Union Instruments CWD2005 SPC Instruction Manual

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

OPERATING INSTRUCTIONS
CWD2005 SPC
Union Instruments GmbH
Zeppelinstrasse 42
76185 Karlsruhe
Germany
 [phone]
 [phone]
 [e-mail]
 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.

OPERATING INSTRUCTIONS
CWD2005 SPC
Table of contents
1Technical data.........................................................................................................1—1
2EC declaration of conformity .................................................................................2—1
3Safety notes.............................................................................................................3—1
4Safety device system..............................................................................................4—1
5Connections, transport, setting up........................................................................5—1
6Commissioning, operation, removing from service .............................................6—1
7Maintenance and service........................................................................................7—1
8Disposal...................................................................................................................8—1
9Spare parts..............................................................................................................9—1
10 Annex.....................................................................................................................10—1

OPERATING INSTRUCTIONS
CWD2005 SPC

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 1—1
1 Technical data
Ex-characteristic acc. to approval
Ex characteristic
Class 1, Division 2, Group D (NEC500)
Ambient temperature:
5°C ≤ Tamb ≤ 40°C
Gas inlets
Number of measuring 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
Calibration gas
See operating instructions CWD2005 plus
Power supply
Voltage:
230 VAC/50Hz or 115 VAC/50Hz
Power consumption:
1500 VA max.
Protection class:
I
Degree of protection
IP65 (protective housing)
Compressed air supply
max. input pressure
10 bar
min. input pressure
5 bar
Quantity/power:
20000 l/h
Ambient conditions
Operating temperature:
5 - 40°C
Humidity:
0 - 95 % relative humidity
Ambient pressure:
800 - 1100 hPa (0.8 - 1.1 bar)
Storage temperature:
-15 - 60°C
Interfaces
Relay:
3
Dig. interface:
RS232
Analog interfaces:
0-20 mA
Dimensions
Height:
2453 mm, with exhaust
Width:
1150 mm
Depth:
626 mm
Weight
Weight:
up to 350 kg
Details –See Overall drawing

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 1—2
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.

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 1—3
1.1 System limits and overview
The system comprises:
•a protective housing
opurged with compressed air
ostainless steel as weather protection
•two terminal boxes
•a venting system of the protective housing
•a compressed air supply with filter, controller and manometer
•a combustion calorimeter
List of the important assembly groups, details according to drawing and parts list,
see overall drawing.
Fig. 1.1: System overview

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

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

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 2—2

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—1
3 Safety notes
3.1 Warnings and symbols......................................................................................3—2
3.2 Fundamentals of proper use..............................................................................3—3
3.3 Personnel 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 Compressed air supply..............................................................................3—8
3.4.6 Flue gas.....................................................................................................3—9
3.5 Operator safety precautions ..............................................................................3—9
3.6 Regular operator training...................................................................................3—9
3.7 Workplace hazard analysis..............................................................................3—10

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—2
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.
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 dangerous situations in potentially explosive
atmospheres are marked by this symbol in the operating instructions.

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—3
3.2 Fundamentals of proper use
WARNING
Proper use includes following these operating instructions! In addition to the
following safety notes, always follow the safety instructions of the linked system
components.
Additional equipment or accessories that are not installed, delivered or
manufactured by 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. The system, is designed as a device with overpressure
encapsulation and rinsing by compressed air.
The system is intended according to the marking for use in an EX-zone acc. to
NEC Class 1, Division 2, Group D.
Determining the calorific value of gas supports process control in industrial
systems.
The system is intended for use in weather-proof areas for stationary mounting and
installation and for an external power supply with 230V/50Hz and a compressed
air supply.
In the case of toxic and explosive gases, observe the safety instructions at the
setup site.
Any other use is considered improper. The manufacturer is not liable for the
resulting damage; the associated risk is borne by the installer, fitter, operator or
user. Only certified professionals may alter the system (calorimeter and protective
cabinet) (mechanical, electrical or pneumatic modifications).

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—4
3.3 Personnel and qualifications
Establishing gas connections and working on the electric equipment of the system
may only be carried out by specialists adhering to the safety regulations, especially
those regarding explosive areas.
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.

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—5
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
•After installation, all gas conducting parts must be checked for leaks
according 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
performed by trained personnel.

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—6
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. If necessary,
disconnect system from the voltage mains!
NOTE
Changes to the electric installation by persons without corresponding
authorisation/qualification cause loss of type test approval.
Only operate relay with functional extra low voltage.
Do not connect to the mains power supply.

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—7
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
•The connecting parts need to be clean and free of residue. Impurities can
enter the calorimeter and cause incorrect measurements and/or damage.
•The inlet pressure for the gas connections must not exceed the values
specified 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 separate line to drain off the condensate.
ATTENTION
The process gas must be free of condensate and dust if the system has no gas
preparation system (or gas cooler).

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—8
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.

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—9
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, H2, and H2S ensure sufficient room
ventilation.
NOTE
Flue gases / residual heat must be emitted to the open air through a suitable
exhaust system.
3.5 Operator safety precautions
WARNING
•The operator needs to provide suitable safety equipment for the system to
reliably prevent individuals from being injured from gas leaks.
•Danger of stumbling over improperly laid supply lines.
Other safety precautions taken by the operator: corresponding chapters!
3.6 Regular operator training

OPERATING INSTRUCTIONS
CWD2005 SPC
chapter —page: 3—10
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.
Technical developments can give rise to deviations from these operating
instructions. 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
Zeppelinstrasse 42
76185 Karlsruhe
Germany
 [phone]
 [phone]
 [e-mail]
 http://www.union-instruments.com
.