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)
231
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
231
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
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:
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
16495
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
534
7
6
10
2
11
11 89
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
•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
I5.2Input support gas
2
Test gas
I5.1Input test gas
3
Calibration gas 2
I2.3Input calibration gas 2
4
Calibration gas 1
I.2.2Input calibration gas 1
5
Combustion gas
I1.1Input 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:
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
5.19 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 9.2Grundsätzliche 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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