Union Instruments CWD2000 EX User manual

April-2015 V1.04
Original operating instructions
Combustion calorimeter
CWD2000 EX

Union Instruments GmbH
Zeppelinstraße 42
76185 Karlsruhe
Germany
 [phone]
 [phone]
 [e-mail]
 http://www.union-instruments.com
© 2015
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.

Table of contents
3
Table of contents
1Technical data ...............................................................................................................5
1.1 Dimensions...................................................................................................................5
1.2 Ex marking according to EC type examination.............................................................. 7
1.3 Device specifications....................................................................................................7
1.4 Interfaces .....................................................................................................................7
1.5 Display times of calorific value measurement0F ...........................................................7
1.6 Calibration gas ............................................................................................................. 7
1.7 Process gas..................................................................................................................7
1.8 Linearity and measuring range .....................................................................................8
1.9 Ambient conditions.......................................................................................................8
1.10 Power supply................................................................................................................8
1.11 Weight..........................................................................................................................8
2EC declaration of conformity...................................................................................... 11
3Safety instructions...................................................................................................... 13
3.1 Warnings and symbols ...............................................................................................13
3.2 Principle, correct use..................................................................................................14
3.3 Personnel and qualifications....................................................................................... 14
3.4 Safety instructions......................................................................................................15
3.4.1 General safety notes................................................................................................ 15
3.4.2 Notes on specific hazards ........................................................................................15
3.5 Operator safety precautions .......................................................................................15
3.5.1 Regular operator training.......................................................................................... 16
3.5.2 Workplace hazard analysis.......................................................................................16
4Safety devices ............................................................................................................. 17
4.1 Ex- enclosure .............................................................................................................17
4.2 Flame arrestor............................................................................................................17
4.3 Purging system...........................................................................................................17
4.4 Cable glands ..............................................................................................................17
4.5 Thermal fuse ..............................................................................................................17
4.6 Solenoid valve............................................................................................................ 18
4.7 Markings and warnings............................................................................................... 19
5Description and connections...................................................................................... 23
5.1 Accessories................................................................................................................ 25
6Transport, installation and acceptance ..................................................................... 26
6.1 Transport.................................................................................................................... 26
6.1.1 Specific Gravity Sensor............................................................................................27
6.1.2 Gas pressure regulator.............................................................................................28
6.1.3 Flue Stack................................................................................................................28
6.2 Ambient conditions..................................................................................................... 29
6.2.1 Storage conditions....................................................................................................29
6.3 Installing and connecting............................................................................................30
6.3.1 Setup site.................................................................................................................30
6.3.2 Ensure extractor hood remains unobstructed so that exhaust gas can flow freely and
heat cannot accumulate. Room ventilation............................................................... 30
6.3.3 Attachment............................................................................................................... 30
6.3.4 Process gas .............................................................................................................31
6.3.5 Calibration gas......................................................................................................... 32
6.3.6 Flue gas................................................................................................................... 33
6.3.7 Opening, closing of cover plate ................................................................................34
6.3.8 Electrical connection ................................................................................................ 34
6.3.9 Groundig of the EX-d box......................................................................................... 35

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6.3.10 Removing / attaching the transport safeguard ..........................................................36
6.4 Documentation ...........................................................................................................37
7Commissioning/start-up .............................................................................................39
8Description of the workplaces / operating elements.................................................41
9Operation .....................................................................................................................43
9.1 Starting –Switching on...............................................................................................43
9.2 Operation of film keyboard/ description of display.......................................................43
9.3 Basics on operation....................................................................................................46
9.4 Available displays.......................................................................................................46
9.5 General information on the start screen......................................................................47
9.6 Menu structure............................................................................................................48
9.7 Main menu .................................................................................................................49
9.7.1 Main menu - Options ...............................................................................................50
9.7.2 Main menu - Trend ..................................................................................................74
9.7.3 Main menu - Eventslist.............................................................................................79
9.7.4 Main menu - Device info ..........................................................................................80
10 Decommissioning / switching off...............................................................................83
10.1 Switching off...............................................................................................................84
11 Maintenance.................................................................................................................85
11.1 Preparations...............................................................................................................85
11.2 Maintenance work/Inspection .....................................................................................88
11.3 Special note for maintenance of the flame arresters...................................................91
11.3.1 Maintenance flame arrester flue stack......................................................................91
11.3.2 Maintenance flame arrester air supply......................................................................92
11.3.3 Maintenance flame arrester gas supply....................................................................92
12 Troubleshooting..........................................................................................................93
12.1 Preparations for troubleshooting.................................................................................94
12.2 Changing/replacing fuses ...........................................................................................94
12.3 Instable measured value.............................................................................................94
12.3.1 Drift of the measured value ......................................................................................94
12.4 Faulty ignition .............................................................................................................95
12.4.1 Fault / status messages with description ..................................................................95
13 Service .........................................................................................................................97
14 Disposal .......................................................................................................................99
15 Spare parts.................................................................................................................101
16 Annex .........................................................................................................................102
Index102
List of figures .....................................................................................................................103

Technical data
5
1 Technical data
1.1 Dimensions
Fig. 1.1: Dimensions of rack, System overview (exemplary)

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Technical data
7
1.2 Ex marking according to EC type examination
Ex marking :
II 2G Ex d IIA T3 Gb
EC type examination :
BVS 04 ATEX E 018 X
Ambient temperature:
-20°C ≤ Tamb ≤ + 45°C
1.3 Device specifications
Parameter:
calorific value
Other parameters:
net calorific value, Wobbe index, rel. density, air
consumption
Measuring range:
8.4 –13.1 kWh/m³
30.2 –47.2 MJ/m³
Accuracy
calorific value / Wobbe:
± 1% measured value
Accuracy of density:
± 0.5% full scale
Linearity:
± 0.2%
Reproducibility:
± 0.1%
0 point stdev:
± 0.2% per month
1.4 Interfaces
Analog outputs:
4 - 20mA for heating value, Wobbe and density
Digital outputs:
8 relays and 4 open-collectors
Digital inputs:
Start calibration, start measurement, hold signals,
cancel calibration
1.5 Display times of calorific value measurement0F
1
Dead time:
3 seconds
50% - time:
7 seconds
90% - time:
20 seconds
99% - time:
45 seconds
1.6 Calibration gas
Calibration gas:
Methane, max. 0.05% impurity
(purity ≥ 3.5)
Calibration interval:
At least once per day
(recommended by the manufacturer)
Duration of calibration:
Up to 20 minutes
Gas consumption:
Up to 5 l/calibration
1.7 Process gas
Process gas:
Natural gas
Gas connection primary
pressure:
20 - 40 mbar
Gas consumption:
15 - 20 l/h (min. rel. density 0.555 with 0.50 mm
nozzle)
1
The display times are measured when the new gas reaches the burner. Display times refer to
measurements with pure methane.

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Air requirement
Approx. 30 m³ per hour (air in installation room:
contains max. 50 ppm combustible components)
1.8 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 %. The hydrogen
content in the gas increases the measuring range span. Inert gases, such as N2,
O2or CO2, limit the measuring range.
1.9 Ambient conditions
DANGER
The calorimeter must not be operated outside the specified ambient temperature,
-20 ° C ≤ Tamb ≤ + 45 ° C.
Beyond this temperature, the type approval expires.
Installation site:
Installation room required
(enclosed documentation!)
Climate:
Recommended room temperature -10°C –40°C
Temperature changes:
≤5°C per hour
Humidity:
95 % rel. humidity
1.10 Power supply
Voltage:
240 VAC 50/60 Hz
Power consumption:
1200 VA max.
Protection class:
I
Degree of protection
IP54
1.11 Weight
Weight:
app. 400 kg
Further information:
enclosed documentation!

Technical data
9

EC declaration of conformity
11
2 EC declaration of conformity
Further information:
enclosed documentation!

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Safety instructions
13
3 Safety instructions
3.1 Warnings and symbols
In the operating instructions, the following names and symbols are used to denote
particularly important information:
DANGER
The calorimeter is approved in accordance with the EC type approval for use in
hazardous areas.
Immediate danger in potentially explosive areas that can lead to serious physical
injury or death!
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 combustion calorimeter
or help prevent property damage.

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3.2 Principle, correct 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 combustion calorimeter is a digitally controlled calorimeter. It measures using
the dry measurement principle. The heat is transferred from the burner to the
measuring elements through air.
The combustion calorimeter is a sensor system to determine the calorific values of
different process gases, the analysis serves for process control.
The combustion calorimeter is designed for use in weather-protected areas for
fixed mounting and installation.
Is determined according to the ex-markings for use in EX zone 1, group II category
2 G.
In the case of toxic and explosive gases, observe the safety instructions at the
setup site.
The process gas must be free from condensate.
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. Changes to the combustion calorimeter (mechanical/electrical must only be
done by specialists.
3.3 Personnel and qualifications
Establishing gas connections and working on the electric equipment of the
combustion calorimeter may only be carried out by specialists adhering to the
safety regulations, especially those regarding explosive areas.

Safety instructions
15
3.4 Safety instructions
3.4.1 General safety notes
WARNING
The combustion calorimeter 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
Observe national regulations for the installation and construction, e.g. IEC/EN
60079-14!
After installation, all gas conducting parts must be checked for leaks
according to national regulations.
All repairs that require the protective covering to be opened may only be
performed by specifically instructed trained personnel.
3.5 Operator safety precautions
WARNING
The operator needs to provide suitable safety equipment for the combustion
calorimeter to reliably prevent individuals from being injured from gas leaks.
Any leaking process gas needs to be diverted into a safe environment.
Danger of stumbling over improperly laid supply lines.
Other safety precautions taken by the operator: corresponding chapters!

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3.5.1 Regular operator training
NOTE
Country-specific regulations about regular user training by the operator must be
observed, in particular training on handling explosive areas, gases, and electrical
equipment.
3.5.2 Workplace hazard analysis
NOTE
Depending on national regulations and possible independent of the CE marking of
this combustion calorimeter, the operator has to create a workplace risk analysis
and to specify the personal protective equipment for the different phases of
operation.
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:

Safety devices
17
4 Safety devices
The calorimeter is a combination of an explosion proof box (analyzer) and
pressurized box with an air heater and PLC. The connection between the boxes is
the Instrument air tube. In the case of loosing the instrument air pressure a non-
return valve prevent a flow back to the heating system. In addition the total system
is powered down and solenoid valves are closed. The heating element is PTC
heating with a self-limitation function (between 200 and 300 °C).
4.1 Ex- enclosure
Inside of the housing components are installed, which could cause an ignition.
The design of the openings of the enclosure are designed for preventing a possible
ignition hazard to the outside.
4.2 Flame arrestor
Flame arresters preventing the dispersal of a possible ignition hazard to other
system components.
4.3 Purging system
The pressurized system ensures by continuous flushing with air, that no explosive
mixture inside of the overall system can occur.
Also ensures a permanent overpressure inside of the EX-p box, that no explosive
gas mixtures can penetrate.
The pre- purge time and the over- pressure is monitored all the time.
Further information:
enclosed documentation! - Manual Pressurized enclosure system -
4.4 Cable glands
Cables and wires which are connected to the housing must guarantee the sealing
and withstand a potential explosion pressure.
The selection of cables and the installation is done by operators.
Exchanging or adding of cable glands leads to the loss of the type approval.
Further information:
enclosed documentation! - Cert cable glands -
4.5 Thermal fuse
NOTE
The irreversible thermal fuse (melting fuse) triggers at 72 °C.
The self-resetting thermal fuse switches off the heater at 50 °C.

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4.6 Solenoid valve
In case of faults, the solenoid valves of the combustion calorimeter close
automatically. The combustion calorimeter then needs to be restarted.

Safety devices
19
4.7 Markings and warnings
Fig. 4.1: Markings and warnings (exemplary)
1.
2
1
3
6
5
4
7

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2.
3.