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Union Instruments CWD2005 SPC Operating Instructions And Safety Notes

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OPERATING INSTRUCTIONS
AND
SAFETY NOTES
CWD2005 SPC
Feb -2017 V1.02

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  • Page 1 OPERATING INSTRUCTIONS SAFETY NOTES CWD2005 SPC Feb -2017 V1.02...
  • Page 2 OPERATING INSTRUCTIONS CWD2005 SPC 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

    OPERATING INSTRUCTIONS CWD2005 SPC Table of contents Technical data ......................1—1 EC declaration of conformity ................. 2—1 Safety notes ......................3—1 Safety device system ....................4—1 Connections, transport, setting up ................ 5—1 Commissioning, operation, removing from service ..........6—1 Maintenance and service ..................7—1 Disposal ........................
  • Page 4 OPERATING INSTRUCTIONS CWD2005 SPC...

  • Page 5: Technical Data

    OPERATING INSTRUCTIONS CWD2005 SPC Technical data Ex-characteristic acc. to approval Ex characteristic Class 1, Division 2, Group D (NEC500) 5°C ≤ T ≤ 40°C Ambient temperature: Gas inlets Number of measuring points: Calibration inlets: 1, internal through gas bottle Gas connections: Clamp ring connection 6 mm ≤...
  • Page 6 OPERATING INSTRUCTIONS CWD2005 SPC DANGER The system must not be operated outside of the specified ambient temperature, 5°C ≤ T ≤ 40°C. Outside of this temperature range, the approval becomes void. chapter — page: 1—2...

  • Page 7: Fig. 1.1: System Overview

    OPERATING INSTRUCTIONS CWD2005 SPC 1.1 System limits and overview The system comprises: • a protective housing o purged with compressed air o stainless steel as weather protection • two terminal boxes • a venting system of the protective housing •...

  • Page 8: Fig. 1.2: System Overview, Protective Housing With Combustion Calorimeter

    OPERATING INSTRUCTIONS CWD2005 SPC Fig. 1.2: System overview, protective housing with combustion calorimeter chapter — page: 1—4...

  • Page 9: Ec Declaration Of Conformity

    OPERATING INSTRUCTIONS CWD2005 SPC 2 EC declaration of conformity EC Declaration of Conformity for the combustion calorimeter UNION CWD2005 plus see operating instructions combustion calorimeter CWD2005 Plus. chapter — page: 2—1...
  • Page 10 OPERATING INSTRUCTIONS CWD2005 SPC chapter — page: 2—2...

  • Page 11: Safety Notes

    OPERATING INSTRUCTIONS CWD2005 SPC 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 12: Warnings And Symbols

    OPERATING INSTRUCTIONS CWD2005 SPC 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 13: Fundamentals Of Proper Use

    UNION Instruments GmbH require the approval of UNION Instruments GmbH as the manufacturer! Otherwise the guarantee expires. The system CWD2005 SPC - protective housing and combustion calorimeter CWD2005 Plus - is a sensor system to determine the calorific value of flammable process gases.

  • Page 14: Personnel And Qualifications

    NOTE Changes to the electric installation, equipment or gas-bearing modules by persons 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 authorisation/qualification cause loss of type test approval.

  • Page 15: Safety Notes

    OPERATING INSTRUCTIONS CWD2005 SPC 3.4 Safety notes 3.4.1 General safety notes WARNING The system may only be operated when all of the protective equipment is available and operable. Additional safety notes:  before the corresponding chapters! 3.4.2 Notes on specific hazards DANGER •...

  • Page 16: Electrical Connection

    OPERATING INSTRUCTIONS CWD2005 SPC 3.4.3 Electrical connection DANGER Danger from electrical shock! 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 17: Process Gas

    OPERATING INSTRUCTIONS CWD2005 SPC 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 18: Compressed Air Supply

    OPERATING INSTRUCTIONS CWD2005 SPC 3.4.5 Compressed air supply WARNING Compressed air generates the protective functions against explosions by purging and creating an overpressure! Establishing compressed air connections and working on the compressed air equipment of the system may only be carried out by specialists adhering to the safety regulations, especially those regarding explosive areas.

  • Page 19: Flue Gas

    OPERATING INSTRUCTIONS CWD2005 SPC 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 20: Workplace Hazard Analysis

    OPERATING INSTRUCTIONS CWD2005 SPC 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 combustion calorimeter.

  • Page 21: Safety Device System

    OPERATING INSTRUCTIONS CWD2005 SPC 4 Safety device system Main switch ....................... 4—2 Compressed air purged and pressurised encapsulated housing GFK ....4—2 Locks and door of the protective cabinet ............4—2 Flame arresters ....................4—2 Cable / line glands ..................... 4—2 Pressure switch, pressure too low ..............
  • Page 22 OPERATING INSTRUCTIONS CWD2005 SPC 4.1 Main switch Switches the power supply for the protective cabinets and the process gas analyser in the protective cabinet. Fig. 4.1: Main switch (example) 4.2 Compressed air purged and pressurised encapsulated housing GFK Components that can cause ignition are installed in a housing that is purged with compressed air.

  • Page 23: Fig. 4.2: Markings And Warnings

    OPERATING INSTRUCTIONS CWD2005 SPC 4.7 Markings and warning system Fig. 4.2: Markings and warnings Type plate Warnings, purge duration, switching on chapter — page: 4—3...

  • Page 24: Fig. 4.3: Markings And Warnings, Terminal Boxes

    OPERATING INSTRUCTIONS CWD2005 SPC Fig. 4.3: Markings and warnings, terminal boxes Warning note electricity Warning note hot surface chapter — page: 4—4...

  • Page 25: Connections, Transport, Setting Up

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

  • Page 26: Connections Of The System

    OPERATING INSTRUCTIONS CWD2005 SPC Connections of the system Fig. 5.1: Connections of the system Outlet flue gas, compressed air Connection of signal lines Connection of power supply Protective ground connection, multiple points Compressed Air Inlet Gas inlet, process, calibration, test gas chapter —...

  • Page 27: Accessories

    OPERATING INSTRUCTIONS CWD2005 SPC 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! Observe the Ex approval! Only use original accessories or accessories that have been approved by Union Instruments GmbH.
  • Page 28 OPERATING INSTRUCTIONS CWD2005 SPC NOTE Shocks during transport can impair the protective housing. Therefore, check system/protective housing after transport for damage! In case of damage during transport from improper handling, the carrier should perform a damage report within seven days (railway, post office, freight forwarder).

  • Page 29: 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 under ambient conditions other than those specified! 5.3.1 Storage conditions of the system...

  • Page 30: Setup Site

    OPERATING INSTRUCTIONS CWD2005 SPC 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 room •...

  • Page 31: Attachment

    OPERATING INSTRUCTIONS CWD2005 SPC 5.4.2 Attachment The system is designed for fixed installation on the ground. Provide suitable means of attachment. Ensure sufficient space for operating, maintenance the system. Ensure sufficient load-bearing capacity of the environment and the means of attachment.

  • Page 32: Opening And Closing The Housing Lids/Doors

    OPERATING INSTRUCTIONS CWD2005 SPC 5.4.3 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! Protective housing of combustion calorimeter See operating instructions protective housing •...

  • Page 33: Process Gas

    OPERATING INSTRUCTIONS CWD2005 SPC 5.4.4 Process gas DANGER Risk of explosion! Danger due to invalid line glands! If improper line glands are used, the explosion protection cannot be ensured anymore! • Only use line glands approved for the required ignition protection type! •...

  • Page 34: Connection Of Process And Calibration Gas

    OPERATING INSTRUCTIONS CWD2005 SPC 5.4.5 Connection of process and calibration gas Maximum gas inlet pressure see technical data. Then connect the process gas inlet with the screw connection and to the housing of the system, see Fig. 5.1. Screw connections see provided operating instructions.

  • Page 35: Compressed Air Connection

    OPERATING INSTRUCTIONS CWD2005 SPC 5.4.6 Compressed air connection Maximum inlet pressure of compressed air see technical data. Then connect the process gas inlet with the screw connection and to the housing of the system, see Fig. 5.1. The inlet for compressed air to the protective housing and combustion calorimeter is already connected.

  • Page 36: Electrical Connection

    OPERATING INSTRUCTIONS CWD2005 SPC 5.4.7 Electrical connection DANGER Danger from electrical shock! 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 37: Fig. 5.4: Electric Connection System - Power Supply X16

    OPERATING INSTRUCTIONS CWD2005 SPC Electric connection system – power supply X16 Fig. 5.4: Assignment see provided wiring diagram! Connect the system via terminals L1, N, PE to the voltage supply according to national/internal regulations. X16.16. Connection L1 X16.18. Connection N1 X16.20.
  • Page 38 OPERATING INSTRUCTIONS CWD2005 SPC Electric connection system – signal lines X17 Fig. 5.5: Customer Union Instr. Cable Union Instr. Relay X17.2 Relay K1 X17.1 nnG1.1 X14.1 lower row Process X17.4 X17.3 nnG1.2 X14.2 X17.6 X17.5 nnG1.3 X14.3 X17.8 Relay K2 X17.7...
  • Page 39 OPERATING INSTRUCTIONS CWD2005 SPC WARNING Outputs (relay, analog, digital) and inputs must only be operated with safety extra- low voltage! Do not connect to mains / supply voltage! Maximum load of the relay connections 30VDC / 1A. chapter — page:...

  • Page 40: Operator Safety Precautions

    OPERATING INSTRUCTIONS CWD2005 SPC 5.4.9 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 reliably prevent individuals from being injured from gas leaks.

  • Page 41: Documentation

    OPERATING INSTRUCTIONS CWD2005 SPC 5.6 Documentation NOTE Union Instruments GmbH recommends keeping a maintenance manual and documenting all jobs and tests. chapter — page: 5—17...
  • Page 42 OPERATING INSTRUCTIONS CWD2005 SPC chapter — page: 5—18...

  • Page 43: Commissioning, Operation, Removing From Service

    OPERATING INSTRUCTIONS CWD2005 SPC 6 Commissioning, operation, removing from service Commissioning/start-up ..................6—2 Description of the workplaces / operating elements ........... 6—4 6.2.1 Workplaces ....................6—4 Operation ......................6—4 Decommissioning / switching off ................ 6—6 chapter — page: 6—1...
  • Page 44 OPERATING INSTRUCTIONS CWD2005 SPC 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 45 OPERATING INSTRUCTIONS CWD2005 SPC Open calibration gas supply when combustion calorimeter is configured with automatic calibration. NOTE For first stating or starting up after a long downtime, back up the configuration of the system / gas analysis device. Let a service technician do the backup or ask Service for special instructions.

  • Page 46: Fig. 6.1: Workplaces

    OPERATING INSTRUCTIONS CWD2005 SPC 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...
  • Page 47 OPERATING INSTRUCTIONS CWD2005 SPC 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 protection function and automatic analysis operation, •...
  • Page 48 OPERATING INSTRUCTIONS CWD2005 SPC 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 49: Maintenance And Service

    OPERATING INSTRUCTIONS CWD2005 SPC 7 Maintenance and service Service ......................7—2 7.1.1 Preparations ....................7—2 7.1.2 Maintenance work/Inspection ..............7—4 Troubleshooting ....................7—5 7.2.1 Preparations ....................7—6 7.2.2 Changing/replacing fuses ................7—6 7.2.3 Messages/malfunctions ................7—7 Service ......................7—7 chapter — page:...

  • Page 50: Service

    OPERATING INSTRUCTIONS CWD2005 SPC 7.1 Service When working in the potentially explosive areas, observe the pertinent safety precautions. The measuring quality of the gas analyser can only be ensured if the service intervals 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 51 OPERATING INSTRUCTIONS CWD2005 SPC 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 overpressure. There is no protection against explosions! • Bridging only for service and maintenance work! •...

  • Page 52: Maintenance Work/Inspection

    OPERATING INSTRUCTIONS CWD2005 SPC 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 53: Troubleshooting

    OPERATING INSTRUCTIONS CWD2005 SPC Interval Inspection (recommended) Weekly inspection weekly, or when Compressed air inlet free required weekly, or when Filter for compressed air free required weekly, or when Pressure indicator at protective cabinet readable and plausible required weekly, or when...

  • Page 54: Preparations

    OPERATING INSTRUCTIONS CWD2005 SPC NOTE Troubleshooting in the system is divided into the following categories: • insufficient pressure of compressed air For other faults, observe related operating instructions of the process gas analyser and other components! 7.2.1 Preparations The feed lines to linked system components can be closed for servicing purposes.

  • Page 55: Messages/Malfunctions

    7.3 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, telephone 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 56 OPERATING INSTRUCTIONS CWD2005 SPC chapter — page: 7—8...

  • Page 57: Disposal

    OPERATING INSTRUCTIONS CWD2005 SPC 8 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 58 OPERATING INSTRUCTIONS CWD2005 SPC chapter — page: 8—2...

  • Page 59: Spare Parts

    If components are discontinued or components by different manufacturers are used, request the manufacturer approval by Union Instruments GmbH. Spare parts can be ordered from Union Instruments GmbH: Identify and write down type, number and designation of the part, order part. chapter — page:...
  • Page 60 OPERATING INSTRUCTIONS CWD2005 SPC chapter — page: 9—2...

  • Page 61: Annex

    Connections ........5—2 Process gas ......3—7, 5—9 Contact Proper use ......... 3—3 Service ........... 7—7 Union Instruments GmbH ..... 3—10 Safety notes ........3—5 Service ........7—2, 7—7 Decommissioning ..... 6—6, 8—1 Setup site .......... 5—6 Spare parts ........9—1 EC declaration of conformity ....
  • Page 62 OPERATING INSTRUCTIONS CWD2005 SPC List of figures Fig. 1.1: System overview ..................1—3 Fig. 1.2: System overview, protective housing with combustion calorimeter ..... 1—4 Fig. 4.1: Main switch (example) ................4—2 Fig. 4.2: Markings and warnings ................4—3 Fig. 4.3: Markings and warnings, terminal boxes .............
  • Page 63 OPERATING INSTRUCTIONS CWD2005 SPC chapter — page: 10—3...

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