Union Instruments CWD3000 EXP Operating Instructions Manual

Mrz-2019 V1.02
Translation of operating instructions
Explosion-Protected
Combustion Calorimeter
CWD3000 EXP
UNION Instruments GmbH
Zeppelinstraße 42 76185 Karlsruhe Germany
+49 (0)721-680381-0 +49 (0)721-680381-33
support@union-instruments.com
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
1 Technical 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
2 EU Declaration of Conformity ..................................................................................... 13
3 Safety 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
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
4 Protective 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
5 Description and connections...................................................................................... 27
5.1 External overview and housing connections ............................................................... 27
5.2 Interior connections and components ......................................................................... 28
5.3 Accessories ................................................................................................................ 29
6 Transport, installation and acceptance ..................................................................... 31
6.1 Transport ................................................................................................
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
......................................................................................... 17
.................... 31
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
7 Commissioning/Switching on ..................................................................................... 53
8 Description of the work stations/operator control elements .................................... 55
9 Operation ..................................................................................................................... 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
9.5 Menu 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

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

1.1 Name plate

Technical data
6
Fig. 1.2: Housing dimensions

1.2 Dimensions

Weight: approx. 140 kg
7

1.3 Device overview

Explosion marking:
II 2G Ex pxb IIC T4 Gb
EC type examination:
BVS 19 ATEX 012 X
Ambient temperature:
10°C ≤ T
amb
≤ +50°C
Explosion marking:
Ex pxb IIC T4 Gb
IECEx certificate (CoC):
BVS 19.0000X
Ambient temperature:
10°C ≤ T
amb
≤ +50°C
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
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

1.5 Marking as per the IECEx scheme

IECEx marking and data provisional.

1.6 Voltage supply

Technical data
8
Interfaces:
RS232, Profibus, Fieldbus, Industr. Ethernet
Analog outputs:
3, 4 – 20 mA for heating value, Wobbe index and density
Digital outputs:
3 relays
90% time:
CWD3000: ≤ 15 seconds
Process gas:
1
Calibration inputs:
1, optional 2
Test gas input:
1, optional
Carrier gas input:
1, optional
Gas connections:
Compression fitting: 6 mm
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
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

1.7 Interfaces

1.8 Heating value measurement display times1

1.9 Gas inputs

1.10 Process gas, calibration gas and test gas

1.11 Ignition protection gas

1
The 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
DANGER
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).
The calorimeter may not be operated outside the specified ambient temperature range: –10°C ≤ T
The approval is void outside this temperature range.
≤ 50°C.
amb
Technical data
10
NOTE
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
Application
Measuring accuracy
[Wobbe index]
Series
CWD2500
Series
CWD3000
Industries producing and using natural gas
Natural gas and biomethane
kcal/750 – 1,500 BTU
Refineries
Refinery gas
kcal/650 – 1,800 BTU
Iron and steel
Blast furnace gas (BFG)
BTU
Coke oven gas (COG)
– 740 BTU
Mixed gas (BFG + COG)
180 BTU
Mixed gas (BFG + COG)
BTU
Mixed gas (BFG + COG)
160 BTU
Mixed gas (BFG + COG)
kcal/130 – 320 BTU/ft3

1.12 Combustion gas

The combustion gas must be free of condensate, dust and other contaminants, such as naphthalene.

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 N
, O2 and CO2 reduce the measuring range span.
2
Applic. No.
001
004
005
006
007
008
Application (process gas type)
Measuring range
(Wobbe index)
(and gases associated with crude oil)
30 – 60 MJ/m3 I 8.0 – 16.0 kWh/7,000 – 14,000
25 – 70 MJ/m3 I 7.0 – 20.0 kWh/6,000 – 16,500
3 – 5 MJ/m3 I 0.8 – 1.4 kWh/700 – 1,200 kcal/80 – 130
19 – 29 MJ/m3 I 5.3 – 8.0 kWh/4,500 – 7,000 kcal/480
4 – 7 MJ/m3 I 1.1 – 1.9 kWh/1,000 – 1,700 kcal/100 –
3 – 5 MJ/m3 I 0.8 – 1.4 kWh/700 – 1,200 kcal/80 – 130
±1% FS ±1% MV
±1.5% FS ±1.5% MV
±2% FS Not used
±1% FS ±1% MV
±2% FS Not used
±2% FS Not used
009
010
3.2 – 6.2 MJ/m3 I 0.9 – 1.7 kWh/750 – 1,500 kcal/80 –
5.0 – 12.5 MJ/m3 I 1.4 – 3.5 kWh/1,200 – 3,000
±2% FS Not used
±2% FS Not used
11
Application
Applic. No.
Measuring accuracy
[Wobbe index]
Series
CWD2500
Series
CWD3000
Mixed gas (BFG + COG)
kcal/130 – 260 BTU/ft3
Mixed gas (BOFG + NG)
kcal/110 – 320 BTU/ft3
Biogas plants
Raw biogas
175 BTU/ft3
Oil & gas chemicals
Flare gas
BTU
Flare gas
3,000 BTU
Flare gas
BTU/ft3
Synthesis gas
Synthesis gas
BTU/ft3
Metallurgy
Carbide gas “low”
kcal/210 – 320 BTU/ft3
Carbide gas “high”
kcal/320 – 480 BTU/ft3
Testing and certification
Mixed gas LPG (Liquefied Petroleum Gas) + air
kcal/810 – 1,480 BTU
LPG
Mixed gas LPG + air
kcal/1,070 – 1,500 BTU/ft3
LPG
kcal/1,780 – 2,220 BTU/ft3
MJ: Mega Joule; BTU: British Thermal Unit; FS: Full Scale; MV: Measured Value
Technical data
Application (process gas type)
Measuring range
(Wobbe index)
011
012
017
019
020
021
024
5.2 – 10.5 MJ/m3/1.4 – 2.9 kWh/1,250 – 2,500
4.2 – 12.6 MJ/m3 I 1.2 – 3.5 kWh/1,000 – 3,000
4.0 – 7.0 MJ/m3/1.1 – 1.9 kWh/950 – 1,650 kcal/100 –
0 – 90 MJ/m3 I 0 – 25 kWh/0 – 21,500 kcal/0 – 2,290
0 – 118 MJ/m3 I 0 – 32.8 kWh/0 – 28,180 kcal/0 –
> 800 MJ/m3 I > 222 kWh/> 191,000 kcal/> 20,340
0 – 10 MJ/m3 I 0 – 2.8 kWh/0 – 2,390 kcal/0 – 250
±2% FS Not used
±2% FS Not used
±1.5% FS ±1.5% MV
±3% FS ±2% FS
±3% FS ±2% FS
±3% FS ±2% FS
±3% FS ±2% FS
025
026
027
029
030
8.4 – 12.4 MJ/m3 I 2.3 – 3.4 kWh/2,010 – 2,960
12.5 – 19 MJ/m3 I 3.5 – 5.3 kWh/2,990 – 4,540
(compliance)
32 – 58 MJ/m3 I 8.9 – 16.1 kWh/7,640 – 13,850
42 – 59 MJ/m3 I 11.7 – 16.4 kWh/10,030 – 14,090
70 – 87 MJ/m3 I 19.4 – 24.2 kWh/16,720 – 20,780
Fig. 1.4: Measuring ranges and accuracy
±1.5% FS ±1.5% MV
±1.5% FS ±1.5% MV
±1% FS ±1% MV
±1% FS ±1% MV
±1% FS ±1% MV
Technical data
12
NOTICE
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)

1.14 Ambient conditions of installation location

Use of the combustion calorimeter outside the approved range of ambient conditions results in voiding of the approval! Risk of serious accidents.
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

DANGER
DANGER
WARNING
NOTICE
NOTE

3.1 Warning information and symbols

These operating instructions use the following nomenclature and symbols for especially important information:
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.
For an immediate danger that can lead to serious injury or death.
For a potentially dangerous situation that can lead to serious physical injury or death!
For a potentially dangerous situation that can lead to minor physical injury! This may also be used for warnings of property damage!
For information that can improve the operation of the combustion calorimeter or contribute to prevention of property damage.
Safety instructions
16
WARNING

3.2 Principle, intended use

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.
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
Safety instructions
18
WARNING
DANGER
NOTE

3.6 Safety instructions

3.6.1 General safety instructions

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

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

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!
19

3.7.1 Information on explosion protection

WARNING
When opening, observe the instructions on explosion protection in hazardous
Static electricity discharge! Warning plate may only be cleaned with a damp cloth!
WARNING
Safety instructions
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.

3.8 Owner safety precautions

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
NOTE

3.8.1 Performing a workplace risk assessment

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
+49 (0)721-680381-0 +49 (0)721-680381-33
support@union-instruments.com
http://www.union-instruments.com
21

4 Protective equipment

The CWD3000 EXP is supplied without a main switch, as the owner must provide suitable equipment for separating the supply voltage as part of the voltage supply equipment.

4.1 Pressurized enclosure ignition protection type

Pressurized enclosure ignition protection type “p” as per IEC EN 60079-2 enables the operation of electrical devices in explosive atmospheres in which the creation of a hazardous gas atmosphere in the device is prevented. This is achieved by always maintaining overpressure with an ignition protection gas inside the device. The housing may contain points of release. Before starting the device, the device interior is flushed with ignition protection gas to thin any gas present and flush it out of the housing.
The CWD3000 EXP is operated with compressed air as the ignition protection gas. Before startup, the the housing is flushed out with compressed air equaling several times its volume. Overpressure is then generated. These parameters are controlled and monitored with control unit FS870 S located outside.
The CWD3000 EXP is divided into containment areas. In the inner containment area, the combustible gas enters the combustion chamber for analysis. In the surrounding containment areas, the pressure is higher, which prevents uncombusted gas from being distributed further should a fault occur. The difference in pressure is monitored by the pressure switch.
For analysis of the combustion gas, the gas flows into a combustion chamber and is fully burned there through the corresponding air admixture. The combustion gas pressure is reduced to 18 mbar inside the device, and the gas flows into the combustion chamber at approx. 0.5 mbar. Thanks to the overpressure of 23 – 35 mbar in the surrounding housing, the gas cannot spread further in the device.
Protective equipment
22
Fig. 4.1: Housing, rooms with lockable doors
Fig. 4.2: Depiction of control unit for pre-flushing and overpressure (example)

4.2 Protective housing with doors

Pressure-tight housing which prevents the penetration of ambient atmosphere when closed and ready for operation.
Protective covers (doors) of the housing separate electrical, ignitable modules and hot surfaces from the environment. Hasps may only be opened with a tool.

4.3 Monitoring of the flushing process and overpressure of flushing system

Control unit for monitoring flush volume and overpressure of the ignition protection gas. Prevents startup and operation of the device in case of insufficient characteristic values.

4.4 Cable bushings

Cable bushings for control and signal lines with ATEX/IECEx approval ensure a sealed connection between the cable harness and housing/screw fitting.
23

4.5 Thermal cutoff

NOTE
Fig. 4.3: Depiction of combustion gas inlet solenoid valves (example)
The tripping temperature of the thermal cutoff is 72°C.
When tripped, the thermal cutoff separates the 24 V voltage supply from the solenoid valves. The device is separated from the combustion gas. Solenoid valves are closed in the current-free state.

4.6 Solenoid valve

Should combustion malfunctions occur or the overpressure be insufficient, the solenoid valves at the combustion gas inlet of the combustion calorimeter close. A restart of the combustion calorimeter is necessary.
Protective equipment
Protective equipment
24
Fig. 4.4: Depiction of pressure switches (example)

4.7 Pressure switches

Monitor differential pressures of the media in the housing, deenergize the device if limits are violated and solenoid valves at the combustion gas inlet close.
25

4.8 Markings and warning information

Fig.
No.
Designation
Warning information: hot surface (internal)
1
Warning information: electricity (external)
Warning information: risk of explosion
supply has been shut off!
2
1
Protective equipment
4.5: Markings and warning information (example)
- 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 of 16,000 l/h of compressed air at 4.5 – 5
2
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!
- Housing is overpressurized! Do not open until ignition protection gas
Protective equipment
26
Fig. 4.6: Warning information on electrical connection plate (example) Fig.
NOTE
Name plate with explosion marking
Interior, cell 3 – voltage supply
4.7: Name plate with ATEX/IECEX marking (example)
Malfunction in case of interruption of ignition protection gas supply/compressed air!
When a valve for shutting off the ignition protection gas supply is installed by the owner, a sign is to be posted at that location. In case of accidental, unauthorized shut-off, the calorimeter switches off.
27

5 Description and connections

Fig.
Item
No.
1
Flue gas and cooling air outlet
2
Wall mounting eyelet, 4x
3
Door of cell 2 with 7 hasps
4
Ignition protection gas/compressed air inlet
5
Signal line cable glands of cell 2
6
Display and operating unit, door of cell 3 with 4 hasps
7
Control unit with electrical voltage supply connection
8
Gas inlets (max. 5, depending on the options)
9
Door of cell 1 with 2 hasps
8
7
1 6 4 9 5
3
2

5.1 External overview and housing connections

5.1: Device overview
Designation
Description and connections
28
Fig. 5.2: Housing with no doors (example showing carrier gas option)
Item
No.
1
Gas inlet block with solenoid valves
2
Carrier gas processing (optional)
3
Combustion gas/exhaust air outlet
4
Pressure switches, 3x
5
Thermal element with combustion chamber
6
Ignition transformer
7
Precision pressure controller with mixer block
8
Digital valve, compressed air infeed with silencer
Proportional valve with pressure controller, actuator for control unit and compressed air infeed with silencer
10
Voltage distribution, power supply distribution rail
11
Electronics input and output signals
12
Control unit
1
5 3 4
7
6
10
2
11
11 8 9

5.2 Interior connections and components

Designation
9
29

5.3 Accessories

WARNING
Description and connections
Risk of injury/damage!
Using non-approved accessories may cause damage and put persons at risk. Such use will void the warranty! The owner is then liable for any resulting damage!
Pay attention to the ATEX type examination/IECEx certificate!
Only use genuine accessories or accessories approved by UNION Instruments GmbH!
Description and connections
30
31

6 Transport, installation and acceptance

NOTE
WARNING
NOTE
The combustion calorimeter is generally commissioned by UNION Instruments GmbH or correspondingly qualified service technicians.
If it is not commissioned by UNION Instruments GmbH (e.g. internal transport/resale), a suitable procedure must be agreed upon with UNION Instruments GmbH (

6.1 Transport

Chapter 13 Service).
Tipping over or dropping of the combustion calorimeter from the pallet or load­carrying means may cause injuries!
Use suitable load-carrying means when unpacking and transporting.
Check slings, if applicable, for adequate load-bearing capacity and sound condition and fasten them carefully!
Never walk or stand under suspended loads!
If strong shocks occur during transport, these may damage the housing. Therefore, check the transport container for damage before opening!
In case of transport damage that is indicative of improper handling, a damage assessment by the transport carrier (rail, mail, shipping company etc.) must be arranged within seven days.
Ensure before starting or restarting transport that all transport securing devices are attached.
Transport, installation and acceptance
32
WARNING
Risk of injury/damage!
The protective function of the housing can be adversely affected by transport damage. In case of damage to the transport packaging or signs of improper transport, closely inspect the housing!
33

6.2 Environmental conditions

NOTICE
NOTE
Ensure that the combustion calorimeter is free of gas/moisture residue.
Frozen condensate water in the combustion calorimeter may cause damage.
Ambient temperature:
0 – 60°C
Air humidity:
0 – 95% relative humidity
Ambient pressure:
700 – 1,400 hPa (0.7 – 1.4 bar)
Transport, installation and acceptance
Comply with environmental conditions for storage and installation! Contact UNION Instruments GmbH if the combustion calorimeter is stored for longer than 3 months or must be operated or stored outside the prescribed ambient conditions!

6.2.1 Storage conditions

Transport, installation and acceptance
34
NOTICE
DANGER
When selecting/replacing suitable sealing plugs, comply with the technical data!

6.3 Installing and connecting

If there is an “X” after the certificate number, pay attention to the conditions on installation and operation in the type examination.
The local installation provisions, especially the requirements of IEC/EN 60079­14, are to be observed.
Risk of explosion!
Non-approved cable entry points pose a hazard!
If non-approved cable entry points are used, explosion protection is no longer guaranteed!
Use only cable entry points approved for the required ignition protection type! When selecting/replacing cable and line entry points, comply with the technical
data!
Open holes and unused cable entry points pose a hazard!
Explosion protection is no longer guaranteed if there are open holes or unused cable entry points!
Always close up open holes and unused cable entry points with sealing plugs or
stoppers approved for this purpose!
Sealing plugs must be inserted with a tool!
35

6.3.1 Installation location

WARNING
NOTE
The installation location of the combustion calorimeter must meet the following conditions:
Carry out installation in accordance with the conditions of the explosion marking. Clean environment suitable for gas-analysis/measurement purposes. Mounting to a solid wall – ensure sufficient load-bearing capacity of the wall. Working space on the left-hand side of at least 60 cm, and on the right side at
least 50 cm.
Protect against direct sunlight and ensure sufficient shade;
temperature changes above 5°C/h affect measurement results.
Provided with clean and adequate compressed air (ignition protection gas) for
unbiased measurement result (combustion calorimeter requires max. 30,000 l/h air) (see technical data).
Off-gases must be discharged protected from air draft using a suitable pipe/tube.
Connection points must be checked for proper seal.
Transport, installation and acceptance
Risk of injury due to temperature of off-gases/housing!
The off-gas temperature is between 8 – 20°C above the housing temperature!
Use personal safety equipment to prevent burns!
In case of unfavorable circulation/installation conditions, appropriate deflecting sheets must be provided which prevent fresh air from flowing directly onto the combustion calorimeter.
Transport, installation and acceptance
36
WARNING
Fig. 6.1: Wall mounting

6.3.2 Wall mounting

Risk of injury due to the weight of the device!
For weight, see technical data!
Specify measures to prevent the device from falling down and use suitable hoisting devices!
The combustion calorimeter is intended for mounting to a solid wall. There are four 11 mm fastening eyelets on the housing . The wall used for mounting must be sufficiently sturdy to bear the weight of the combustion calorimeter.
Adequate distance must be provided between the side wall of the installation location and the combustion calorimeter for service and maintenance (left side: approx. 60 cm, right side: approx. 50 cm).
37

6.3.3 Gas connections

DANGER
Check for proper sealing of connections and ensure this during operation!
NOTE
NOTE
Transport, installation and acceptance
Risk of explosion!
Non-approved lines and insufficient connections pose a hazard!
Gas connections may only be installed by qualified personnel!
Accessories must be clean and free of residue. Contaminants may reach
inside the combustion calorimeter and may cause false measurements and/or damage.
The input pressure for the gas connections must not exceed the
specifications of the technical data of the combustion calorimeter.
Check each connection carefully for leaks. When leaks are present, the
system draws air and indicates false measured values.
Do not use sealant for sealing the gas connections. Sealant components
may falsify the measurement result.
Only suitable lines may be used.
6.3.3.1 Ignition protection gas supply – Compressed air
Compressed air is required as the ignition protection gas for operation of the combustion calorimeter. Ensure sufficient supply and seal of the connections – check connection point for proper seal.
Device requires compressed air at 4.5 – 5 bar, 16,000 – 30,000 l/h, for operation. Air recommendation as per ISO 8573-1, class 533 (solid material: 40 μm (class
5)/dew point: –20°C (class 3)/oil quality: 1 mg/m³ (class 3))
When installing a shut-off valve of the ignition protection gas supply
Post warning information: Warning – Valve of the ignition protection gas supply – Follow instructions before closing!
Transport, installation and acceptance
38
Fig. 6.2: Ignition protection gas connection, compressed air, 6 mm screw fitting
WARNING
NOTE
1
1 Compressed air/ignition gas connection, 6 mm pipe fitting,
pressure: 4.5 – 5 bar, use preinstalled pressure controller.
Two compressed air pressure controllers (external and in device). Set external controller to no higher than 5 bar. Do not change setting of internal pressure controller.
6.3.3.2 Combustion gas
Off-gases must be discharged by the owner to a safe environment!
Check connections for proper seal!
Gas input pressure depending on the gas, maximal 500 mbar, minimum: 20
mbar.
Chapter 1.9
Combustion gas must be free of contaminants and condensate.
39
6.3.3.3 Carrier gas supply
NOTE
WARNING
NOTE
For combustion gases that do not have stable combustion, a carrier gas can
be added.
Carrier gases maintain combustion and make no increased contribution to
the combustion value of the combustion gas.
Combustion calorimeters can be subsequently converted to a carrier gas
supply. Contact the manufacturer regarding this.
6.3.3.4 Calibration gas
Transport, installation and acceptance
If a pressure reducer is not installed, escaping calibration gas must be discharged by the owner to a safe environment!
Calibration gas must be free of contaminants and condensate.
The calibration gas quality must be similar to the combustion gas quality
(see Section 1.10).
For device versions with two measuring ranges, up to two calibration gases
may be necessary.
Software-side configuration of the calibration gas.
Section 9.3 Available displays)
(
Transport, installation and acceptance
40
Fig. 6.3: Connections for process, calibration, carrier and test gases, 6 mm screw fitting
1
Carrier gas
I5.2 Input support gas
2
Test gas
I5.1 Input test gas
3
Calibration gas 2
I2.3 Input calibration gas 2
4
Calibration gas 1
I.2.2 Input calibration gas 1
5
Combustion gas
I1.1 Input process gas
1
1
Number of connections optional, 1 shows input of gas from the top down
41
6.3.3.5 Flue gas/Exhaust air
WARNING
NOTE
Fig. 6.4: Flue gas/exhaust air connection
1
Transport, installation and acceptance
Risk of serious injury from escaping flue gases!
Flue gases must be discharged safely!
For flue gases containing CO, H
ensured!
, and H
2
S, a safe environment must be
2
Flue gases/residual heat must be discharged protected from air draft and without interruption through a vent.
An accumulation of residual heat leads to false measurement results.
1 Flue gas/exhaust air connection
Transport, installation and acceptance
42
DANGER
WARNING

6.3.4 Opening and closing of the housing doors

Risk of explosion!
Damaged seal/improper closing pose a hazard!
Explosion protection is no longer guaranteed if seals are damaged or doors are closed improperly!
Risk of severe injury – Housing is overpressurized!
Switch the device off first, then shut off the ignition gas supply and finally
open the doors!
Wait 5 minutes after switching off and allow thermal element to cool down!
Keep doors (one door per cell) closed during operation. Open only when switched off, and observe safety provisions.
Close all hasps of all doors. Close with key/tool!
43

6.3.5 Electrical connection

DANGER
DANGER
Transport, installation and acceptance
Risk of electric shock!
Changes to the electrical equipment of the combustion calorimeter may be carried out only by skilled electricians in accordance with the electrotechnical rules.
Parts of the open combustion calorimeter marked with the adjacent symbol may still carry voltage even when the main switch is switched off! If required, separate the combustion calorimeter from the supply network!
Risk of explosion!
Non-approved cable bushings pose a hazard! Cable bushings which are not suitable for the cable cross section pose a hazard!
Use only cable bushings with ATEX/IECEx approval which fit the cable cross section!
Explosion protection is no longer guaranteed if seals are damaged or doors are closed improperly!
Transport, installation and acceptance
44
Fig. 6.5: Electrical connection, control unit (example)
6.3.5.1 Voltage supply
Connect the combustion calorimeter to the voltage supply using connections 19, 20 – 21, 22 and PE (23, 24, 25 and 26) of the control unit in accordance with national requirements.
Observe control unit operating instructions!
When making connection in terminal box of the control unit, observe the following:
Tightening torques, min/max min.: 0.3 Nm, max.: 0.4 Nm Wire cross section, min/max rigid: 0.2 – 2.5 mm², flexible: 0.2 – 2.5 mm²
Use external protective conductor terminal (grounding bolt) on left side of housing!
Connect protective conductor firmly, secure against loosening. Protect connecting parts effectively against corrosion, pay attention to suitable material. Cable cross­section at least phase conductor cross-section.
Transport, installation and acceptance
45
WARNING
NOTE
After the line voltage is switched off, the device capacitors still carry voltage for up to 5 minutes!
This time must be allowed to elapse before starting work on the high-voltage electrical system.
The specifications of the VDE, the local and regional safety regulations, and the factory-internal safety rules must be complied with at all times during work on the combustion calorimeter!
Check whether the line voltage present is consistent with the device voltage
of the combustion calorimeter.
The combustion calorimeter may only be operated with effective protective
conductor connection in accordance with local requirements for high operating currents.
Transport, installation and acceptance
46
WARNING
DANGER
Fig. 6.6: Disconnector unit Gönnheimer FS852, example

6.3.6 Electrical interfaces

Endangerment of people and equipment when the combustion calorimeter is commissioned by non-instructed personnel!
Allow only instructed/trained service technicians to carry out commissioning!
Risk of explosion!
Electrical interfaces - only connect analog signals and relays using the disconnector unit supplied!
The disconnector unit SR852 could be placed in hazardous area. It is certified on its own in protection type Ex e.
Transport, installation and acceptance
47
Fig. 6.7: Connector assignment of input/output IO external type 06
WARNING

6.3.7 Connector assignment for input/output signals

Do not connect to line voltage!
Only operate outputs (relay, analog and digital) and inputs with safety extra-low voltage!
Transport, installation and acceptance
48
Connector X14 relay outputs
Digital output
Pin/Connector X14
Function
Status display
1
1 Common
3 Normally closed
Process
D 2
2
4 Common
6 Normally closed
Maintenance
D 4
3
7 Common
9 Normally closed
Filter change
D 5
4
10 Common
12 Normally closed
Fault
D 6
5
13 Common
15 Normally closed
Function, optionally
if applicable
D 7
6
16 Common
18 Normally closed
Function, optionally
if applicable
D 8
7
19 Common
21 Normally closed
Function, optionally
if applicable
D 9
8
22 Common
24 Normally closed
Function, optionally
if applicable
D 10
Connector X5 mA outputs
Analog output
Pin/Connector X5
Function
Disconnecting
No. open
1
1 +mA 2 -mA
Wobbe
TR 1/JP 5
2
3 +mA 4 -mA
Density
TR 2/JP 6
3
5 +mA 6 -mA
Heating value
TR 3/JP 7
4
7 +mA
Function, optionally
applicable
TR 4/JP 8
5
9 +mA
Function, optionally
applicable
TR 5/JP 9
6
11 +mA
Function, optionally
applicable
TR 6/JP 10
7
13 +mA
16 n.c.
Function, optionally
TR 7/JP 11
2 Normally open
5 Normally open
8 Normally open
11 Normally open
14 Normally open
17 Normally open
20 Normally open
23 Normally open
assigned
assigned
assigned
assigned
module No./Jumper
8 -mA
assigned if
10 -mA
12 -mA
14 -mA 15 n.c.
assigned if
assigned if
assigned if applicable
Transport, installation and acceptance
49
Connector X3 digital control inputs
Control
Pin/Connector X3
Function
Status
diode
1
1 2 Start measurement Start measurement
D 25
2
3 4 Start calibration Start calibration
D 24
3
5 6 Function, optionally assigned if applicable
D 23
4
7 8 Function, optionally assigned if applicable
D 22
5
9 10
Function, optionally assigned if applicable
D 21
6
11 12
Function, optionally assigned if applicable
D 20
7
13 14
Function, optionally assigned if applicable
D 19
8
15 16
Function, optionally assigned if applicable
D 18
Serial interface RS232
Pin/Connector
X11
Signal
1 -mA analog input 1
2 +mA analog input 1
3 -mA analog input 2
4 +mA analog input 2
5 PT 100 air conditioner
6 PT 100 air conditioner
7 Not assigned
8 RI
9 RTS
10 CTS
11 DSR
12 DTR
13 TXD
14 RXD
15 DCD
16 RS232 GND
Pin/Connector
X1
Signal
1 DCD
2 RXD
3 TXD
4 DTR
5 RS232 DND
6 DSR
7 RTS
8 CT
9 RI
inputs
display
Transport, installation and acceptance
50
NOTE
Fig. 6.8: Transport securing devices (example shown)
Item
No.
Transport securing device for density measuring cell
Transport securing device of pressure controller
2x retaining belts; 1x bubble wrap (inside)
2
1

6.3.8 Removing/attaching transport securing devices

Before commissioning/transport of the combustion calorimeter, it must be ensured that all transport securing devices are removed/attached.
The following transport securing devices must be removed/attached within the combustion calorimeter:
Component Type of securing device
1
2
4x cable ties; 1x screw 5x16
Transport, installation and acceptance
51
Fig. 6.9: Transport securing devices of pressure controller
Order of removal/attachment of
transport securing device
Remove the retaining belts.
Reclose the protective flap.
Order of removal/attachment of
transport securing device
Remove the white cable ties around
freely.
Transport securing device in the pressure controller
Transport securing device
Open the protective flap (screw
Transport securing device of pressure controller
closure).
Remove the transport securing device (bubble wrap).
Proceed in reverse order to reattach the transport securing device.
Transport securing device of density measuring cell
Transport securing device
Transport securing device of density measuring cell
Proceed in reverse order to reattach the transport securing device.
Observe the length of the screw!
the density measuring cell.
Loosen the screw.
Density measuring cell must swing
Transport, installation and acceptance
52
WARNING
gas with
NOTE

6.4 Owner safety precautions

Operate combustion calorimeter in accordance with the requirements for
hazardous areas.
Exhaust discharged flue gas/off-gas to a safe environment!
In case of toxic gases, mark outlet location of discharged flue gas/off-
a warning!
Tripping hazard from improperly routed supply lines!

6.5 Documentation

UNION Instruments GmbH recommends keeping a maintenance log and documenting all work and tests.
53

7 Commissioning/Switching on

NOTICE
NOTE
NOTE
In order to establish start readiness, also establish the start readiness of linked system components according to their operating instructions!
For initial commissioning or before an extended operating shutdown, back up the device configuration.
Have the backup made by service technicians or in response to a special service instruction.
The following table contains significantly shortened steps for commissioning after an extended downtime.
To switch on the combustion calorimeter again after a short shutdown, some steps can be omitted:
Right column!
Commissioning/Switching on
54
Switching
on
Check whether the transport securing device of the density cell has been removed. The density cell must be able to swing freely.
Check whether the transport securing device of the gas pressure
must be removed.
Check whether the ambient conditions correspond to the ATEX approval and IECEx certificate.
Check whether the ambient conditions correspond to the requirements.
Check whether the combustion calorimeter is securely mounted.
Check whether the device is suitable for the combustion gas.
Check whether the combustion gas is correct.
Check whether the calibration gas (and carrier/test gas if applicable) is correct.
Check whether the gas connections are correct and sealed.
Check whether the compressed air supply is correct.
Furnish/switch on owner-side energy supplies and media supply.
Ensure voltage.
Ensure that the doors are closed and that all hasps are closed.
Switch on compressed air.
Switch on voltage.
Establish start readiness of linked system components.
Steps Commissioning
X
controller has been removed. The bubble wrap within the controller
X
X
X
X
X
X
X
X
X
X
X
X X
X X
X X
X X
When the combustion calorimeter has been switched off only temporarily, production can be resumed!
During startup, the device is first flushed with compressed air. Following this rinsing and once overpressure is reached, the control unit activates voltage to the combustion calorimeter. The CWD3000 EXP starts up.
55

8 Description of the work stations/operator control elements

NOTE
Fig. 8.1: Work stations (example)
Item
No.
1
Display
Status display and calorimeter operation
2
Control unit
Status display and operate control unit
1
This chapter contains only elements for operation of the combustion calorimeter by the normal operator.
Designation Function/Activity
Description of the work stations/operator control elements
56
57

9 Operation

WARNING
NOTE
Fig. 9.1: Operator control elements/Structure of display
4.2
5.1 9 4.1
4.3
4.4
6
Risk of injury!
Only operate the combustion calorimeter when all lines are installed and checked for proper seal in accordance with the country-specific regulations!

9.1 Operation of membrane keyboard/Description of display

The software controller is operated using a membrane keyboard. The buttons shown can be selected by a key press.
Damage to membrane keyboard!
Operation with pointed or sharp objects may damage the membrane keyboard!
Operation
58
Item
No.
1
Numeric display
Output of current measured values
2
Display field
Information field
Arrows/Enter
Arrow keys enable movement to an input field. The Enter key confirms the entered value.
Menu
Menu key returns you to the main menu from any other menu level. The key simultaneously saves the input data in memory.
4.2
Start
Start key starts the measurement.
Stop
Stop key stops the measurement without switching off the power supply.
ESC
ESC key cancels the current input operation regardless of the menu level.
Input
Input keys are used to input numeric data. A value field on the screen must be active for this.
Screenshot
This key creates and automatically saves a screenshot on the
For service purposes only!
LED status display
Power: Device switched on
Flame: Flame is burning
Menu keys
Menu keys are described in the software. Their meaning changes
Section 9.2 Grundsätzliche Bedienung!
8
Graphic display
Graphic representation of current measured values.
9
Curve values
Value display for selected curves.
3
4.1
4.3
4.4
5
Designation Function
5.1
6
7
inserted USB memory stick.
Operation: Process, calibration Service: Service required Fault: Major fault
according to which menu is selected. The function is labeled on the current screen.
59

9.2 Basic operation

Symbol
Function
Back:
back to the main menu.
Scroll:
start.
Selection: Plus/Minus:
Causes the selected numbers/fields to be summed or unsummed.
Arrow:
Causes a jump to the next digit of a numeric input.
NOTE
The keys described in the following are used for operation of the combustion calorimeter on the part of the software.
Operation
Causes the menu to jump to the next higher menu level all the way
Causes the display of other menus that cannot be displayed in the
currently displayed screen due to limited space. The individual menus are displayed in a rolling manner over and over from the
Enables a selection from a list.
Other symbols not described above refer to the different menus. These are described in the corresponding screens.

9.3 Available displays

The available displays and their function are described below. The displays are accessed using the menu and function keys shown in the chapter headings.
The structure shown in item 9.5 forms the basis of the controller. Different colors represent the different depth of the menu structure.
Operation
60
Fig. 9.2: General information
Display
(example values)
V 4.44R16
Version number of the software
Process
Current status of the device (e.g. START, STOP, Process, Cal.)
26.02.2019 09:24:46
Current date/time
T1
Temperature of cooling air at thermoelectric battery input
T2
Temperature of cooling air at thermoelectric battery output
T2 – T1
Temperature differential
NOTE

9.4 General information

Information
STD: During a calibration, 0.015 is typically achieved. The calibration is concluded after that.
Operation
61
Fig. 9.3: Information on overpressure differential pressure
Display
(example values)
dp air
Pressure at thermal pipe aperture – housing overpressure to combustion air pressure differential
dp wobbe
Pressure at density cell – housing overpressure to combustion gas pressure differential
Information
Operation
62
Operation
63

9.5 Menu structure

9.6 Main Menu ................................................................................................................. 64
9.6.1 Main Menu - Options ............................................................................................... 65
Main Menu - Options - I/O ..................................................................................... 66
Main Menu - Options - I/O - Analog Outputs ..................................................... 67
Main Menu - Options - I/O - Digital Outputs ....................................................... 68
Main Menu - Options - I/O - mA display ............................................................ 70
Main Menu - Options - I/O - Digital Inputs ......................................................... 71
Main Menu - Options - I/O - Display .................................................................. 72
Main Menu - Options - Calibration ........................................................................ 73
Main Menu - Options - Calibration - Configuration of calibration gas ................. 74
Main menu - Options - Calibration - Automatic calibration ................................. 75
Main menu - Options - Calibration - Automatic calibration 2 .............................. 76
Main menu - Options - Calibration - Calibration ................................................. 76
Main menu - Options - Calibration - Save base calibration ................................ 76
Main menu - Options - Calibration - Calibration limits ........................................ 77
Main menu - Options - System .............................................................................. 78
Main menu - Options - System - General .......................................................... 79
Main menu - Options - System - Ignition ........................................................... 81
Main menu - Options - System - Update ........................................................... 81
Main menu - Options - System - Load factory settings ...................................... 82
Main menu - Options - System - CSV Export .................................................... 82
Main menu - Options - System - Hold signal On/Off .......................................... 82
Main menu - Options - System - Settings .......................................................... 83
Main menu - Options - System - Settings – Date/Time ..................................... 83
Main menu - Options - System - Settings - Language ....................................... 84
Main menu - Options - System - Settings - Password ....................................... 85
Main menu - Options - System - Settings - Change color ................................. 86
Main menu - Options - System - Settings - Hardware 1 .................................... 87
Main menu - Options - Service .............................................................................. 88
9.6.2 Main menu - Trend .................................................................................................. 89
Main menu - Graphic - Select time ........................................................................ 90
Main menu - Graphic - Select value ...................................................................... 91
Main menu - Graphic - Select signal ..................................................................... 92
Main menu - Graphic - Select unit ......................................................................... 92
Main menu - Graphic - Select curve ...................................................................... 93
9.6.3 Main menu - Event list ............................................................................................. 94
9.6.4 Main menu - Device information .............................................................................. 96
Operation
64

9.6 Main Menu

The main menu is the standard display during active operation.
The following submenus are accessed from the main menu:
Options
Trend
Eventlist
Device Info
65

9.6.1 Main Menu - Options

I/O
Configuration option for the following parameters:
Display
Calibration
Configuration option for the following parameters:
Calibration limits
System
Configuration option for the following parameters:
Disable system
Service
For service technician only.
Activate serial interface.
Operation
Analog outputs
Digital (relay) outputs
mA display
Digital inputs
Configuration of calibration gas
Automatic calibration
Automatic calibration 2
Calibration
Save base calibration
General
Ignition
Update
Load factory settings
CSV export
Hold signal On/Off
Settings (e.g. date, language and password)
Operation
66
Main Menu - Options - I/O
Options for configuration for the following parameters:
Analog outputs
Digital outputs
mA display
Digital inputs
Display
67
Main Menu - Options - I/O - Analog Outputs
The mA signals are configured in this menu. The following must be observed for this:
Units:
xxx/m
³ correspond to a gas temperature of 0°C and a barometric pressure of 1,013 mbar.
xxx/Sm³ corresponds to a gas temperature of 15°C (60°F) and a barometric pressure of
1,013 mbar.
xxx stands for MJ, kcal or kWh.
BTU/ft³ corresponds to a gas temperature of 15°C (60°F) and a barometric pressure of 1,013 mbar.
Operation
Operation
68
Main Menu - Options - I/O - Digital Outputs
Digital signals (relay outputs and floating change-over contacts) are configured in this menu. The following must be observed for this:
Zero position:
The zero position of the digital outputs can be freely selected: low/high.
Process:
The combustion gas solenoid valve is open, and the flame is burning.
Calibration:
The calibration gas solenoid valve is open, and the flame is burning.
Maintenance:
The device must be checked in the foreseeable future, but is still ready for operation. The reason for maintenance can be obtained from the “General information” field. Examples reasons include:
Filter change (air filter)
No calibration gas (calibration canceled)
Room temperature too high (air inlet temperature > 52°C)
Gas pressure is too low
Calibration deviation outside of tolerances
The calibration was unstable and was canceled
Operation
69
Fault:
Device is no longer usable because
Air differential pressure is too low (< 3.5 mbar) Sensor break (PT100, thermoelectric battery or temperature at burner is too high) Gas pressure is too low
Operation:
The flame is burning. Thermoelectric voltage of process or calibration gas is greater than the ignition threshold.
Operation delayed:
The flame is burning. Thermoelectric voltage of process or calibration gas is greater than the ignition threshold and the delay time has elapsed.
Overtemperature:
The flame is too hot. The Wobbe signal is greater than 76 mV, i.e. the temperature rise in the inner tube of the thermoelectric battery is greater than 50°C.
Calibration deviation:
The value determined during base calibration is exceeded or undershot.
Internal pressure:
Insufficient process or calibration gas.
Operation
70
Main Menu - Options - I/O - mA display
The mA values for the currently active outputs are displayed in this menu. With the mA display key, all channels can be displayed one after the other. The value can be obtained from the “General information” field.
71
Main Menu - Options - I/O - Digital Inputs
open
Calibration starts
open
No calibration
closed
Calibration starts
open
Measuring starts
closed
Measuring stops
open
Measuring stops
closed
Measuring starts
open
Hold mA
closed
mA online
open
mA online
closed
Hold mA
open
Calibration cancellation
open
No calibration cancellation
closed
Calibration cancellation
Various digital signals are configured in this menu. The following must be observed here:
The pin assignment is preassigned.
Section 6.3.7 !
Signals Zero position Contact CWD3000
Operation
high
Start calibration
low
high
Start measurement
low
high
Hold signals
low
high
Cancel calibration
low
closed No calibration
closed No calibration cancellation
Operation
72
Main Menu - Options - I/O - Display
The display of measured values is configured in this menu. A signal and a unit are assigned to each of the four display windows.
73
Main Menu - Options - Calibration
Operation
In this menu, the calibration values are configured and calibration can be started manually (Calibrate).
Operation
74
Main Menu - Options - Calibration - Configuration of calibration gas
The calibration gas is configured in this menu.
The following must be observed here:
The calibration gas is input as a Wobbe index (Wobbe i and Wobbe s) and as a relative density. These values are calculated from the gas components of the calibration gas.
The manufacturer always uses dry gas as the basis.
Units:
xxx/m
³ correspond to a gas temperature of 0°C and a barometric pressure of 1,013 mbar.
xxx/Sm³ corresponds to a gas temperature of 15°C (60°F) and a barometric pressure of
1,013 mbar.
xxx stands for MJ, kcal or kWh.
BTU/ft³ corresponds to a gas temperature of 15°C (60°F) and a barometric pressure of 1,013 mbar.
75
Main menu - Options - Calibration - Automatic calibration
NOTE
The automatic calibration is configured in this menu.
The following must be observed here:
Input:
Day is a list field (Su, Mo, Tu, We etc.). Time and Cycle are value fields.
Duration of calibration:
Depending on the device type, the calibration duration is 10 – 20 min.
Operation
With a restart of the device or a change of calibration gas, the calibration may have to be started multiple times until the pulse line is sufficiently flushed with calibration gas and the stability criterion is met.
Operation
76
Main menu - Options - Calibration - Automatic calibration 2
The automatic calibration that is defined by a situation is configured in this menu.
Criterion 1:
Automatic calibration after restart.
Criterion 2:
Automatic calibration at a defined change in ambient temperature compared to the last calibration.
Main menu - Options - Calibration - Calibration
The calibration is started with this key. This stops the automatic calibrations.
Main menu - Options - Calibration - Save base calibration
The measured values are saved with this key. These values are reference values for additional calculations during the next calibration. Any deviations from these reference values are stored in the event list.
77
Main menu - Options - Calibration - Calibration limits
The calibration tolerances are set and the deviations from the base calibration are displayed in this menu. If the calibration values exceed the defined tolerances, this is indicated as a calibration deviation for digital outputs.
Operation
Operation
78
Main menu - Options - System
The basic configurations of the device, such as ignition, time of day, language and code key, are specified in this menu.
79
Main menu - Options - System - General
The “Change signals after holding” command causes a smooth transition after calibration or removal of the signal holding state. A sudden rise or fall of the measured value in the analog output signal is avoided. The continuous transition is specified in seconds.
Operation
General system values are configured in this menu.
The following must be observed here:
Change signals after holding:
When the Hold signals (mA) function is ended, an adjustment of the old and new measured values is made over a time ramp.
Flushing time after cooling air or device start:
Specifies the length of time after the device start that the solenoid valve is open until ignition starts.
Screen switch-off time:
Specifies the time after which the screen will be switched off if no input is made.
Display rate:
Refers to a time constant for various burners. It is preset by the manufacturer and dependent on the burner type.
Carrier gas test cycles:
The time intervals for carrier gas calibrations, in hours, is defined.
Operation
80
Operation delay:
The “Operation” relay output is activated only after the delay time elapses.
Minimum internal pressure:
When the minimum internal pressure is undershot, the device goes to STOP state; default value is 8 mbar.
Internal pressure warning threshold:
Below the warning threshold, insufficient gas is signaled for internal pressure and service. Default value is 14 mbar.
81
Main menu - Options - System - Ignition
NOTE
The combustion calorimeter can only be ignited when the door is closed.
Operation
The ignition monitoring is configured in this menu.
The following must be observed here:
Single ignition or interval ignition must be chosen.
Single ignition:
After device start and the flushing time period (10 s), the ignition starts for the maximum set ignition duration. This time can turn out to be shorter if the ignition threshold is reached before the ignition duration elapses. If the ignition threshold is not reached within the specified time, the combustion calorimeter goes to the STOP state.
Interval ignition:
After device start and the flushing time period (10 s), the ignition starts for a maximum set ignition duration and is repeated after a pause equal to the ignition duration. This is repeated until the ignition threshold is reached.
The ignition threshold specifies the differential temperature between the cooling air and flue gas. Default value is 3°C.
Main menu - Options - System - Update
An update from a USB data stick is initiated with this key.
Operation
82
Main menu - Options - System - Load factory settings
The factory settings are loaded with this key.
Main menu - Options - System - CSV Export
Three files are exported as an ASCI file with this key: 30 min at 1-second intervals, 3 hours at 10-second intervals and 5 days at 1-minute intervals.
The values are separated by TAB. All possible 25 curves are written at once to a CSV file. This file can be processed, e.g. with a conventional spreadsheet.
Main menu - Options - System - Hold signal On/Off
The “Hold signal” function is switched on and off with this key.
Hold signal:
Storage of the mA values is activated with this function. After the function is ended, an adjustment of the old and new mA signals is made over a time ramp (120 s).
83
Main menu - Options - System - Settings
Increments selected numbers
Decrements selected numbers
Moves one field left
Moves one field right
Main menu - Options - System - Settings – Date/Time
Operation
The date and time are set in this menu.
Operation
84
Main menu - Options - System - Settings - Language
The Language menu item contains 10 submenus for inserting, copying and correcting various languages, even those that have to be represented by bitmaps (e.g. Chinese). Languages can be downloaded onto a memory stick, corrected and then re-imported to the combustion calorimeter.
The language can be changed and your own bitmaps configured in this menu.
85
Main menu - Options - System - Settings - Password
NOTE
The time must be greater than 0. Otherwise, the system can no longer be unlocked!
The password is changed in this menu.
The following must be observed here:
Factory password:
The combustion calorimeter is delivered with factory password of 0. This can be changed, if necessary.
Unlock time:
This time specifies when the system will be locked and the password must be re­entered.
Operation
Operation
86
Main menu - Options - System - Settings - Change color
The display colors can be changed here.
87
Main menu - Options - System - Settings - Hardware 1
NOTE
Only change this menu in consultation with the manufacturer.
Operation
The parameters for a multi-range measuring device are configured in this menu.
Operation
88
NOTE
Main menu - Options - Service
Only change this menu in consultation with the manufacturer.
The device is provided with a default password at the factory for service mode, with which the owner must specify handling!
The menu is password-protected. Setting for service only.
The device is provided with a default password, 0721, with which the owner must specify handling!
The serial interface can be activated with OK and Enter using the menu sequence Options | Service – entry of the service password and other customer-specific data.
For activation, the
menu button of the keyboard must be pressed
calorimeter must be switched off and on once
89

9.6.2 Main menu - Trend

The graphics are configured in this menu.
The following must be observed here: Up to three different curves in various colors can be displayed.
Selection:
A selection can be made from the following parameters:
Select time
Select value
Select signal
Select unit
Select curve
Operation
Operation
90
Main menu - Graphic - Select time
The diagram can be optimally designed. The increments for increasing and reducing are programmed to obtain a resolution for this purpose.
The diagram is subdivided into 10 segments on the x-axis. The segment time and the total displayed time can be set as follows:
Increase segment time
Reduce segment time
Minimum segment time: 1 s Maximum segment time: 12 h
The time values can be viewed as follows:
Shift to later values
Shift to earlier values
91
Main menu - Graphic - Select value
Values for the curves can be set in this menu.
The curves can be viewed as follows:
Operation
Ref y-value linearly to y-axis Ref y-value linearly from y-axis
dy-value compressed y-axis
dy-value stretched y-axis
Operation
92
Wobbe i
Heating value
mVSA
Frequency
T amb
Wobbe s
Combustion value
mV
p Wobbe
T in
Main menu - Graphic - Select signal
Signals for the curves can be selected in this menu.
Example signals:
Main menu - Graphic - Select unit
Units for the signals can be selected in this menu.
93
Main menu - Graphic - Select curve
Individual curves can be selected in this menu in order to change parameters.
Operation
Operation
94
NOTE

9.6.3 Main menu - Event list

The event list stores all events that are of interest for operation and service of the device.
A total of 1,000 events can be stored.
Show all:
All events
95
Show startup:
Selection of the start events
Operation
Show calibration:
Selection of the calibration events
Operation
96
NOTE
1
Device data:
Device number
2
Measuring ranges:
Density
3
Equipment:
Burner
4
Additional options:
Installed additional options are listed here, if applicable.
5
Analog outputs:
Heating value
3 4 5

9.6.4 Main menu - Device information

The values shown are very important for remote diagnostics when errors occur and can be loaded onto the USB memory stick and sent to the manufacturer by email (e.g. using a screenshot; see CSV keyword index).
Type
Gas type
Carrier gas
Wobbe
Nozzle MR1
Nozzle MR2
Wobbe i
Density
97

10 Decommissioning/Switching off

WARNING
NOTICE
NOTE
Switching
off
Decommi
ssioning
Set calorimeter to Stop/End measurement, STOP button on control panel.
Disconnect the device from the process, professionally shut off the gas­carrying lines.
Bring linked system components to a standstill.
Shut off air supply.
Disconnect voltage supply.
If the combustion calorimeter is to be taken out of service only temporarily, the process ends here!
Professionally separate/switch off owner-side energy supplies, media supply and signal transmission.
When appropriate, pack the combustion calorimeter in a suitable manner.
attached.
Endangerment of people when the combustion calorimeter is decommissioned by non-instructed personnel!
Endangerment of equipment when the combustion calorimeter is decommissioned by non-instructed personnel!
To decommission the combustion calorimeter, you must decommission the linked system components according to their operating instructions as well!
The following table contains steps for decommissioning for extended periods.
To switch off the combustion calorimeter only temporarily, some steps can be omitted:
Switching off column!
Steps
Ensure before starting or restarting transport that all transport securing devices are
X X
X X
X X
X X
X X
X
X
Decommissioning/Switching off
98
99

11 Maintenance

DANGER
WARNING
When carrying out work in hazardous areas, take the relevant safety precautions.
The quality of measurements and availability of the combustion calorimeter can only be guaranteed when the maintenance intervals are adhered to.

11.1 Preparations

Supply lines of linked system components can be closed for maintenance purposes. These must be reopened after the device is put back into service.
Risk of ignition by electricity!
Risk of serious injury from electricity!
Parts of the combustion calorimeter with the adjacent symbol may still carry
voltage even when the main switch is switched off! If required, separate the combustion calorimeter from the supply network!
Device does not have a main switch – disconnect the device from the voltage
supply if necessary and take steps to prevent reconnection!
Only skilled electricians are permitted to work on the electrical equipment of
the combustion calorimeter!
Risk of serious injury from escaping gases!
Before carrying out maintenance work on the combustion calorimeter and
whenever necessary, also bring the the linked system components to a standstill.
Valve of the ignition protection gas supply – Follow instructions before
closing!
Work on gas connections may only be carried out by qualified personnel!
Guidelines applicable at the installation location must be observed!
Incomplete combustion during maintenance operation may cause the
exhaust air to become polluted with combustion gas!
In case of toxic gases, the applicable safety provisions must be complied
with.
Risk of serious injury from burns caused by burner components!
Before carrying out maintenance work on the burner system, always wait 5 minutes for it to cool down!
Maintenance
100
NOTE
DANGER
Steps
Set calorimeter to Stop/End measurement, STOP button on control panel.
Disconnect voltage supply.
Shut off air supply.
Open door of cell 2.

11.2 Maintenance/Inspection

Maintenance work must be performed according to the inspection and maintenance schedule! The nature and amount of wear depends greatly on the individual use and operating conditions. All specified intervals are therefore guide values.
The following items must be ensured before carrying out maintenance work:
1. Make a note of the following values on the combustion calorimeter!
Wobbe i/s
Heating value/Combustion value
Density
mV signals
mA signals
Internal pressure
Differential pressure, Wobbe
Differential pressure, air
2. Notify the control room
3. If no default values via PLC are possible, activate “Hold signal” on the combustion calorimeter (see 9.6.1).
4. Close combustion gas shut-off valve to combustion calorimeter and carry out leak testing.
The nature and amount of wear depends greatly on the individual use and operating conditions. All specified intervals are therefore guide values.
To guarantee operational reliability, use only genuine spare parts of the manufacturer.
The calorimeter can be operated with a door open for maintenance purposes. In this operating mode, ignition protection is no longer ensured!
Make sure that there is not an explosive atmosphere around the calorimeter during operation with an open door!
Maintenance operation may only be carried out by instructed persons!
Observe national, local and company-internal specifications on maintenance operation in hazardous areas, e.g. fire permit!
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