Union Instruments CWD 2005 User manual

Users Manual
CWD 2005
Combustion Calorimeter
For high speed measurement of fuel gases

Manual CWD 2005
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Union Instruments GmbH
Zeppelinstrasse 42
D 76185 Karlsruhe, Germany
Phone : +49 721 95243 0
Fax : +49 721 95243 33
Email : [email protected]
Web : http://www.union-instruments.com
Represented in China by:
Anshan Union Industry and Commerce Company Ltd.
c3-311#, Luse Zhihui Cheng, Lishan District, Anshan, Liaoning, 11404 / China
Tel : [phone]
0086 412 5921396
Fax : [phone]
Email : [email protected]
Represented in North America by:
Delta Instrument LLC
148 Veterans Drive
Northvale
NJ 07647
Phone : [phone]
Fax : [phone]
Web : DeltaInstrument.com
Email : [email protected]

Manual CWD 2005
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Attention:
Please read all safety instructions before you connect the
CWD 2005
See section 1.1 page 6

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Manual CWD 2005
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Contents
1. Important Information........................................................................ 9
1.1. Safety Instructions........................................................................... 10
2. Introduction ..................................................................................... 13
2.1. Output values.................................................................................. 13
2.2. Available measurement ranges....................................................... 14
2.3. Response times .............................................................................. 14
3. Analyzer Overview .......................................................................... 16
3.1. Dimensions, weights ....................................................................... 21
3.2. Gas connections ............................................................................. 22
3.3. Gas consumption ............................................................................ 22
3.4. Electrical power supply.................................................................... 24
3.5. Measurement ranges ...................................................................... 24
3.6. Ambient temperature limits.............................................................. 24
4. Installation....................................................................................... 25
4.1. Shelter requirements....................................................................... 27
4.2. Room ventilation ............................................................................. 27
4.3. Exhaust gas discharge.................................................................... 27
4.4. Electrical power connection............................................................. 28
4.5. Gas connections ............................................................................. 29
4.5.1. Process gas filters........................................................................... 29
4.5.2. Pressure Regulators........................................................................ 30
4.5.3. Sample gas pump ........................................................................... 31
4.5.4. Carrier gas Support......................................................................... 32
4.5.5. Fast Loop connection...................................................................... 32
4.6. Interfaces ........................................................................................ 33
5. Commissioning................................................................................ 35
6. Software.......................................................................................... 38
6.1. Screen and Keypad layout .............................................................. 38
6.1.1. Menu keypad................................................................................... 39
6.1.2. Trend display................................................................................... 39
6.1.3. Numeric display............................................................................... 39
6.1.4. Information field............................................................................... 39
6.1.5. Menu............................................................................................... 39
6.1.6. Start/Stop........................................................................................ 39
6.1.7. Numeric keypad .............................................................................. 40
6.1.8. Burner window ................................................................................ 40
6.1.9. Status display.................................................................................. 40
6.1.10. Arrow and data entry keypad .......................................................... 40
6.1.11. Data input........................................................................................ 40
6.1.11.1. Value fields...................................................................................... 40
6.1.11.2. List fields......................................................................................... 40

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6.1.12. Keypad............................................................................................ 41
6.1.13. Menu Navigation ............................................................................. 41
6.2. Menu Overview ............................................................................... 42
6.2.1. Options............................................................................................ 44
6.2.1.1. Input/Output I/O............................................................................... 45
6.2.1.1.1. Analog outputs ................................................................................ 45
6.2.1.1.2. Relay output.................................................................................... 46
6.2.1.1.3. Display mA...................................................................................... 47
6.2.1.1.4. Digital inputs.................................................................................... 47
6.2.1.1.5. Display ............................................................................................ 48
6.2.1.2. Calibration....................................................................................... 49
6.2.1.2.1. Configure Calibration gas................................................................ 50
6.2.1.2.2. Automatic calibration....................................................................... 50
6.2.1.2.3. Calibrate.......................................................................................... 51
6.2.1.2.4. Store Basic Calibration.................................................................... 52
6.2.1.2.5. Calibration Limits............................................................................. 52
6.2.1.3. System............................................................................................ 53
6.2.1.3.1. General ........................................................................................... 54
6.2.1.3.2. Ignition............................................................................................. 55
6.2.1.3.3. Update............................................................................................. 55
6.2.1.3.4. Load factory configuration............................................................... 56
6.2.1.3.5. Curve Data to CSV File................................................................... 56
6.2.1.3.6. Hold Signal on..off........................................................................... 56
6.2.1.3.7. Settings........................................................................................... 57
6.2.1.3.7.1. Time/Date........................................................................................ 57
6.2.1.3.7.2. Language........................................................................................ 58
6.2.1.3.7.2.1. Change language............................................................................ 59
6.2.1.3.7.2.2. .............................................................................. 59
6.2.1.3.7.2.3. Transfer W. D:>C:........................................................................... 60
6.2.1.3.7.2.4. Transfer W. C:>D:........................................................................... 60
6.2.1.3.7.2.5. Read PCX files................................................................................ 60
6.2.1.3.7.2.6. Store PCX files................................................................................ 60
6.2.1.3.7.2.7. Delete PCX files.............................................................................. 60
6.2.1.3.7.2.8. PCX Info.......................................................................................... 60
6.2.1.3.7.2.9. New dictionary................................................................................. 60
6.2.1.3.7.2.10. Change USB................................................................................... 61
6.2.1.3.7.3. Password ........................................................................................ 61
6.2.1.3.7.4. Color Settings.................................................................................. 62
6.2.1.3.7.5. Hardware 1...................................................................................... 62
6.2.1.4. Service............................................................................................ 64
6.2.1.5. Customer specific application.......................................................... 65
6.2.1.5.1. Air conditioning room temperature .................................................. 66
6.2.1.5.2. Serial Printer ................................................................................... 66

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6.2.1.5.3. Dual Sample Streams ..................................................................... 69
6.2.2. Trend Display.................................................................................. 70
6.2.2.1. Move cursor .................................................................................... 71
6.2.2.2. Change time.................................................................................... 71
6.2.2.3.  ......................................................................... 72
6.2.2.4. Change signals ............................................................................... 73
6.2.2.5. Change units................................................................................... 74
6.2.3. Event List ........................................................................................ 75
6.2.4. Device Info...................................................................................... 76
7. Maintenance.................................................................................... 78
7.1. Safety instructions for maintenance or repair.................................. 78
7.2. Periodic maintenance...................................................................... 78
7.3. Consumables .................................................................................. 78
7.4. Replacement I/O Boards................................................................. 79
7.5. Spare parts packages ..................................................................... 79
8. Troubleshooting .............................................................................. 80
8.1. Event list.......................................................................................... 80
8.2. Unstable readings ........................................................................... 80
8.3. Drift in readings............................................................................... 80
8.4. Incomplete ignition .......................................................................... 81
8.5. Software troubleshooting................................................................. 81
9. Measurement principle.................................................................... 84
9.1. Heating Value measurement, an overview...................................... 84
9.2. Thermopile measuring system ........................................................ 85
9.2.1. Specific Gravity measuring cell ....................................................... 87
9.2.2. Operational overview of the measuring cell..................................... 87
9.2.3. Functional diagram.......................................................................... 88
9.2.4. Output signals................................................................................. 88
9.2.5. Commissioning................................................................................ 88
9.2.6. Testing and calibration.................................................................... 89
9.2.7. Maintenance.................................................................................... 89
9.2.8. Technical specifications .................................................................. 89
10. Circuit diagrams .............................................................................. 90
10.1. Input-Output card: E/A internal........................................................ 90
10.2. Input-Output Card E/A external....................................................... 93
10.2.1. Input-Output Card E/A external Type _06....................................... 93
10.2.1.1. Relay outputs .................................................................................. 94
10.2.1.2. Analog outputs ................................................................................ 95
10.2.1.3. Digital/ Relay contact inputs............................................................ 96
10.2.1.4. Open collector drives or mA outputs ............................................... 97
10.2.1.5. Serial interface RS232 (Option) ...................................................... 98
10.2.1.6. Profibus-DP Interface...................................................................... 99
11. Appendices ................................................................................... 100

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11.1. Spare parts list .............................................................................. 100
11.2. Pressure regulators....................................................................... 100
11.3. Low sample pressure.................................................................... 100
11.4. Gas conditioning ........................................................................... 100
11.5. Gas connections ........................................................................... 101
11.5.1. Adjust pressure regulator.............................................................. 101
11.5.2. Calibration gas connection............................................................ 101
11.5.3. Process gas connection................................................................ 102
11.6. Double Range............................................................................... 104
11.7. Carrier Gas.................................................................................... 105
11.8. Fast loop ....................................................................................... 106
11.9. Air Consumption (Option).............................................................. 106
11.9.1. Calculated Air Consumption.......................................................... 106
11.9.2. Air Consumption with CO measurement....................................... 107
12. Spare parts.................................................................................... 110
12.1. Spares electronics......................................................................... 110
12.2. Spares Electric.............................................................................. 111
12.3. Spares gas.................................................................................... 114
12.4. Spares measurement system........................................................ 116
12.5. Spares burner ............................................................................... 118
12.6. Spares air...................................................................................... 120
12.7. Spares enclosure .......................................................................... 120
13. Technical Data .............................................................................. 121

Manual CWD 2005 Important Information
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1. Important Information
Thank you for specifying a Union CWD 2005 Heating Value Analyzer for your online
process measurement application.
Please read this manual and follow all directions before installation and use of this
gas analyzer.
Unpacking and initial inspection of this unit requires only normal precautions and
procedures applicable to the handling of analytical equipment. All shipping containers
should be carefully checked for any included accessories. Check the shipment
against the packing slip and any system arrangement drawings to ascertain that the
shipment is complete.
The analyzer was carefully inspected and calibrated at the factory. Check the
shipment for possible damage incurred during transit. If there is any sign of visible
damage to the crate or hidden damage inside the shipment, notify the carrier and the
factory immediately as the equipment warranty does not cover damage in shipping.
In the event of trouble during start-up, please contact a factory representative and
inform them of the model and serial number of the unit, plus a fully description of the
problem. Note: The factory will not be responsible if the customer should attempt
repair of the unit during the warranty period without first following any detailed factory
instruction.
All possible care has been taken in the publication of this user manual but Union, its
agents and distributors, accept no liability for any inaccuracies or omissions that may
be found. This manual reflects the state of the product at the issue date below but
further refinements may mean that the manual does not fully reflect your particular
system.
Union Apparatebau reserves the right to make change without notice both to this
publication and the product that it describes.

Important Information Manual CWD 2005
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1.1. Safety Instructions
Before start up and use of the CWD 2005, please take time to carefully review this
manual and its contents. Observe all Warnings, Cautions and Notes.
Warning:
Reasons to safe persons allow maintenance only after disconnect the main switch.
Before maintenance or repair work on the electrical or on the high voltage equipment
the following points have to be considered.
After switching off the main switch the capacities of the equipment store up to 5 min
high voltage. It is important to wait this time till the voltage brake down to zero.
At the installation of the protective earth please consider the existing rules for
instruments with higher leakage current (> 1,5 mA)
Please pay attention about the safety function of the person current circuit breaker. It
is forbidden to manipulate to get a malfunction. (safty switch in the main door).
Before the service at the burner system consider that parts of the burner could be
very hot (more than 200 °C). Please wait more than 15 min to cool down all burner
parts before doing any service.
At the start up and service or not optimal conditions (not 100 % burnt gas ) there is a
danger of bad components in the burnt gases of the outlet of the system.
If process gas has toxic components please consider that all actual safety rules have
to be abode.
Non toxic gases are without problems. They are very high diluted with cooling air.
All electrical connections to line power must be carried out by a qualified electrician.
The analyzers internal electrical components are wired in accordance with NEC, VDE
and International standards. Check the power supply voltage, details can be found on
the technical data label inside the door.
The gas connections have to be installed only from fort his work qualified persons. All
for this job actual laws and rules have to be considered.
The CWD 2005 operates over a specified ambient temperature range. Installing the
instrument directly outside is not recommended, since damage to the analyzer may
occur from the adverse weather conditions if an outdoor shelter is not used.
Caution:
Caution is necessary during installation because pressurized flammable gases are
connected to the instrument and any installation work performed by the customer
must conform to all applicable local and national codes. All internal sample gas
components have been leak tested at 1.5 times the normal operating pressure during
assembly at the factory. After installation, the entire sample gas system should be
pressurized and tested for leaks before use.

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When planning the installation, local site conditions must be taken into account. The
instrument has a small open flame inside so consult any hazardous area regulations
for applicability. If supplied the analyzer shelter may require an air purge system to
conform to hazardous area regulations.
Note: A purge system can also be useful for installations in very dusty areas.
A small source of air for combustion is necessary, generally you must ensure that
flue gas is not allowed to accumulate the inside of the shelter (CO, H2and H2S may
be present) and that any combustion heat is discharged so that the analyzers thermal
stability remains unchanged. Any outside vent needs protection from wind to avoid
back flow of flue gases into the unit and the possibility of unstable readings.
The analyzer is fitted with numerous safety features and instrument ignition can only
occur with the door closed. In the event of failure of gas or cooling air supply, the gas
solenoid valve will close and after a short interval the solenoid will reopen and the
instrument will enter an ignition cycle. If the ignition cycle or online measurement
function is aborted due to flame out or power failure, the gas supply solenoid reverts
to its normally closed position and the small amount of sample gas flow is instantly
terminated. User intervention is then necessary to resolve the problems source.
Calibration is only possible if a calibration gas cylinder is available and contains the
correct certified gas. The mixture will normally be similar to the major process gas
components with a value around 80% of the analyzers range.
CWD 2005 gas consumption is between 8 and 200 liters per hour and the quantity
will depend on the characteristics of the process gas. When designing an outdoor
shelter the use of a gas flow restrictor is recommended since it will limit the 

An air purge system will ensure the LEL inside the enclosure remains well within the
allowable limits of the standards defined by local or national electrical codes.

Introduction Manual CWD 2005
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Manual CWD 2005 Introduction
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2. Introduction
Combustion calorimeters have been an important part of the process industry control
scene for a number of years. Some units are valued for their low maintenance
requirement, rugged durability and ability to understood and serviced quickly by just
about anyone without needing any special tools. Combustion calorimeters burn a
small sample of gas and measure the temperature rise of a fluid (usually air) through
the system and report this as heat release. The goal of a few manufactures has been
to improve response speed of these online units. Over the years, technical progress
and the embodiment of smart design strategies have improved response times from
around 5 minutes for the old mechanical water bath based units down to just a few
seconds for the newly introduced CWD 2005 series.
The CWD 2005 is the successor to the CWD 2000, CW95, CW85, CW71 and all
previous models (about 10,000 units supplied) during more than 85 years service to
the gas industry.
The CWD 2005 is a high-speed combustion calorimeter with a small industrial PC
and large digital display, mounted with the combustion chamber, thermopile and
other vital components in a custom wall mounted enclosure. A small amount of
process gas is measured continuously and the temperature rise from heat of
combustion is transferred from the burner to the thermopile, via the cooling air supply
and is measured by its thermopile sensor as heat rise.
Measurement is based on the real time Wobbe Index and Specific Gravity values of
the gas (a specific gravity sensor is built into the calorimeter). The PC based
microprocessor calculates Calorific Value using the following formula:
GravitySpecificIndexWobbevalueCalorific
The W 2005 model measures Wobbe Index values of process gas and is supplied
without a Specific Gravity sensor.
Most of the CWD 2005 units are supplied to customers that need to measure the
Calorific Value of their process gas and simultaneous outputs are available for both
upper and lower Calorific Values as well as Wobbe index and Specific Gravity.
The CWD 2005 is a high-speed combustion calorimeter and is usually preferred in
control applications as the response time is fast, the measurement is direct and is
simple to maintain online by Gas, Industrial, Steel and Petrochemical companies.
Petrochemical industries often need to measure flare gases with many unknown gas
components and need to meet the uptime requirements of tough environmental
regulations. The CWD 2005 combustion calorimeter responds to all unknown
components in the process gas and reports them as heating value or Wobbe index.
2.1. Output values
The output values depend on the model (CWD 2005 or W 2005) and these values
can be shown on the instruments alphanumeric display. The connection board PCB

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provides a series of removable terminal strips where the 0-20 or 4-20 mA DC isolated
outputs (proportional to the measuring range) and eight user programmable alarm
contacts are available for customer connection. See section 10.2 for details.
The combustion calorimeter is designed to measure very small temperature changes.
When selecting a suitable location, avoid dusty areas, locations with strong drafts,
rapid temperature changes, direct sunlight or other sources of thermal radiation.
TRE - 7°C < TR < TRE + 7°Cwhere
hour
C
dt
dTR2
TR Room temperature
TRE Room temperature during calibration
2.2. Available measurement ranges
Normally 40 - 100 % of the full- scale range can be utilized depending on the gas
composition. The measurement range can be wider for gases with a very high flame
speed and the analyzer is designed for a second measuring range, which can be
supplied as an option. This dual range option can extend the measurement range
from 20 to 100 % and moving from one measuring range to the next provides a step-
less transition, and is displayed as one continuous output. Two calibration gases are
required for the dual range option. If one calibration gas is in the transition zone from
one measuring range to the next, a single calibration gas can be sufficient for both
measuring ranges. This must be tested on an application basis by the factory.
Measuring ranges that are too far apart or contain vastly different components can
only be combined into a single measuring range under very specific circumstances.
Another more radical triple range option is available for process gas streams with
very wide ranges. A carrier gas option can provide a usable range of 0100%
displayed as one continuous output (a continuous supply of Natural Gas or Hydrogen
is required for this option).
2.3. Response times
Dead time 3 sec
50% time 7 sec
90% time 20 sec
99% time 45 sec
Response times are measured when the new gas reaches the burner and the values
shown above were measured using Methane. Gases with other specific gravities and
flame speeds generate different response times, some faster and some slower,
depending on the properties of the gas. In addition to the dead time and response
time, the sample lag time for the flow of sample gas through the supply tube and
fittings installed upstream of the unit must be added. The gas consumption is based
on the total sample volume up to the burner and by using the formula in section 3.3 it
is possible to calculate the total installed response time. A fast loop is recommended
on long sample lines, see section 4.5.4.

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Analyzer Overview Manual CWD 2005
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3. Analyzer Overview
All major components are shown below and can be replaced if necessary as a spare
part. Items marked with an * are not visible on this drawing see following drawings.
Figure 1: CWD 2005 components shown above but without doors for clarity

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1 Output thermopile (mV Wobbe Index)
2 Fixing screws thermopile
3 PT 100 sensor temperature correction
4 PT 100 sensor temp correction differential temperature
5 PT 100 sensor temp correction differential temperature
6 -
7 +
8 Air pressure sensor differential pressure
9 Ignition electrode
10 Enclosure purging
11 Burner
12 Ignition transformer
13 Line filter ignition transformer
14 Air fan
15 Power supply for fan air
16 Line filter power supply fan air
17 Terminal block power supply
18 Cable gland signals
19 Cable gland signals
20 Cable gland signals
21 Cable gland signals
22 Cable gland line power
23 Cable gland signals
24 Electronic - extern output signals digital and analog
25 Safety switch ignition transformer
26 PT 100 sensor box inlet temperature
27 Electronic - Intern A/D-converter solenoid valve control
28 Differential pressure Wobbe jet
29 Cap for Wobbe jet
30 Precision pressure regulator
31 Pressure sensor gas
32 Jet differential pressure S.G.Cell
33 Gas pre pressure regulator
34 S.G.cell
35 Solenoid valve process gas
36 Solenoid valve calibration gas
37 Discharge gas air flow

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Figure 2: Rear inside view of main door
1 Power supply 2 Port for connections
3 Blower power supply 4 Main Board
5 ETX Board 6 Blower ETX Board
7 Keypad back side

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Figure 3: Front view
1 Cable gland signals 2 Cable gland signals
3 Cable gland signals 4 Cable gland signals PS M20
5 Cable gland ground M16 6 Filter cover
7 S 8 Door lock
9 Discharge 10 Display
11 Cover analog signals

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Figure 4: Enclosure shown from left hand side
1 Cable gland, signal 1 Cable gland power
3 Cable gland, signals 4 Cable gland, signals
5 Cable gland, signals 6 USB Connection
7 Interface connections 8 Fast loop
9 Carrier gas (SV.X11/3-4)* 10 Calibration gas 2 (SV. X14/3-4)*
11 Calibration gas (SV.X14/1-2) 12 Process gas (SV. X11/ 1-2)
The above drawing shows a standard instrument or instruments equipped with one
or two calibration gases or carrier gas. Instruments with the option of two process
gases have a different inlet arrangement and this will be labeled on the instrument.

not supplied as standard.