Union CWD2005 DPC User manual

Operating instructions
Combustion calorimeter
CWD2005 DPC
Mai-2017 V2.01

CWD2005 DPC
II
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.

CWD2005 DPC
I
Table of contents
1Technical Data CWD2005 DPC...............................................................................1—1
1.1 Technical Data Combustion calorimeter............................................................1—3
1.2 System limits and overview ...............................................................................1—5
1.3 Dimensions .......................................................................................................1—6
2EC declaration of conformity .................................................................................2—1
3Safety notes.............................................................................................................3—1
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
3.5 Operator safety precautions ..............................................................................3—9
3.6 Regular operator training.................................................................................3—10
3.7 Workplace hazard analysis..............................................................................3—10
4Safety device system..............................................................................................4—1
4.1 Main switch .......................................................................................................4—2
4.2 Instrument air purged and pressurised housing.................................................4—2
4.3 Locks and doors of the housing.........................................................................4—2
4.4 Flame arresters.................................................................................................4—2
4.5 Cable / line glands.............................................................................................4—2
4.6 Pressure switch, pressure too low.....................................................................4—2
4.7 Safety switch.....................................................................................................4—3
4.8 Thermal fuse.....................................................................................................4—3
4.9 Solenoid valve...................................................................................................4—3
4.10 Fan....................................................................................................................4—3
4.11 Markings and warning system...........................................................................4—4
5Connections, transport, setting up........................................................................5—1
5.1 Description and connections..............................................................................5—2
5.2 Transport...........................................................................................................5—6
5.3 Ambient conditions............................................................................................5—7
5.4 Installing and connecting...................................................................................5—7
5.5 Startup after setup...........................................................................................5—23
5.6 Documentation................................................................................................5—26
6Commissioning, operation, removing from service ...........................................6—27
6.1 Commissioning / start-up.................................................................................6—28
6.2 Description of the workplaces / operating elements.........................................6—30
6.3 Operation ........................................................................................................6—31
6.4 Decommissioning / switching off......................................................................6—32
7Operation combustion calorimeter......................................................................7—33
7.1 Operation of film keyboard / description of display...........................................7—34
7.2 Basics on operation.........................................................................................7—36
7.3 Available displays............................................................................................7—36
7.4 General information on the start screen...........................................................7—37
7.5 Menu structure ................................................................................................7—38
7.6 Main menu ......................................................................................................7—39
8Maintenance and service........................................................................................8—1
8.1 Service..............................................................................................................8—2
8.2 Troubleshooting Ex protective housing..............................................................8—8
8.3 Troubleshooting Combustion Calorimeter........................................................8—11

CWD2005 DPC
II
8.4 Preparations for troubleshooting......................................................................8—12
8.5 Changing / replacing fuses..............................................................................8—13
8.6 Instable measured value..................................................................................8—13
8.7 Service ............................................................................................................8—16
9Disposal...................................................................................................................9—1
10 Spare parts ............................................................................................................10—1
11 Annex.....................................................................................................................11—3
Index ........................................................................................................................11—3
List of figures ..................................................................................................................11—4

CWD2005 DPC
Technical Data CWD2005 DPC
chapter — page: 1—1
1 Technical Data CWD2005 DPC
1.1 Technical Data Combustion calorimeter............................................................1—3
1.1.1 Specifications ............................................................................................1—3
1.1.2 Display times of calorific value measurement ............................................1—3
1.1.3 Calibration gas...........................................................................................1—3
1.1.4 Linearity and measuring range...................................................................1—4
1.2 System limits and overview ...............................................................................1—5
1.3 Dimensions .......................................................................................................1—6
Ex-characteristic acc. to approval
Ex characteristic
Class I, Division 2, Group B, C, 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
Power supply
Voltage:
115 VAC/50Hz
Power consumption:
185 VA max.
Protection class:
I
Degree of protection:
IP50
External circuit breaker:
required, 240VAC/120VAC, 10A
Instrument air supply
max. input pressure:
10 bar / 145 psi
min. input pressure:
5 bar / 73 psi
Quantity / power:
25000 l/h (under standard conditions)
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
Analogue interfaces:
0-20 mA

CWD2005 DPC
chapter — page: 1—2
Dimensions
Height:
1798 mm, additional 300 mm for flame arrestor
Width:
822 mm
Depth:
399 mm
Weight
Weight:
up to 85 kg
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.

CWD2005 DPC
Technical Data CWD2005 DPC
chapter — page: 1—3
1.1 Technical Data Combustion calorimeter
1.1.1 Specifications
Measured gas properties:
Lower Wobbe-index, specific gravity
Calculated gas properties:
Higher Wobbe-index, lower heating value (calorific
value), higher heating value (higher calorific value)
Calculated gas properties
options:
combustion air requirement index (CARI), combus-
tion air requirement
Gas type, inlet pressure, typical consumption CWD2005 DPC
Gas type Range
[MJ / m³] Range [MJ / m³]
Flare gas1)
0–15
40
0–15
40
Blast furnace
gas
3.5–6 40 3.5–6 3.0 170
Converter
gas
4.5–9 40 4.5–9 1.5 140
Mixed gas
5–10
40
5–10
2.0
140
Coke-oven
gas
15–30 40 15–30 1.5 60
Biogas
25–35
40
25–35
1.5
70
Natural gas
25–48
20
25–45
1.0
25
Refinery gas
25–50
40
25–50
1.5
25
LPG
40–90
20
40–90
1.5
15
1) Gas with a heating value < 3.5 MJ/m³ does not burn autothermic, carrier gas needed. The combus-
tibility always depends on the gas type.
2) FS = linearity error in relation to full scale value
1.1.2 Display times of calorific value measurement1
Dead time:
3 seconds
50% - time:
7 seconds
90% - time:
15 seconds
99% - time:
45 seconds
1.1.3 Calibration gas
Calibration gas:
Mixture of main gas components, Wobbe-index
should be between 75% and 100% of full scale,
specific gravity greater than 0.555
Calibration interval:
Programmable, from hourly to monthly
Duration of calibration:
Typical 10 minutes
Gas consumption:
Typical 1/6 of gas consumption per hour, refer to ta-
ble above
1The display times are measured when the new gas reaches the burner. Display times refer to
measurements with pure methane.
Pressure
[mbar] Accuracy [ ± %FS] Gas Flow
[l/h]
2.0

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chapter — page: 1—4
1.1.4 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 % (Wobbe-index).

CWD2005 DPC
Technical Data CWD2005 DPC
chapter — page: 1—5
1.2 System limits and overview
The system comprises:
•a protective enclosure purged with compressed air
•two terminal boxes
•a venting system of the protective housing
•a pressure manometer and pressure switch inside the housing
•a compressed air supply with controller and ball valve
•a combustion calorimeter
List of the important assembly groups, details according to drawing and parts list,
see overall drawing.
Fig. 1.1: System overview

CWD2005 DPC
chapter — page: 1—6
1.3 Dimensions
Fig. 1.2: Dimensions of system
Additional 300 mm height for flame arrestor.

CWD2005 DPC
EC declaration of conformity
chapter — page: 2—1
2 EC declaration of conformity
Der Hersteller / The manufacturer UNION Instruments GmbH
Zeppelinstraße 42
G-76185 Karlsruhe
erklärt hiermit, dass folgend bezeichnete Produkte / hereby declares, that following named products:
Produktbezeichnung: Verbrennungskalorimeter Gerätegruppe: CWD2005
Product name: Calorimeter device group: CWD2005
konform sind mit den Anforderungen, die in der EG – Richtlinie festgelegt sind / are compliant with the require-
ments as defined in the EC directive:
2006/95/EG Elektrische Betriebsmittel zur Verwendung innerhalb bestimmter Spannungsgrenzen
2006/95/EC electrical equipment designed for use within certain voltage limits
2004/108/EG Elektromagnetische Verträglichkeit
2004/108/EC Electromagnetic compatibility
Angewandte harmonisierte Normen / Used harmonized standards:
DIN EN 61010-1:2011 Sicherheitsbestimmungen für elektrische Mess-, Steuer-, Regel- und Laborge-
räte - Teil 1: Allgemeine Anforderungen
Safety requirements for electrical equipment for measurement, control, and
laboratory use - Part 1: General requirements
DIN EN 61326-1:2006 Elektrische Mess-, Steuer-, Regel- und Laborgeräte - EMV-Anforderungen -
Teil 1: Allgemeine Anforderungen
Electrical equipment for measurement, control and laboratory use - EMC re-
quirements -- Part 1: General requirements
Name des Dokumentationsbevollmächtigten: Schlichter
Name delegate of documentation
Adresse des Dokumentationsbevollmächtigten: siehe Adresse des Herstellers
address delegate of documentation see address of manufacturer
Bei einer nicht autorisierten Änderung des Gerätes verliert diese Erklärung ihre Gültigkeit. / Any unauthorized mo-
dification of the device results in invalidity of this declaration.

CWD2005 DPC
chapter — page: 2—2

CWD2005 DPC
Safety notes
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 Instrument air supply .................................................................................3—8
3.4.6 Flue gas.....................................................................................................3—9
3.5 Operator safety precautions ..............................................................................3—9
3.6 Regular operator training.................................................................................3—10
3.7 Workplace hazard analysis..............................................................................3—10

CWD2005 DPC
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 at-
mospheres are marked by this symbol in the operating instructions.

CWD2005 DPC
Safety notes
chapter — page: 3—3
3.2 Fundamentals of proper use
WARNING
Proper use includes following these operating instructions! In addition to the fol-
lowing safety notes, always follow the safety instructions of the linked system
components.
Additional equipment or accessories that are not installed, delivered or manufac-
tured by UNION Instruments GmbH require the approval of UNION Instruments
GmbH as the manufacturer! Otherwise the guarantee expires.
The combustion calorimeter CWD2005 Plus inside the protective housing - is a
sensor system to determine the calorific value of flammable process gases. The
device – calorimeter and protective housing, is designed as a device with over-
pressure encapsulation and purging by compressed air.
The combustion calorimeter CWD2005 DPC is intended according to the marking
for use in an EX-zone acc. to NEC Class I, Division 2, Group B, C and D.
Determining the calorific value of gas supports process control in industrial sys-
tems.
The system is intended for use inside closed rooms for stationary mounting and
installation and for an external power supply 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 result-
ing damage; the associated risk is borne by the installer, fitter, operator or user.
Only certified professionals may alter the system (calorimeter and protective cabi-
net) (mechanical, electrical or pneumatic modifications).

CWD2005 DPC
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 per-
sons 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 author-
isation / qualification cause loss of type test approval.

CWD2005 DPC
Safety notes
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 availa-
ble 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 accord-
ing 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 per-
formed by trained personnel.

CWD2005 DPC
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 ac-
cordance 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 authorisa-
tion / qualification cause loss of type test approval.
Only operate relay with functional extra low voltage.
Do not connect to the mains power supply.

CWD2005 DPC
Safety notes
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 en-
ter the combustion calorimeter and cause incorrect measurements and/or
damage.
•The inlet pressure for the gas connections must not exceed the values speci-
fied 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).

CWD2005 DPC
chapter — page: 3—8
3.4.5 Instrument air supply
WARNING
Protective gas - instrument air generates the protective functions against explo-
sions by purging and creating an overpressure!
Establishing instrument air connections and working on the instrument air equip-
ment of the system may only be carried out by specialists adhering to the safety
regulations, especially those regarding explosive areas.