Union Instruments CWD3000 EXP User manual

Mrz-2019 V1.02
Translation of operating instructions
Explosion-Protected
Combustion Calorimeter
CWD3000 EXP

UNION Instruments GmbH
Zeppelinstraße 42
76185 Karlsruhe
Germany
[phone]
[phone]
[e-mail]
http://www.union-instruments.com
02608199964
© 2019
Mrz-2019 V1.02
This documentation is protected by copyright. All rights, in particular the rights of translation,
reprint, extraction of figures, radio transmission, and duplication by photomechanical or other
means and of storage in data processing systems, in whole or in part, are reserved.
Technical data subject to change.

3
Table of contents
1Technical data ............................................................................................................... 5
1.1 Name plate................................................................................................................... 5
1.2 Dimensions................................................................................................................... 6
1.3 Device overview ........................................................................................................... 7
1.4 Explosion marking as per EC type examination............................................................ 7
1.5 Marking as per the IECEx scheme ............................................................................... 7
1.6 Voltage supply.............................................................................................................. 7
1.7 Interfaces ..................................................................................................................... 8
1.8 Heating value measurement display times .................................................................. 8
1.9 Gas inputs .................................................................................................................... 8
1.10 Process gas, calibration gas and test gas..................................................................... 8
1.11 Ignition protection gas .................................................................................................. 8
1.12 Combustion gas.......................................................................................................... 10
1.13 Linearity and measuring ranges.................................................................................. 10
1.14 Ambient conditions of installation location................................................................... 12
2EU Declaration of Conformity..................................................................................... 13
3Safety instructions ...................................................................................................... 15
3.1 Warning information and symbols............................................................................... 15
3.2 Principle, intended use ............................................................................................... 16
3.3 Other applicable operating instructions....................................................................... 16
3.4 Additional information ................................................................................................. 16
3.5 Personnel and qualification
......................................................................................... 17
3.6 Safety instructions ...................................................................................................... 18
3.6.1 General safety instructions ....................................................................................... 18
3.6.2 Information on specific hazards................................................................................ 18
3.7 Recurring operator training ......................................................................................... 18
3.7.1 Information on explosion protection.......................................................................... 19
3.8 Owner safety precautions........................................................................................... 19
3.8.1 Performing a workplace risk assessment ................................................................. 20
4Protective equipment .................................................................................................. 21
4.1 Pressurized enclosure ignition protection type............................................................ 21
4.2 Protective housing with doors..................................................................................... 22
4.3 Monitoring of the flushing process and overpressure of flushing system..................... 22
4.4 Cable bushings........................................................................................................... 22
4.5 Thermal cutoff ............................................................................................................ 23
4.6 Solenoid valve ............................................................................................................ 23
4.7 Pressure switches ...................................................................................................... 24
4.8 Markings and warning information .............................................................................. 25
5Description and connections...................................................................................... 27
5.1 External overview and housing connections ............................................................... 27
5.2 Interior connections and components ......................................................................... 28
5.3 Accessories................................................................................................................ 29
6Transport, installation and acceptance ..................................................................... 31
6.1 Transport.................................................................................................................... 31
6.2 Environmental conditions............................................................................................ 33
6.2.1 Storage conditions.................................................................................................... 33
6.3 Installing and connecting ............................................................................................ 34
6.3.1 Installation location................................................................................................... 35
6.3.2 Wall mounting .......................................................................................................... 36
6.3.3 Gas connections ...................................................................................................... 37
6.3.4 Opening and closing of the housing doors................................................................ 42

Technical data
4
6.3.5 Electrical connection ................................................................................................ 43
6.3.6 Electrical interfaces .................................................................................................. 46
6.3.7 Connector assignment for input/output signals ......................................................... 47
6.3.8 Removing/attaching transport securing devices........................................................ 50
6.4 Owner safety precautions ........................................................................................... 52
6.5 Documentation ........................................................................................................... 52
7Commissioning/Switching on..................................................................................... 53
8Description of the work stations/operator control elements.................................... 55
9Operation ..................................................................................................................... 57
9.1 Operation of membrane keyboard/Description of display............................................ 57
9.2 Basic operation...........................................................................................................59
9.3 Available displays ....................................................................................................... 59
9.4 General information .................................................................................................... 60
9.5Menu structure............................................................................................................ 63
9.6 Main Menu ................................................................................................................. 64
9.6.1 Main Menu - Options ............................................................................................... 65
9.6.2 Main menu - Trend .................................................................................................. 89
9.6.3 Main menu - Event list ............................................................................................. 94
9.6.4 Main menu - Device information .............................................................................. 96
10 Decommissioning/Switching off................................................................................. 97
11 Maintenance................................................................................................................. 99
11.1 Preparations ...............................................................................................................99
11.2 Maintenance/Inspection............................................................................................ 100
11.2.1 Cleaning the surface and display............................................................................ 101
12 Troubleshooting ........................................................................................................ 105
12.1 Preparations for troubleshooting............................................................................... 106
12.2 Changing/replacing fuses ......................................................................................... 107
12.3 Changing/replacing the battery ................................................................................. 107
12.4 Unstable measured value ......................................................................................... 107
12.5 Drift of measured value............................................................................................. 107
12.5.1 Faulty ignition ......................................................................................................... 107
12.5.2 Error/status messages............................................................................................ 108
13 Service ....................................................................................................................... 111
14 Disposal ..................................................................................................................... 113
15 Spare parts................................................................................................................. 115
16 Appendix .................................................................................................................... 117
Profibus data structure....................................................................................................... 117
Serial interface RS 232 data structure (optional)................................................................ 118
Index ................................................................................................................................. 119
Figures............................................................................................................................... 120
List of tables....................................................................................................................... 120

5
1 Technical data
1.1 Name plate
Fig. 1.1: Name plate (example)
1. Device description and product code
2. Technical information
3. Approval information (example)
2
3
1

Technical data
6
1.2 Dimensions
Fig. 1.2: Housing dimensions
Weight: approx. 140 kg

Technical data
7
1.3 Device overview
Fig. 1
.
3: Markings and warning information
1. Explosion-protection warning information
2. Warning information for electricity
3. Name plate
1.4 Explosion marking as per EC type examination
Explosion marking:
II 2G Ex pxb IIC T4 Gb
EC type examination:
BVS 19 ATEX 012 X
Ambient temperature:
–10°C ≤ Tamb ≤ +50°C
1.5 Marking as per the IECEx scheme
IECEx marking and data provisional.
Explosion marking:
Ex pxb IIC T4 Gb
IECEx certificate (CoC):
BVS 19.0000X
Ambient temperature:
–10°C ≤ Tamb ≤ +50°C
1.6 Voltage supply
Voltage:
230 volts or 115 volts, 50/60 Hz alternating current
Power consumption:
185 VA max.
Protection class:
I
IP rating:
IP44
2
3
1

Technical data
8
1.7 Interfaces
Interfaces:
RS232, Profibus, Fieldbus, Industr. Ethernet
Analog outputs:
3, 4 – 20 mA for heating value, Wobbe index and
density
Digital outputs:
3 relays
1.8 Heating value measurement display times1
90% time:
CWD3000: ≤ 15 seconds
1.9 Gas inputs
Process gas:
1
Calibration inputs:
1, optional 2
Test gas input:
1, optional
Carrier gas input:
1, optional
Gas connections:
Compression fitting: 6 mm
1.10 Process gas, calibration gas and test gas
Calibration gas:
Dependent upon combustion gas
Calibration interval:
Dependent upon combustion gas
Calibration duration:
Process lasts up to 20 minutes,
gas flow approx. 10 minutes
Gas consumption:
Approx. 7 l gas per calibration
(dependent on the calibration gas)
Input pressure, max.:
Max. 500 mbar
Input pressure, min.:
20 mbar, dependent on the gas
1.11 Ignition protection gas
Ignition protection gas:
Compressed air, instrument air
Input pressure, max.:
5 bar
Input pressure, min.:
4.5 bar
Temperature, max.:
50°C
Consumption:
Max. 30,000 l/h under normal conditions
Operating pressure:
23 – 35 mbar
Operating pressure, min.:
23 mbar
Operating pressure, max.:
40 mbar
pre-purge volume, min.:
1020 l
1The display times are measured from the time the new gas reaches the burner. Display times are
based on measurements with pure methane.

Technical data
9
NOTE
Provide sufficient buffer volume for ignition protection gas; volume is dependent
upon the switching frequency of the compressor and the possible operating time
without the compressor.
UNION recommends compressed air of class 533 as per ISO 8573-1
corresponding to solids of 40 μm (class 5)/dew point of –20°C (class 3)/oil quality
of 1 mg/m³ (class 3).
DANGER
The calorimeter may not be operated outside the specified ambient temperature
range: –10°C ≤ Tamb ≤ 50°C.
The approval is void outside this temperature range.

Technical data
10
1.12 Combustion gas
NOTE
The combustion gas must be free of condensate, dust and other contaminants,
such as naphthalene.
Gas connection inlet
pressure:
Max. 500 bar, min. 20 mbar
Combustion gas
consumption:
30 – 40 l/h (min. rel. density 0.50 with 0.55 mm
nozzle)
Calibration gas
consumption:
Approx. 1/6 of the combustion gas; gas flow during
calibration: approx. 10 minutes ≈ 1/6 hour
1.13 Linearity and measuring ranges
The measuring ranges cannot be utilized from 0% to 100%. The range is
dependent on the gas composition. Ranges of 45 – 100% are typical for a
measuring range. Hydrogen content in the gas increases the measuring range
span. Inert gases such as N2, O2and CO2reduce the measuring range span.
Application
Applic. No.
Application (process gas type)
Measuring range
(Wobbe index)
Measuring accuracy
[Wobbe index]
Series
CWD2500
Series
CWD3000
Industries producing and using natural gas
001
Natural gas and biomethane
(and gases associated with crude oil)
30 – 60 MJ/m3 I 8.0 – 16.0 kWh/7,000 – 14,000
kcal/750 – 1,500 BTU
±1% FS ±1% MV
Refineries
004
Refinery gas
25 – 70 MJ/m3 I 7.0 – 20.0 kWh/6,000 – 16,500
kcal/650 – 1,800 BTU
±1.5% FS ±1.5% MV
Iron and steel
005
Blast furnace gas (BFG)
3 – 5 MJ/m3 I 0.8 – 1.4 kWh/700 – 1,200 kcal/80 – 130
BTU
±2% FS Not used
006
Coke oven gas (COG)
19 – 29 MJ/m3 I 5.3 – 8.0 kWh/4,500 – 7,000 kcal/480
– 740 BTU
±1% FS ±1% MV
007
Mixed gas (BFG + COG)
4 – 7 MJ/m3 I 1.1 – 1.9 kWh/1,000 – 1,700 kcal/100 –
180 BTU
±2% FS Not used
008
Mixed gas (BFG + COG)
3 – 5 MJ/m3 I 0.8 – 1.4 kWh/700 – 1,200 kcal/80 – 130
BTU
±2% FS Not used
009
Mixed gas (BFG + COG)
3.2 – 6.2 MJ/m3 I 0.9 – 1.7 kWh/750 – 1,500 kcal/80 –
160 BTU
±2% FS Not used
010
Mixed gas (BFG + COG)
5.0 – 12.5 MJ/m3 I 1.4 – 3.5 kWh/1,200 – 3,000
kcal/130 – 320 BTU/ft
3
±2% FS Not used

Technical data
11
Application
Applic. No.
Application (process gas type)
Measuring range
(Wobbe index)
Measuring accuracy
[Wobbe index]
Series
CWD2500
Series
CWD3000
011
Mixed gas (BFG + COG)
5.2 – 10.5 MJ/m3/1.4 – 2.9 kWh/1,250 – 2,500
kcal/130 – 260 BTU/ft
3
±2% FS Not used
012
Mixed gas (BOFG + NG)
4.2 – 12.6 MJ/m3 I 1.2 – 3.5 kWh/1,000 – 3,000
kcal/110 – 320 BTU/ft
3
±2% FS Not used
Biogas plants
017
Raw biogas
4.0 – 7.0 MJ/m3/1.1 – 1.9 kWh/950 – 1,650 kcal/100 –
175 BTU/ft
3
±1.5% FS ±1.5% MV
Oil & gas chemicals
019
Flare gas
0 – 90 MJ/m3 I 0 – 25 kWh/0 – 21,500 kcal/0 – 2,290
BTU
±3% FS ±2% FS
020
Flare gas
0 – 118 MJ/m3 I 0 – 32.8 kWh/0 – 28,180 kcal/0 –
3,000 BTU
±3% FS ±2% FS
021
Flare gas
> 800 MJ/m3 I > 222 kWh/> 191,000 kcal/> 20,340
BTU/ft
3
±3% FS ±2% FS
Synthesis gas
024
Synthesis gas
0 – 10 MJ/m3 I 0 – 2.8 kWh/0 – 2,390 kcal/0 – 250
BTU/ft
3
±3% FS ±2% FS
Metallurgy
025
Carbide gas “low”
8.4 – 12.4 MJ/m3 I 2.3 – 3.4 kWh/2,010 – 2,960
kcal/210 – 320 BTU/ft
3
±1.5% FS ±1.5% MV
026
Carbide gas “high”
12.5 – 19 MJ/m3 I 3.5 – 5.3 kWh/2,990 – 4,540
kcal/320 – 480 BTU/ft
3
±1.5% FS ±1.5% MV
Testing and certification
027
Mixed gas LPG (Liquefied Petroleum Gas) + air
(compliance)
32 – 58 MJ/m3 I 8.9 – 16.1 kWh/7,640 – 13,850
kcal/810 – 1,480 BTU
±1% FS ±1% MV
LPG
029
Mixed gas LPG + air
42 – 59 MJ/m3 I 11.7 – 16.4 kWh/10,030 – 14,090
kcal/1,070 – 1,500 BTU/ft
3
±1% FS ±1% MV
030
LPG
70 – 87 MJ/m3 I 19.4 – 24.2 kWh/16,720 – 20,780
kcal/1,780 – 2,220 BTU/ft
3
±1% FS ±1% MV
MJ: Mega Joule; BTU: British Thermal Unit; FS: Full Scale; MV: Measured Value
Fig. 1.4: Measuring ranges and accuracy

Technical data
12
1.14 Ambient conditions of installation location
NOTICE
Use of the combustion calorimeter outside the approved range of ambient
conditions results in voiding of the approval! Risk of serious accidents.
Installation location:
Protect against direct sunlight and ensure sufficient
shade.
Temperature change:
≤ 5°C per hour
Air humidity:
0 – 95% rel. humidity
Ambient pressure:
800 – 1,100 hPa (0.8 – 1.1 bar)
Direct sunlight can cause changes in temperature; temperature changes above
5°C/h affect measurement results.
For other requirements, see Section 6.3.

13
2 EU Declaration of Conformity
Der Hersteller/The manufacturer
UNION Instruments GmbH
Zeppelinstraße 42
76185 Karlsruhe, Germany
erklärt hiermit, dass folgend bezeichnete Produkte/hereby declares, that the following named products:
Produktbezeichnung: Verbrennungskalorimeter Gerätegruppe: CWD3000 EXP
Product name: Calorimeter device group: CWD3000 EXP
Explosionsgruppe: II 2G Ex pxb IIC T4 Gb EG-Baumusterprüfung: BVS 19 ATEX 012 X
Explosion group: II 2G Ex pxb IIC T4 Gb EC type examination certificate: BVS 19 ATEX 012 X
Benannte Stelle für Baumusterprüfung/Notified body for type examination:
DEKRA Testing and Certification GmbH, Bochum, Germany, No. 0158
Benannte Stelle für QS-Überwachung/Notified body for QA assessment:
TÜV Product Service GmbH, Munich, Germany, No. 0123
konform sind mit den Anforderungen, die in der EU – Richtlinie festgelegt sind/are compliant with the
requirements as defined in the EU directive:
2014/34/EU ATEX Richtlinie
2014/34/EU ATEX directive
2014/30/EU Elektromagnetische Verträglichkeit
2014/30/EU Electromagnetic compatibility
Angewandte harmonisierte Normen/Harmonized standards used:
EN 60079-0:2012 Explosionsfähige Atmosphäre Teil 0: Betriebsmittel -Allgemeine Anforderungen
Explosive atmospheres - Part 0: Equipment - General requirements
EN 60079-2:2014 Explosionsgefährdete Bereiche – Teil 2: Geräteschutz durch Überdruckkapselung “p”
Explosive atmospheres – Part 2: Equipment protection by pressurized enclosure “p”
EN 61326-1:2013 Elektrische Mess-, Steuer-, Regel- und Laborgeräte - EMV-Anforderungen - Teil 1:
Allgemeine Anforderungen
Electrical equipment for measurement, control and laboratory use - EMC
requirements - Part 1: General requirements
Name des Dokumentationsbevollmächtigten: Schlichter
Name of documentation delegate:
Adresse des Dokumentationsbevollmächtigten: siehe Adresse des Herstellers
Address of documentation delegate: see address of manufacturer
Bei einer nicht autorisierten Änderung des Gerätes verliert diese Erklärung ihre Gültigkeit. /Any unauthorized
modification of the device results in invalidity of this declaration.

EU Declaration of Conformity
14

15
3 Safety instructions
3.1 Warning information and symbols
These operating instructions use the following nomenclature and symbols for
especially important information:
DANGER
The combustion calorimeter is approved for use in hazardous areas as per the
EC type examination/IECEx certification.
In these operating instructions, information on possible dangerous situations
which could arise in hazardous areas is marked with the symbol shown here.
DANGER
For an immediate danger that can lead to serious injury or death.
WARNING
For a potentially dangerous situation that can lead to serious physical
injury or death!
NOTICE
For a potentially dangerous situation that can lead to minor physical injury! This
may also be used for warnings of
property damage!
NOTE
For information that can improve the operation of the combustion
calorimeter or contribute to prevention of property damage.

Safety instructions
16
3.2 Principle, intended use
WARNING
Intended use also includes following these operating instructions. In addition to
the following safety information, the safety information of linked system
components must also be observed at all times!
Additional equipment or accessory parts not installed, supplied, or made by
UNION Instruments GmbH require manufacturer's approval by UNION
Instruments GmbH! Any warranty is otherwise voided!
The combustion calorimeter CWD3000 EXP is an analyzer used for determining
the Wobbe index and the gas density of various combustion gases. This analysis
is used for process control. The principle is based on the principle of the dry
calorimeter, where the gas is burned and the heat transferred by mixing it with a
stream of air. The temperature increase of the stream of air, which is proportional
to the energy released, is measured.
The device is based on ignition type “p” – pressurized enclosure. Compressed air
is used as the ignition protection gas.
The calorimeter CWD3000 EXP is intended for use in weather-proof areas and for
fixed mounting to a wall and fixed installation (temperature range: 10°C – 50°C).
The calorimeter CWD3000 EXP is designed for continuous operation – intervention
is not required during operation.
The calorimeter CWD3000 EXP is suitable for operation in hazardous areas and
is intended for use in explosion protection zone 1, group II, category 2G in
accordance with its explosion marking. The CWD3000 EXP is approved as per
Directive 2014/34/EU and the IECEx scheme.
The device is not suitable for the analysis of combustion gas mixtures which are
already ignitable.
The safety provisions applicable at the installation location are to be complied with.
Toxic gas risk assessments are to be carried out by the owner.
3.3 Other applicable operating instructions
The operating instructions of the Gönnheimer pressurized enclosure control unit
F870S are also to be taken into account.
3.4 Additional information
The owner is responsible for supplying the ignition protection gas (compressed air,
class 3). The owner is responsible for supplying electrical voltage. The device is
switched on and off by a control unit. Additional separation from the voltage supply
is to be installed by the owner.

Safety instructions
17
3.5 Personnel and qualification
Gas connections and work on the electrical equipment of the combustion
calorimeter may only be carried out by a professional in compliance with safety
provisions, especially for hazardous areas.

Safety instructions
18
3.6 Safety instructions
3.6.1 General safety instructions
WARNING
Only operate the combustion calorimeter when all protective equipment is
present and operational!
Further safety information:

Preceding the corresponding sections!
3.6.2 Information on specific hazards
DANGER
•After installation, all gas-conveying parts must be checked for proper seal
according to national regulations!
•Observe the national regulations on installation and setup, e.g. IEC/EN 60079-
14!
•All repairs must be carried out by trained specialists, regardless of the type
of work!
3.7 Recurring operator training
NOTE
Country-specific regulations regarding the recurring instruction of operators
must be observed by the owner, particularly with regard to the handling of
hazardous areas, gases and electrical equipment!

Safety instructions
19
3.7.1 Information on explosion protection
WARNING
When opening, observe the instructions on explosion protection in hazardous
areas! May be opened by specialists only!
The device must first be flushed after opening the housing and switching on
again! Minimum flow volume is 16,000 l/h of compressed air at 4.5 – 5 bar!
You must wait for at least 5 minutes after separation of the power supply before
any doors of the housing may be opened.
Static electricity discharge! Warning plate may only be cleaned with a damp cloth!
3.8 Owner safety precautions
WARNING
•Toxic gases – The owner must provide suitable protective equipment for the
combustion calorimeter that can reliably prevent injuries to personnel, e.g.
from escaping gas!
•Tripping hazard from improperly routed supply lines!
Other owner-side safety precautions:
 Corresponding section!

Safety instructions
20
3.8.1 Performing a workplace risk assessment
NOTE
Depending on the national regulations and, if necessary, independent of the CE
marking of this combustion calorimeter, the owner must prepare a hazard
assessment and specify personal safety equipment for different phases of
operation.
Further technical developments may result in deviations from these operating
instructions. If you would like more information or if you encounter problems that
are not covered in detail in this manual, contact us at the following address:
UNION Instruments GmbH
Zeppelinstraße 42
76185 Karlsruhe
Germany
[phone]
[phone]
[e-mail]
http://www.union-instruments.com