01 Vol% Volume share of methane mV=24.56...

  • Page 66: Menu Structure

    CWD2005 DPC 7.5 Menu structure Main menu ...................... 7—39 7.6.1 Main menu - Options ................7—40 7.6.1.1.1 Main menu - Options - I/O ............. 7—41 7.6.1.1.1.1 Main menu - Options - I/O - Analogue outputs ......7—42 7.6.1.1.1.2 Main menu - Options - I/O - Relay output ........ 7—43 7.6.1.1.1.3 Main menu - Options - I/O - mA display ........

  • Page 67: Main Menu

    CWD2005 DPC Operation combustion calorimeter 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 chapter — page:...

  • Page 68: Main Menu - Options

    CWD2005 DPC 7.6.1 Main menu - Options NOTE The free part of the info field is filled with important information, depending on the menu selection, which refers to current activities, e.g. filter change, temperature too high. Option to configure the following parameters: •...

  • Page 69: Main Menu - Options - I/O

    CWD2005 DPC Operation combustion calorimeter 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 chapter — page: 7—41...

  • Page 70: Main Menu - Options - I/O - Analogue Outputs

    CWD2005 DPC 7.6.1.1.1.1 Main menu - Options - I/O - Analogue outputs Signal (list field) Wobbe-index, density, heating value, Type (list field) 4 – 20 mA Unit (list field) kcal/m³, relative MB from MB to value fields for numeric input chapter —...

  • Page 71: Main Menu - Options - I/O - Relay Output

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.1.2 Main menu - Options - I/O - Relay output The digital output can e.g. comprise signals in combination with limit values or op- eration messages. Example: The Wobbe signal in MJ/m³ has an alarm value at 47,000 and 50,000 MJ. The zero position is high.

  • Page 72: Main Menu - Options - I/O - Ma Display

    CWD2005 DPC 7.6.1.1.1.3 Main 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: Main Menu - Options - I/O - Digital Inputs

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.1.4 Main menu - Options - I/O - Digital inputs Signal and zero position are list fields. These inputs can start a calibration or switch a holding amplifier on or off. The inputs are queried once per second; i. e. a change must be pending for at least one second in order to be detected by the system.

  • Page 74: Main Menu - Options - I/O - Display

    CWD2005 DPC 7.6.1.1.1.5 Main menu - Options - I/O - 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.

  • Page 75: Main Menu - Options - Calibration

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.2 Main menu - 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: Main Menu - Options - Calibration - Configuration Of Calibration Gas

    CWD2005 DPC 7.6.1.1.2.1 Main menu - Options - Calibration - Configuration of calibration gas The calibration gas values are entered as Wobbe-index and relative density. These values are calculated from the gas components of the calibration gas if the calibra- tion gas producer only specified %-numbers of the gas components and not dv and heating value.

  • Page 77: Main Menu - Options - Calibration - Automatic Calibration

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.2.2 Main menu - Options - Calibration - Automatic calibration Day is a list field (Son, Mon, Tue …) while time and cycle are value fields. The device itself determines the duration of purge time for the calibration gas. For this purpose it uses a stability criterion.

  • Page 78: Main Menu - Options - Calibration - Automatic Calibration 2

    CWD2005 DPC 7.6.1.1.2.3 Main menu - Options - Calibration - Automatic calibration 2 There are 2 situations in which a calibration is done automatically: • absolute deviation of the current outside temperature and the temperature during the previous calibration (unit °C) and •...

  • Page 79: Main Menu - Options - Calibration - Calibration Limits

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.2.6 Main 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: Main Menu - Options - System

    CWD2005 DPC 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. chapter — page: 7—52...

  • Page 81: Main Menu - Options - System - General

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.3.1 Main menu - Options - System - General The command "Change signals after hold" causes a smooth transition after a cali- bration or after switching off the signal stop condition. This avoids a sudden rise or drop of the measurement value in the measurement curve.

  • Page 82: Main Menu - Options - System - Ignition

    CWD2005 DPC 7.6.1.1.3.2 Main menu - Options - System - Ignition The ignition type can be individual ignition or interval ignition. The ignition break always equals the ignition duration. The longest possible ignition duration is 100 sec. Normally it should be between 15 and 20 sec. Upon reaching the ignition threshold the ignition stops.

  • Page 83: Main Menu - Options - System - Settings

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.3.5 Main menu - Options - System - Settings Settings includes all menu items referring to the basic settings which are used only rarely or once. 7.6.1.1.3.6 Main menu - Options - System - Settings - Date and time System time and date are set here.

  • Page 84: Main Menu - Options - System - Settings - Language

    CWD2005 DPC 7.6.1.1.3.7 Main menu - Options - System - Settings - Language The menu item Language contains 10 sub-menus to introduce or to correct differ- ent language, including those displays as bitmaps (e.g. Chinese). Languages can be downloaded to a memory stick, corrected and uploaded onto the hard drive of the combustion calorimeter again.

  • Page 85: Main Menu - Options - System - Settings - Change Colour

    CWD2005 DPC Operation combustion calorimeter 7.6.1.1.3.9 Main menu - Options - System - Settings - Change colour Here you can change the display colours. chapter — page: 7—57...

  • Page 86: Main Menu - Options - System - Settings - Hardware 1

    CWD2005 DPC 7.6.1.1.3.10 Main menu - Options - System - Settings - Hardware 1 This menu should only be modified after consulting the manufacturer. It controls the limits of measuring devices over two or three ranges. The overlap is optimised. For this purpose you need to specify functional parameters. The time constants of the burners are specified.
  • Page 87 CWD2005 DPC Operation combustion calorimeter Range cfg. is a binary coding for the measurement conditions while a measuring range switchover is in process. measuring range not loaded nozzle set 2 or nozzle set 1 air nozzle on or off flammable carrier gas on or off...

  • Page 88: Main Menu - Options - System - Database

    CWD2005 DPC 7.6.1.1.3.11 Main menu - Options - System - Database The menu Database shows the configuration of the database. The time interval is in minutes. The Database menu displays date and time of saving the database as well as date and time of database export.

  • Page 89: Main Menu - Options - Service

    CWD2005 DPC Operation combustion calorimeter 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: Main Menu - Trend

    CWD2005 DPC 7.6.2 Main menu - Trend The combustion calorimeter has a very comfortable graphics display that enables the presentation of measurement values in wide ranges of time. Up to three differ- ent curves can be displayed in different colours.

  • Page 91: Main Menu - Trend - Time Selection

    CWD2005 DPC Operation combustion calorimeter 7.6.2.1.1 Main menu - Trend - Time selection The diagram can be started optimally. The steps to increase or reduce the resolu- tion are already programmed. The diagram shows a window over 5 seconds with a distance of 30 minutes from line to line.

  • Page 92: Main Menu - Trend - Value Selection

    CWD2005 DPC 7.6.2.1.2 Main menu - Trend - Value selection value linear up Y-axis value linear 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...

  • Page 93: Main Menu - Trend - Signal Selection

    CWD2005 DPC Operation combustion calorimeter 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: Main Menu - Graphics - Curve Selection

    CWD2005 DPC 7.6.2.1.5 Main menu - Graphics - Curve selection With buttons you select the 3 Info screens. To confirm the selection and to select the physical value, the arrow buttons and "Return" are also active. Pressing any button causes a jump to the next unit. The units are:...

  • Page 95: Main Menu - Event List

    CWD2005 DPC Operation combustion calorimeter 7.6.3 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...
  • Page 96 CWD2005 DPC 7.6.4 Main menu - Device info NOTE The shown values are very important for remote diagnostics of any occurring er- rors; they can be saved on the memory stick and then sent to the manufacturer per e-mail. Device data: •...

  • Page 97: Maintenance And Service

    CWD2005 DPC Maintenance and service 8 Maintenance and service Service ......................8—2 8.1.1 Preparations ....................8—2 8.1.2 Maintenance work/Inspection ..............8—4 Troubleshooting Ex protective housing .............. 8—8 8.2.1 Preparations ....................8—9 8.2.2 Changing / replacing fuses ................ 8—9 8.2.3 Messages / malfunctions ................. 8—10 Troubleshooting Combustion Calorimeter ............

  • Page 98: Service

    CWD2005 DPC 8.1 Service When working in the potentially explosive areas, observe the pertinent safety pre- cautions. The measuring quality of the gas analyser can only be ensured if the service inter- vals are maintained. The explosion protection function of the protective housing and the flame arresters can only be ensured if the service intervals are maintained.

  • Page 99: Service

    CWD2005 DPC Maintenance and service DANGER Risk of explosion! If the pressure monitoring system is bridged for maintenance / service work, the device can be operated permanently without compressed air purging and over- pressure. There is no protection against explosions! •...

  • Page 100: Maintenance Work/Inspection

    CWD2005 DPC WARNING Serious risk of injury from exiting gas. • Before maintenance works, shut down the combustion calorimeter and, if necessary, any connected system components! • The gas connections may only be established by trained personnel. Follow the applicable guidelines at the installation site.
  • Page 101 CWD2005 DPC Maintenance and service Ensure the following issues before starting maintenance work: 1. Write down the following values of the combustion calorimeter: • Wobbe i/s • Heating value / calorific value • Density • mV signals • mA signals •...
  • Page 102 CWD2005 DPC NOTE The following overview only describes the checks / work in regard to the protec- tive housing and the functions for explosion protection! Interval Inspection (recommended) Weekly inspection weekly, or when Compressed air inlet free required weekly, or when...
  • Page 103 CWD2005 DPC Maintenance and service NOTE The following overview only describes the checks/work in regard to the combus- tion calorimeter! Interval Inspection (recommended) Weekly inspection Check air filter for dirt / clogging. weekly Calibrate (depending on the requirements for precision, shorten the weekly intervals).

  • Page 104: Troubleshooting Ex Protective Housing

    CWD2005 DPC 8.2 Troubleshooting Ex protective housing DANGER Loss of protective function! • After several short-circuits / ignitions in the protective cabinet, the protective function cannot be ensured anymore! • After resetting/replacing the thermal fuse in the process gas analyser, check the device for proper function! •...

  • Page 105: Preparations

    If necessary, disconnect combustion calorimeter from the voltage mains! 8.2.2 Changing / replacing fuses Fuses may only be exchanged by an electrician or service professional. Choose the type approved by UNION Instruments GmbH. Specification of the fuses, refer to UNION. chapter — page:...

  • Page 106: Messages / Malfunctions

    CWD2005 DPC 8.2.3 Messages / malfunctions 8.2.3.1.1 Display of messages / malfunctions Pressure switch triggers, required overpressure not reached • Check instrument air supply for free flow / dirt • Check inlet pressure of instrument air supply, see technical data •...

  • Page 107: Troubleshooting Combustion Calorimeter

    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. chapter — page: 8—11...

  • Page 108: Preparations For Troubleshooting

    CWD2005 DPC 8.4 Preparations for troubleshooting The feed lines to linked system components can be closed for servicing purposes. Once operation has been resumed, they need to be reopened. NOTE Events list: The software keeps an event list with up to 1000 events in the order of occurrence (tracked date).

  • Page 109: Changing / Replacing Fuses

    Maintenance and service 8.5 Changing / replacing fuses Fuses may only be exchanged by an electrician or service professional. Choose the type approved by UNION Instruments. 8.6 Instable measured value • The pressure regulator cannot hold constant pressure. The process pressure (blast furnace gas) is too low.

  • Page 110: Service

    CWD2005 DPC 8.6.3 Fault / status messages with description 8.6.3.1.1 Filter change • Filter change of air filter • The frequency of the frequency converter is > the set threshold 8.6.3.1.2 Int. pressure • Alarm in case of lack of process gas or calibration gas •...
  • Page 111 CWD2005 DPC Maintenance and service 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). chapter — page: 8—15...
  • Page 112 8.7 Service NOTE If you have any questions UNION Instruments GmbH will be happy to assist. In case of orders or technical questions, 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.

  • Page 113: Disposal

    CWD2005 DPC Disposal 9 Disposal Following decommissioning, the analyser can be returned to UNION Instruments GmbH. Suggestion: Let UNION Instruments GmbH dispose of the combustion calorimeter. WARNING Risk of injury from electricity and exiting gases in the combustion calorimeter, if applicable.
  • Page 114 CWD2005 DPC chapter — page: 9—2...

  • Page 115: Spare Parts

    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. Spare parts can be ordered from UNION Instruments GmbH: Identify and write down type, number and designation of the part, order part.
  • Page 116 CWD2005 DPC chapter — page: 10—2...

  • Page 117: Index

    Connections ........5—2 Operation ......6—31, 7—33 Contact Service ......... 8—16 Personnel and qualifications ....3—4 Union Instruments GmbH ..... 3—10 Process gas ......3—7, 5—12 Proper use ......... 3—3 Decommissioning ....6—32, 9—1 Displays ........... 7—36 Safety notes ........3—5 Service ........
  • Page 118 CWD2005 DPC Annex List of figures Fig. 1.1: System overview ..................1—5 Fig. 1.2: Dimensions of system ................1—6 Fig. 4.1: Main switch (example) ................4—2 Fig. 4.2: Figure of safety switch (example) ............... 4—3 Fig. 4.3: Markings and warnings ................4—4 Fig.
  • 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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