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CWD2005 PLUS - Delta Instrument LLC

1. Using the list it is possible to identify which and when operations have occurred This gives an initial clue when problem solving The list can be downloaded and sent to the factory for analyzing a problem 8 2 Unstable reading 1 The pre pressure regulator is unable to maintain constant pressure Process pressure is insufficient This can be the problem of blast furnace gas A process gas pump must be installed 2 Direct sunlight results in rapid temperature fluctuations In unprotected installations direct sunlight on the analyzer should always be avoided 3 Rapid temperature fluctuations Air conditioning systems or heating units with large cooling capacity and large control hysteresis can cause instability 6 3 Drift in readings The following problems can cause drift in readings 1 Reading drifts upward in one direction and calibration no longer restores the calibration value Air fan frequency control is at its maximum value This problem can be caused by heavy air contamination in the filter that can no longer be corrected by the controlled speed of the air fan Possible solution the filter element must be replaced 2 Reading drifts downward The heat exchanger is worn out It is the case where propane and butane are used and occurred if the gas burned with insufficient primary air Yellow flame The heat exchanger can become clogged with soot and carbon deposits Possible solution remove and wash the heat exchanger with wa
2. Y ra N Y OO O O D O 3 666 gt D O5 O O O Er O 000000000 ST2 1 9 Insulation Fig 9 3 Specific gravity measuring cell heated and insulated 1 Potentiometer 1 Zero 3 Suspension springs 2 Potentiometer 2 Span 4 Insulating discs St2 PIN terminals 1 15V Power Supply 7 VA 2 15V Power Supply 7 VA 3 Location pin 4 GRND5 5 not connected 6 Location pin 7 5V Measurement signal specific gravity 0 5 Volt 8 not connected 9 GRND Measurement principle User Manual CWD2005 Plus User Manual CWD2005 Plus Circuit diagrams 10 Circuit diagrams The following circuit diagrams show only the major components Component level drawings are only supplied under special confidentiality terms and conditions 10 1 Input output card EA internal x14 R2 O SS OR37 2 N RO ORM Ex Er Dr fea oh Er Sr DI DIO Dit DIZ D13 D44 DIS D16 RSS R14 RAS RAT RAB R17 pag pisse d a fee O o i PAT Ice e Le NEI EA A nre ana Daf 00800 A ee IC a C20 R96 R95 ae O Ocag one t a a Es ale LE z gt 900 RS0 REF R20 OOOd Rog _ C22 a t Rome RT et O ICS C23 T3 A R24 O ICS x FIR g 533 eee er O O cr O R74 104 2011 O ce Roz O bes Cig Re CA17 O R75 0 O O O a UNION Apparatebau AE Hi a fs Karlsruhe CW2000E4intern 07 Fig 10 1 Input output card E A internal showing module plug
3. N N 6 2 1 4 setulae 6 2 1 3 3 Automatic Export CSV lb file 6 2 1 2 4 6 2 1 3 4 ra Hold signal pas on off 62125 6 2135 Store basic 621374 calibration 6 2 1 2 6 6 2 1 3 6 Calib limits Oreste Language o N N 621373 Password Color Settings ELE 621375 Hardware 1 Fig 6 2 Menu diagram User Manual CWD2005 Plus Software The info field is in the top right corner lt shows actual information Additionally actual measuring data are indicated according to the actual menu Different information is available in every individual screen All of these will be described in the manual V 1 02 Process 25 05 2009 10 11 06 Methan 109 93 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 97 mbar int press 16 89 mbar mV 23 89 V 1 107 3 11 33 72 19 40 p 4 00 Fr 66 38 Stab 11 870 kWh m3 0 180 Trend Eventlist E ice nfo Y 1 02 Process 29 05 2009 16 11 66 Methan 199 93 Vola my 23 819 V 1 167 T1 33 72 18 46 p 4 66 Fr 66 38 Stab 11 876 Fig 6 3 Info field V 1 02 is the version number of the CWD2005 Plus software The analyzer runs on process gas During calibration it switches to calibration Actual date and time Methane volume percentage is 109 93 23 89 mV is the signal from the thermopile 1 107 Volt is the signal from specific gravity cell 11 33 72 18 40 input air temperature
4. shelter temperature Heating and or cooling can be provided depending on the ambient conditions Cooling is always possible with compressed air air conditioning unit or even water Analyzer Overview User Manual CWD2005 Plus User Manual CWD2005 Plus 4 Installation 59 5 inch 7 m F 151 73 2 inch 59 mm 6 inch 660 mm ULI ELFE E ES ES A es inch 20 mm m Lo il ail 02 HHHH 40 2 Fig 4 1 Enclosure attachment Exhaust B 1 discharge CWD2005 Plus 2 3 flexible aluminum duct hose 4 30 hose clamp fastening strip Installation Installation User Manual CWD2005 Plus The analyzer is intended to be mounted on the wall 2 special fastening strips supplied from the manufacturer They are equipped with 8 mm pins attached to the wall On the back of the analyzer there are holes in the struts affixed according to figure A distance of 840mm must be available between the mounting strips see Figure 4 2 to meet exactly the holes vertical distance on the back of the analyzer 660 4x 8 5 840 ir ir Fig 4 2 Mounting the analyzer The unit can also be installed on a freestanding rack and a stainless steel support bracket is available which must be ordered separately UN 31 User Manual CWD2005 Plus Installation 4 1 Exhaust gas
5. CWD2005 Plus power consumption is as follows 230 Volt 50 60 Hz 250 VA 115 110 Volt 50 60 Hz 250 VA The analyzer is supplied for operation at 230 or 115 Volts Conversion to another voltage by the user requires the following items to convert from 230 to 115 Volts The ignition transformer and a switching relay must be exchanged for more suitable voltage 3 5 Measurement range Measurement range 8 4 13 1 kWh m or 30 2 47 2 MJ ms SUN 27 User Manual CWD2005 Plus Analyzer Overview 3 6 Ambient temperature limits The CWD2005 Plus should be installed in a room that does not exceed minimum and maximum temperature requirements A typical temperature range is 10 C to 38 C 50 F to 100 Higher 100 or more or lower temperatures will require cooling or heating Maximum and minimum ambient temperatures must be specified so that the installation location can be modified if required Slow temperature fluctuations are fully compensated by the analyzer Very rapid temperature fluctuations should be avoided since the compensation is always reactive not pro active The analyzer is able to compensate for rapid fluctuations after a specific time 2 to 3 minutes and steady state conditions return An outdoor shelter with climate control can also be supplied as an optional extra The CWD2005 Plus can be equipped with an optional onboard temperature controller for better temperature control of the whole system environmental temperature
6. UAT ETE CONT AN a um E o A I u o um gt a u n A I E o um gt A o A I E um n x A I Fig 6 34 Configuration menu second layer 64 Software User Manual CWD2005 Plus INIA HA HA HLIVA DARAN IAE MI CNET n gt Option gt Service gt Config Fig 6 35 Configuration menu third layer 6 2 1 4 2 Service Service button will change the display of the analyzer into service mode Some variables which are needed for troubleshooting or service will be displayed on the monitor gt Main gt Option gt Service Fig 6 36 Service mode 6 2 1 4 3 Database Configuration CWD2005 Plus has a database system for measured values calibration as well as recorded events The setting of the database system can be accessed in database menu User Manual CWD2005 Plus Software gt Main gt Option gt Service gt Database Configuration Fig 6 37 Database configuration This menu shows dates and times when these data are being recorded in the system and when these data are exported to USB stick Measured values are recorded according to selectable status All means measured values are recorded non stop on every event Process means measured values are recorded during process event w o Stop means measured values are recorded on every event except stop event DB off database off means measured values will not be recorded in the database On the menu only th
7. will run the cooling air fan continuously and the unit is ready for immediate use after a restart Time delay power down display determines the time before entering the screen saver mode after a period of keypad inactivity V 1 02 Process 25 05 2009 10 14 38 Methan 105 37 VolZ dp air 4 900 mbar W I 5 dp wobbe 3 95 mbar int press 16 78 mbar ALO C V s 0 821844 11 666 ME TE o Fr 66 45 Stab 4 504 General settings Change signals after hold in sec Purge time after fan or instr start up Time delay power doun display Display speed Carrier gas Cal cycles in min delay operation ADC calibration cycle Calibration valve delay in internal pressure mbar pu gt a ain N 0909 09 9 09 0 099 Warning level internal pressure mbar gt Main gt Option gt System gt General settings gt Fig 6 19 General settings Software User Manual CWD2005 Plus Display speed is the constant response speed time This value is preset at the factory and varies from gas family to gas family and measuring ranges Carrier gas Cal cycles determines the carrier gas calibration cycle in minutes Calibration valve delay is the delay of valve opening when entering the calibration cycle Min internal pressure is the minimum pressure of the gas Any pressure above this value produce an error message gas pressure in the info field
8. 3 status ignition break 4 status disturbance 5 status over temperature 6 status calibration measurement range 1 7 status calibration measurement range 2 8 status calibration measurement range 3 9 status service Service needed changing filter For the Anybus Communicator there is a separate manual available 90 Circuit diagrams User Manual CWD2005 Plus User Manual CWD2005 Plus Appendix 11 Appendix 11 1 Spare parts list A list of recommended spare parts for 1 year and 2 3 years operation can be found in chapter 7 in the section consumables If any unusual conditions are inspected at the job site the factory can offer advice so that specially selected spare parts packs can be provided Note In certain countries hardware parts and screws that are commonly available in Europe can be difficult to obtain so a small stock of these parts is available 11 2 Pressure regulators Stable measurement requires very stable pressure regulation and several pressure regulators for process and calibration gases are approved for use by the factory When operating pressures exceeding 6 bar 90 PSIG a 2 stage pressure regulator must always be used 11 3 Low sample pressure A process gas pump is required if the pressure cannot reach 30 mbar 12 H20 60 mbar 24 H20 for low calorific gases The pump should be suitable for the volume gas type and area code requirements and gas consumption see Chapter 3 or detail
9. 636 u gt Main gt Trend Fig 6 44 Move cursor The selection of the three info windows is done with the button and e The arrow and return keypad are used to choose the different variables Every touch of the arrows scrolls to the next variable Cal Vi 2 Wobbe 2 free Spec grav 2 Cal Vs 2 Cal Vi Wobbe Wobbe s Spec grav Cal Vs T sec T ein dl Tamb TI T Res 3 p air p Wobbe p density p res 3 mV All three info windows are prepared for all physical values and can be displayed in the diagram 6 2 3 Event list The event list stores all events that are important and helpful for operating and servicing the CWD2005 Plus The buttons Show start up and Show calibration select these specific events The button Show all displays all events The buttons Previous and Next scroll the screen up and down Status calibration gives deviation from the last calibration in with date and time 70 UN Software 6 2 4 User Manual CWD2005 Plus V 1 02 Process 25 05 2009 10 19 43 Methan 195 42 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 94 mbar int press 16 75 mbar mV 26 26 V 1 108 T11 33 93 17 73 p 4 00 Fr 66 27 Stab 0 010 25 05 2009 10 09 28 Status operation 25 05 2009 10 09 20 Status ignition 25 05 2009 09 57 38 Basic calibration 25 05 2009 09 55 07 Stop status 25 05 2009 09 53 07 Status ignition 25 05 2009 09 53 01 Start up
10. E Value linear down 29 y axis Ak Value linear pressed 25 y axis vi Value linear stretched 25 y axis Now the inferior wobbe index W l i window is selected The following three lines are important to have a good most significant graph of the variable Dif y delta from line to line 0 180 Off y Position of the offset 12 627 value actual value 13 177 6 2 2 3 Change Signals The handling of the menu change signals is the same as before described V 1 02 Process 25 05 2009 10 19 24 Methan 195 42 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 94 mbar int press 16 75 mbar mV 26 29 V 1 197 T1 33 92 17 76 p 4 00 Fr 66 46 Stab 0 010 kWh m 0 180 D EE Se fiele N o u Fig 6 42 Change signals 6 2 2 4 Change units The handling of the menu change signals is the same as described before F 5 V 1 92 Process di Gabbe 4 93 aber 25 05 2009 10 19 28 int press 16 75 mbar Methan 105 42 VolZ mV 26 30 V 1 107 11 33 92 17 76 p 4 00 Fr 66 42 Stab 0 010 q eee Ee ee ee eS DE E S T EE gt Se ee ee N u Fig 6 43 Change units User Manual CWD2005 Plus Software 6 2 2 5 Move cursor E V 1 92 Process dp air 4 900 mbar W I 5 25 05 2009 10 19 32 intime zo 16 80 mbar 14 639 un Methan 105 43 VolZ mV 26 26 V 1 107 11 33 92 17 76 p 4 00 Fr 66 46 Stab 0 010 ESS RE a rr ri Ge el a zi kWh m3 0 180 0 010 0 620 0
11. Under this number the system creates PCX file in the format str 0000 pcx for entering new signs also Chinese 6 2 1 3 5 2 9 New dictionary If a new language is introduced or the existing language is corrected one can upload a new dictionary file to the system 6 2 1 3 5 2 10 Change drive dp air 4 00 mbar W I s dp wobbe 3 94 mbar int press 16 76 mbar V 1 02 Process 25 05 2009 10 15 35 Methan 105 37 VolZ mV 25 78 V 1 107 T1 33 82 17 74 p 4 00 Fr 66 45 Stab 0 439 0 8218 4 Change USB device USB FlashDisk gt Main gt Option gt System gt Settings gt Language gt Change USB device 9 O O Fig 6 27 Change drive The USB port is also available for a floppy disc The switch can be made here User Manual CWD2005 Plus Software 6 2 1 3 5 3 Password gt Main gt Option gt System gt Settings gt Password Fig 6 28 Password A password can be selected if required by the user If selected no system changes can be made without entering the password When unlocked system access is denied after 30 seconds and then will ask for the password Entering 0 switches the password system off A default is available if the password is lost 6 2 1 3 5 4 Color settings gt Main gt Option gt System gt Settings gt Color settings Fig 6 29 Color settings 6 2 1 3 5 5 Hardware 1 This menu contains data parameters for dual range and carrier gas options The amount of dual
12. Warning level internal pressure is the maximum pressure of the gas Any pressure above this value produce an error message gas pressure in the info field 6 2 1 3 2 Ignition Ignition type can be single ignition or repeat ignition The ignition cycle is always the same as the ignition duration The longest ignition duration is 100 seconds Normally an ignition cycle should last between 15 and 20 seconds When the ignition threshold is reached ignition ceases The ignition threshold is the degree count that the thermopile recognizes the flame is burning Flame temperature depends on gas composition The factory will pre set the optimum temperature for the specified measuring range In the example 3 C is the differential temperature of the incoming cooling air flue gas mix at the thermopile T V 1 92 Process ae aire 5 age mbar W L 5 25 05 2009 10 14 47 int press 16 78 mbar 14 632 SI Methan 105 37 VolZ 5 KYWYhimv 25 53 V 1 107 7 1 1 666 3 T1 33 80 17 72 p 4 00 m Fr 66 20 Stab 2 339 Configuration ignition Ignition time sec Ignition threshold deg C gt Main gt Option gt System gt Configuration ignition Fig 6 20 Ignition 6 2 1 3 3 Export CSV file In this menu all data are exported as ASCI files All 25 available data are exported in one session in a CSV file Excel can handle this file 6 2 1 3 4 Hold signal on off The button switches all signals 4 20 mA during the m
13. combination with threshold values or operating status messages If an alarm is triggered a message will appear in the information field and the fault LED on the door will light Example The wobbe signal in MJ m has an alarm point at 47 000 and 50 000 MJ m The zero position is high The relays that are described below switched according to the following conditions Process the solenoid valve for process gas opens and the flame burned Calibration the solenoid valve for calibration gas opens and the flame Maintenance change filter air filter the frequency of the fan speed controller gt 48 Hz or the temperature of inlet air gt 41 C Change filter change filter air filter if the frequency of the fan speed controller gt 48 Hz Fault the air filter is very dirty The air differential pressure is lt 3 5 mbar Operation the flame burned Operation delayed the flame burned and the delay time ran off Over temperature the flame is too hot The wobbe signal is larger than 76 mV that means the temperature increasing in the intern tube of the thermopile larger than 50 C Calibration deviation after calibration one can put an alarm when the calibration process gives a deviation at certain range compare to the basic calibration that has been saved before Error int pressure An alarm is released with lack of process or calibration gas 6 2 1 1 3 mA Display This menu displays the mA output of ea
14. eds 52 FIG 9 16 Calibrator IME sassen aa ei a 53 LE OA O A cater ai nabla ri dial acetal ei anaes T 53 Fig 6 18 System menu second layer 54 FIG 6 19 General seltingsi Lila 54 Fig 6 20 ONIVO cepere pE a ae a a aa ae ETER har 55 719 6 21 Settings ariana 56 Rig 0 22 Dale ana UME ili 56 FIG 6 23 Language MENU Tirst layer iii 57 Fig 6 24 Language menu second layer VV 57 Fig 6 25 Language menu third layer 58 Fid 6 26 Chande languag Gumice 58 FIGs 6 27 Ghange OVE ice ee ten ee 59 FOLO ZF ASS dello 60 FiG 0 29 Colofrselingsa iaia apici 60 AM lag ul lle lille dini DENE 61 FOSG DA ASS aa ee lee CL 62 Fig 6 392 SEINO PR ais ie RARA 63 Figi 6 93 Contiguration menu tirs taverne eee iat o e 64 Fig 6 34 Configuration menu second layer nenn nnene nennen 64 Fig 6 35 Configuration menu third layer nenn enennennnnnn 65 FI 0 90 Service Mode niro 65 SUN 9 User Manual CWD2005 Plus Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 10 6 37 Database configuration iii 66 6 38 Status option in Database 66 6 39 Trend Change time sans dei 67 640 Change UM Osinon oaa 68 64l Cnange v Valesi 68 6 42 Change signal S ereraa a 69 643 ON SR a A 69 6AA MOVE CUSO desig een 70 A A A N 71 5 40 DCVIC NOR e an ee on do nie 71 9 1 CWD2005 Plus scheme e iii od 76 9 2 Func
15. hand side Carrier gas SV X11 3 4 Calibration gas SV X14 1 2 Calibration gas 2 SV X14 3 4 Process gas SV X11 1 2 1 M20 Cable gland signals 2 M25 Cable gland power 3 M20 Cable gland signals 4 M16 M20 Cable gland signals 5 M20 Cable gland signals 6 USB port 7 Interface connections 8 Fast loop 9 0 1 2 4 4 The above drawing shows a standard analyzer or analyzers equipped with one or two calibration gases or carrier gas Analyzers with the option of two process gases have a different inlet arrangement and this will be labeled on the analyzer The items marked with a are available as an option at the time of order and are not supplied as standard Analyzer Overview User Manual CWD2005 Plus 3 1 Dimensions weights 720mm 28 3 inch 38mm 13 3 inch WwW N o E E o N ce 320 mm 12 6 inch Fig 3 5 Enclosure dimensions Height 1020 mm 40 2 inches Width 720 mm 28 3 inches Depth 337 mm 13 3 inches Weight 50 5 kg 111 lbs Protection IP44 NEMA 12 The analyzer is supplied for wall mounting Brackets are included Gas connections are located on the left hand side of the unit Allow enough space for the doors to swing open and other accessibility issues when mounting the unit User Manual CWD2005 Plus Analyzer Overview 3 2 Gas connections Gyrolok tube 6 mm gas connections are located on the left hand side of the unit Process and calibration gases should be conne
16. heat exchanger solenoid valve 11 1 thermopile 1x24 TE 1 1 sensor differential pressure gas h ignition electrode 13 1 ignition transformer O 1 2 1 4 1 6 1 15 1 sensor differential pressure air sensor pre pressure gas This spare parts package serves as a source of local stock If components in the unit fail that are not contained in the spare parts pack they can be ordered from the factory by stating the 5 digits of serial number list on the data plate Without this number the spare part type or version cannot be accurately determined All the serial numbers are registered in a database together with all calibration data and settings that where established before delivery from the factory SUN 73 User Manual CWD2005 Plus Troubleshooting 8 Troubleshooting Troubleshooting section is broken down into various topics such as unstable readings drift in readings and incomplete ignition The following list describes typical faults and corrective actions This list will be updated in the future as the need arises 8 1 Event list The software maintains an event list that records up to 1000 events in order of occurrence with date and time If more than 1000 events have occurred the log will start to overwrite and the oldest event will be erased The list of more than 1000 events can be found in the database Events include Start Stop Ignition Calibration Low cooling airflow Flame out etc
17. number PT100 temperature sensors and the result is included in a calculation which ensures the wobbe index value is linear In addition the response time of the system can be considerably reduced by the use of a proximity equation and end point forecasting The output signal is not yet the calorific value but is proportional to wobbe index since the specific gravity of the gas is taken into account in this measurement For this reason the specific gravity 20 of the sample gas is measured and calculated with the wobbe index to get calorific values Three output signals are generated 1 Wobbe index as a real time measurement 2 Specific gravity as a real time measurement 3 Calorific value as a real time product of the above measurements User Manual CWD2005 Plus Measurement principle 9 2 Specific gravity measuring cell The CWD2005 Plus is equipped with a specific gravity measurement cell which is mounted in the enclosure The specific gravity cell determines the specific gravity of the process gas in a specially designed sample chamber using presence of a modulated acoustical field 9 2 1 Operational overview The process gas flows through the measuring chamber of the measuring cell The oscillations of a transmitter membrane with a constant amplitude and frequency are transferred to a pressure transducer by the gas The amplitude of the signals on the pressure transducer is directly proportional to the density of the process ga
18. on the operational period Consideration should also be given to the country of use and conditions at the site where the analyzer will be used Following careful evaluation the spare parts package can be adapted as necessary The packages shown below contain a sufficient range of parts based on normal operating experience The one year package contains consumables and spare parts for 1 year of normal operation Process criticality installation location and country of use should be taken into consideration to determine what spare parts should always be available locally Spare parts list for one Year operation 2 fuse to power supply 2m EMV door gasket 2 m rubber tube NBR 4x2 mm 1 ignition electrode 1 1 blower power supply 2 3 10 quartz burners jets 4 5 2 paper filters 6 7 1 diaphragm gas pressure regulator 8 The 2 3 years operation package contains the same parts as a 1 year operation package but with an extended supply of consumables as well as electrical and electronic components Based on experience these can fail first in corrosive environments or under other severe operating conditions Spare parts list for 2 3 years operation 2 fuse to power supply 2 m EMV door gasket 2 m rubber tube NBR 4x2 mm 1 heat exchanger 1 1 blower power supply 2 10 quartz burner jets 4 paper filters 6 gt gt A A diaphragm gas pressure regulator 3 9 2 7 1 9 1 gasket for
19. positions Note This card requires no customer connection D1 to D16 are status LEDs Plug X10 Pin 1 24V VI Thermal switch Pin 2 24 V VIS Thermal switch Plug x14 Pin 1 GND Solenoid valve calibration gas Pin 2 24V Solenoid valve calibration gas Pin 3 GND Solenoid valve calibration gas II Pin 4 24V Solenoid valve calibration gas II 82 UN Circuit diagrams Plug x11 Pin 1 Pin 2 Pin 3 Pin 4 Plug x 9 Pin 1 Pin 4 Plug x 8 Pin 1 Pin 4 Plug x15 Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin 10 Pin 11 Pin 12 Plug x 16 Pin Pin Pin Pin Plug x 17 Pin Pin Pin Pin 0 Y O 0420nNn RS D pb D Plug x 2 Pin Pin Pin Pin Pin Pin DIS D Plug x 3 Pin 1 Pin 2 Pin 3 Pin 4 Pin6 Plug x 7 Pin Pin Pin Pin POD Plug x 1 Pin Pin Pin Pin Pin Pin OO O1 D Plug x 4 Pin 1 Pin 2 SUN GND 24V GND 24V N C N C PE GND 15 V DI 15V PE PT1 TOB PT1 TOB PE PT2 TL1 PT2 TL1 PE PT6 PT6 PE Signal door closed Signal door closed PT3 PT3 PE PT4 PT4 PE P1T5 T IPT5 T User Manual CWD2005 Plus Solenoid valve process gas Solenoid valve process gas Solenoid valve carrier gas Solenoid valve carrier gas NC S G cell supply S G cell supply S G cell signal S G cell signal S G cell supply N C N C N C N C Wobbe Signal 30 mV Wobbe Signal Solenoid valve gas upper side fro
20. range overlap can be selected Burner time constant wobbe jet and range configuration are specific to the burner type range and configuration These parameters are application specific and it is strongly recommended that changes in this table should not be made without consultation with the factory The data values have been tested at the factory to 60 SUN Software User Manual CWD2005 Plus match the process gas if the customer decides to change ranges or carrier gas type contact the factory for new data V 1 02 Process 25 05 2009 10 16 13 Methan 105 40 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 94 mbar int press 16 77 mbar mV 25 83 V 1 107 3 T1 33 84 17 72 p 4 00 Fr 66 54 Stab 0 288 KI n3 gt Main gt Option gt System gt Settings gt Configuration hardware 1 Fig 6 30 Hardware 1 The previous screen shot shows all inputs for different ranges and carrier gases Range No the number of ranges installed Maximum number is three Diam Wjet The wobbe Jet diameter in mm Range Cfg Code binary for measuring status during a range change 1 Range not selected or displayed 1 Wobbe jet set 2 or jet set 1 2 Combustion air jet on or off 4 Carrier gas combustible gas on or off 8 Carrier gas non combustible gas on or off 16 Carrier gas combustible or non combustible gas on or off The number 6 means range with jet combination 1 combustible carrier gas with an air jet The number 2 means j
21. should be removed and cleaned Combustion by products can form crystals and these can be washed away with warm water After these parts have been thoroughly dried they can be re installed Note The heat exchanger is mounted on a gasket that remains in place The gasket should always be inspected visually and replaced if necessary whenever the heat exchanger is removed Calibration which usually lasts 5 to 10 minutes uses 5 to 10 liters of calibration gas see formula in section 3 3 It is possible to estimate how long the remaining calibration gas will last if the calibration cycle is programmed at set intervals 7 3 Consumables Consumables include paper filters fuses connection hoses and calibration gas All the consumables considered essential by the factory are contained in the optional spare parts package for normal annual operation Calibration gas should be purchased by the customer in cylinders from a local supplier If possible it can also be purchased from the manufacturer with all necessary fittings Note International and Federal regulations prohibit air transport of compressed gases Maintenance User Manual CWD2005 Plus 7 4 Replacement of I O boards If a replacement board E A internal or E A external becomes necessary a new configuration of software is required delivered with the new board and its configuration files 7 5 Spare parts packages A number of different spare parts packages are available depending
22. technical dimensions Connections Conductor cross section solid 0 14 mm 1 5 mm Conductor cross section stranded 0 14 mm 1 5 mm Stripping length 7 mm 84 Circuit diagrams User Manual CWD2005 Plus 10 2 1 Input Output card E A extern Typ_06 R u R sr IC18 va CELOS Ba gizina sinim R94 R98 R103 14 14 JP 10 JRE HR ccoo ED v 0 v O i co SON YL EUMS SE Mi x84 x6 1 E SOIL 3 gt o xa 1 n N R11 R10 RO Re MER Te HH ra HE rs u N x10 1 7 N n 4 ue R116 R110 R89 R109 R112 TERERECE 00000000 8 060860600000 x12 4 le es ala 7 R73 R111 tr R74 A od 0 6 0 6 OC Od O Fig 10 2 Input output E A extern Typ_06 Terminal blocks X3 X5 X11 and X14 are customer connections for contact inputs relay outputs analog outputs and RS 232 and have removable plugs for wiring D1 to D25 are status LEDs 10 2 1 1 Relay outputs The relay outputs are connected to terminal block X14 The relay contacts have the following specifications maximum current 1 A max 100 Volt 100V DC 30Watt 100V AC 60VA If the relay is operational a red alarm LED is illuminated The functional position for the relay outputs can be user configured from the menu and the standard factory configuration is shown below Block X14 on I O Card EA External type_06 SUN 85 User Manual CWD2005 Plus Position Therminal X14 Function Pin 1 1 Commo
23. the CWD2005 Plus is started Important only the calibration gases subscribed by the factory may be used Other gas compositions will result in an incorrect calibration of the analyzer Gas inlet and gas outlet to the module may be inverted There is no flow direction dictated Fig 11 6 CO Module installed in the CWD2005 Plus 1 CO Measuring cuvette 3 Gas inlet 2 CO Module 4 Gas outlet SUN 97 User Manual CWD2005 Plus Appendix 11 7 3 Housing for outdoor installation The CWD2005 Plus has the type of protection IP54 and is not suitable for an outdoor installation lf no analysis room is available or if the analyzer is to be brought as closely as possible to the process gas line housing is necessary for outdoor installation A heating or cooling system is necessary to compensate a large variation of ambient temperature in the place It is important that the temperature inside the housing should be kept as uniform as possible Each kind of housing can be ordered together with the CWD2005 Plus calorimeter
24. 0 UN Software User Manual CWD2005 Plus A small software program excel file can be obtained from the factory which can also be downloaded from the internet homepage Also the memory stick which is delivered with the analyzer contains this program This includes most of the gases found in many common process gas streams and this utility will help any necessary calculations From literature we know that the value of the variables are taken corresponds to whether the gas is dry or humid as well as the reference temperature that could be 0 C or 15 C The manufacturer always takes as a reference 0 C and 1013 mbar dry gas 6 2 1 2 2 Automatic Calibration Day is a list field Sun Mon Tue etc Time and Cycle are value fields Example Program 1 calibration Monday at 15 00 hour Program 2 calibration every second workday at 12 00 hour Program 3 calibration every day at 23 00 hour The duration of calibration is adaptive and automatically defined by the software The analyzer will look for end point stability and this is normally achieved in 6 to 10 minutes depending on the gas type After a short period of operation about 5 minutes at a value below the programmed stability number the analyzer then automatically switches back to the process gas If the required stability is not achieved the calibration cycle will be aborted after a selected period usually 10 minutes A failed calibration will be recorded in the event list and may indi
25. 1 Adjust pressure regulator The pressure regulator 6 is adjustable by the user and a small adjustment may be necessary on the regulator to allow the small specific gravity differential pressure regulator to operate within its correct input range This facilitates any adjustment to differential pressure as this controls the specific gravity sensor response speed 11 5 2 Adjust pressure regulator Connect the calibration gas using a high pressure dual stage gas regulator with high pressure flexible metal hose and quick connections a regulator for low pressure output 18 mbar and a pressure gauge range 0 25 H2O 0 60 mbar The gauge in front of the CWD2005 Plus is necessary to show inlet pressure level Calibration gas is clean and a filter is not necessary User Manual CWD2005 Plus Appendix w dA A NA C A CI 6 N KA NJ Ky Ay ES AA Ween TES FRE Fig 11 2 Calibration gas supply 1 Calibration gas cylinder 2 Two stage pressure regulator 3 Flexible metal braided gas hose 4 Pre regulator 6 bar to 18 mbar 5 Pressure gauge 0 60 mbar 6 CWD2005 Plus 11 5 3 Process gas connection An inline filter is required at the process gas connection LPG gas or Natural gas is clean and a small filter can be used as protection against particles see section 4 5 1 The use of a pressure gauge 0 25 H2O 0 60 mbar is recommended between the pre regulator and the input of the CWD2005 Plus Steel industry
26. 25 05 2009 09 35 54 Stop status 25 05 2009 09 33 54 Status ignition 20 05 2009 17 08 23 Status operation 20 05 2009 17 08 22 Status ignition 20 05 2009 14 06 08 Status operation 20 05 2009 14 06 07 Basic calibr deviation density gas 1 20 05 2009 14 06 07 Calibration deviation density gas 1 20 05 2009 14 06 07 Basic calibr deviation wobbe gas 1 20 05 2009 14 06 06 Calibr deviation gas 1 20 05 2009 13 50 03 Status calibration gas 1 20 05 2009 12 19 10 Status operation 20 05 2009 12 19 09 Basic calibr deviation density gas 1 20 05 2009 12 19 08 Calibration deviation density gas 1 Show Show start up calibration Fig 6 45 Eventlist Device info CWD2005 Ger tedaten Typ CUDZ005 C UN CE Gasart cdyas Distributor Tr gergas Union a 99803 UNION Instruments GmbH Zeppelinstr 42 Messbereiche 76185 Karlsruhe GERMANY 49 0 721 95243 0 gt 49 0 721 95243 33 Email info union instruments com Wobbe Dichte Ausstattung Diisen MB1 Wobbe 0 55 Wobbe Luft 0 80 Luft Brenner OZ401199952 Tr gergas Zusatzoption keine Optionen installiert Letzte max Kalibrier Abweichung 20 05 2009 14 06 07 0 07 Z Analogausgange C V 5 4 20mA kWh m3 8 400 13 100 S G 4 20mA kg m3 0 500 1 000 W I 5 4 20mA kWh m3 8 000 14 000 Bitte Taste dr cken um zum Men zur ckzukehren Fig 6 46 Device info This Info Menu shows all important data of each analyzer In case of questi
27. 8 at 0 1 u 6 Filter cap 7 Filter housing SS 316nn 23 cm 1 4 ft 4 5 2 Pressure regulators Good pressure regulation is very important for measurement stability Four different pressure regulators for different applications and markets are recommended as options and short description is provided for each regulator in the following section The outlet pressures range between 20 mbar and 55 mbar 10 24 H20 depending on type Gas pressure higher than 6 bars 90 PSI needs a primary regulator to reduce the pressure to the inlet of the pre pressure regulator The standard analyzer consists of one process gas inlet and one calibration gas inlet and both inlet ports require a pre pressure regulator All connectors are mm or inch Adjust the process gas and calibration gas regulator outlet pressures to read the same pressure when gases are switched this is important for measurement stability The first pre pressure regulator lt 6 bar 90 PSI has a die cast zinc housing and internal parts are made of steel and die cast zinc 34 UN Installation User Manual CWD2005 Plus Two control springs are available 12 25 mbar 10 H20 orange and 30 mbar 20 H20 blue ha NE IN N7ZZIZZ ON 4 NN N RK tg 1 gt AL E E On MD bat Matra 155 mm 6 1 inch Fig 4 6 Fisher 912 pre pressure regulator lt 6 bars 90 PSI 1 Inlet 6 mm Gyrolok 2 Outlet 6 mm Gyrolok 3 Control spring 4 Ventilation valv
28. Change language The analyzer has German and English language display Other languages can be included relatively easily A TXT file is available for translation by a customer from one language English into another and requires about 800 words gt Main gt Option gt System gt Settings gt Language gt Change language Fig 6 26 Change language 6 2 1 3 5 2 2 Bit Maps on off This button switches bit maps on or off For example a complete set of Chinese files can be activated for correction or for completing the language file 6 2 1 3 5 2 3 Transfer W E gt C This key starts the copy of the dictionary language files from the memory stick D to the hard disk C of the unit 58 SUN Software User Manual CWD2005 Plus 6 2 1 3 5 2 4 Transfer W C gt E This button starts copying the complete dictionary in English and German language Standard from hard disk to the memory stick Correction can be made and reloaded to the disc of the analyzer 6 2 1 3 5 2 5 Read PCX Files This key starts a copy of PCX files bit map from the memory stick to the hard disk of the unit 6 2 1 3 5 2 6 Store PCX Files This key starts the copy from the hard disk of the unit of PCX files bit maps to the memory stick 6 2 1 3 5 2 7 Delete PCX Files This key deletes all PCX files bit maps on the hard disk C of the unit 6 2 1 3 5 2 8 PCX Info PCX info writes a txt file Every word has a number to identify the expression
29. ERP ANALES COA COONS Sone nlm Fig 6 17 System This menu item contains the following basic analyzer configuration parameters for example Ignition date time language key password and so on Two pages open the different items of the menu The button swiches from one page to the other page on the same layer User Manual CWD2005 Plus Software V 1 02 Process 25 05 2009 10 14 25 Methan 105 39 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 95 mbar int press 16 77 mbar S G q V 25 50 V 1 107 O 8218 kg T1 33 79 17 70 p 4 00 m Fr 66 26 Stab 6 765 E e e e i kWh m3 Dif y 0 180 u gt Main gt Option gt System Lock system gt Settings Database Fig 6 18 System menu second layer 6 2 1 3 1 General The following general configurations are available 54 Change signal after hold provides soft transition to and from the calibration cycle or when switching off the output signal hold module This prevents a sudden rise or fall of the measured value occurring in output signal The transition between values is shown in seconds and this allows the signals to blend together in a smooth transfer Purge time means purge the unit with air from the fan prior to ignition after analyzer s start up The delayed shutdown of the air fan following a system shutdown removes any residual heat from the system The shutdown of the fan saves energy and filter life A value of 0
30. ME CONS Hau see E E ENR 33 4 5 1 Process gas Mer Seneta ad dados 33 4 5 2 Pressure TequlalO a en to 34 4 5 3 sample gaS PUMP il 36 4 5 4 Past LOO CONNECCUON en ee es a ns ae ae 36 nn e o A te 37 9 COMMISSION sitio laa 38 0 SO WAL iaa 40 Bil Screen lavo Ulises 40 6 1 1 Men Keypad sacadas 40 6 1 2 ici E E 41 6 1 3 NU SD ee an ee ci em co 41 6 1 4 o AAA A nn iii 41 6 1 5 NO liceo 41 6 1 6 Sd pci 41 6 1 7 Pi ee 41 6 1 8 BUE WINdOW caia a u 41 6 1 9 StalUlS diS pla Y PRE esse 41 6 1 10 Arrow and data entry keypad nenne nenn anne nenne nenn nano nen nennen 42 A O A Ener Reh 42 A Keypad A O 42 6 1413 WEE NAVIA ION iaia 42 52 Menu alada Mii ci os LAI ao E us See E ol dE o ER etes 43 6 2 1 OOD IONS PPP o e EEEN 44 SUN 7 User Manual CWD2005 Plus 6 2 2 A A A A OPE ee 67 6 2 3 EVE MU IST Es iia ones 70 6 2 4 DEVICE WMO APP A E O ee ne eu telai 71 e Mamnienance ec 72 7 1 Safety instructions for maintenance or repair 72 ke Periodi Maintenance e e ee 72 Koa GOnsuUmMables zu nai 72 7 4 Replacement of I O boardS Re 73 75 Spare Paris Packages anne id 73 Bz Troubleshootihg naro 74 8 1 A lA ee ee re 74 8 2 UNS ADI a0 NG re Reese 74 O reelle 74 SA INGOMPICIS IGRIVON ii rien 74 85 Sollware tro blesho lng zensse I a 75 9 Measurementpinciple aa rer 76 9 1 Wobbe index measurement 76 9 2 Specie Gravity measuring Celia rale ala 78 9 2 1 OperalOnalOVS SW
31. Note A purge system can also be useful for application in very dusty areas A small source of air for combustion is necessary Generally we must ensure that flue gas Is not allowed to accumulate inside the shelter CO H2 and H2S may be present and that any combustion heat is discharged so that the analyzer s thermal stability remains unchanged Any outside vent needs protection from wind to avoid back flow of flue gases into the unit and the possibility of unstable readings The analyzer is equipped with numerous safety features and the ignition can only occur when the door closed In the event of failure of gas or cooling air supply the inlet gas solenoid valve will automatically be closed and after a short time interval the valve will re open and the analyzer will be back in ignition cycle If the ignition cycle or online measurement function is aborted due to flame out or power failure the gas supply valve reverts to its normally closed position and process gas flow is instantly terminated User intervention is then necessary to resolve the problems source Calibration is only possible if a calibration gas cylinder is available and contains the correct certified gas The mixture will normally be similar to the major process gas components with a value around 80 of the analyzer s range CWD2005 Plus gas consumption is between 8 and 200 liters per hour and the quantity will depend on the characteristics of the process gas The use of a gas flow
32. UN USER MANUAL CWD2005 PLUS CALORIMETER Uta E gt o gt mE UNION Combustion Calorimeter For high speed measurement of fuel gases Version V1 01R05 Stand 15 03 2010 User Manual CWD2005 Plus Union Instruments GmbH Zeppelinstrasse 42 76185 Karlsruhe Germany Phone 49 0 721 95243 0 Fax 49 0 721 95243 33 Email info union instruments com WWW http www union instruments com User Manual CWD2005 Plus User Manual CWD2005 Plus User Manual CWD2005 Plus Attention Please read all safety instructions before using the CWD2005 PLUS See Chapter 1 User Manual CWD2005 Plus User Manual CWD2005 Plus Contents Concise 7 li IMPORTARE NOTANO errado 12 2 INTO UCI sa a A ai 16 2 QUPEl Alesi 16 2 2 Available measurement range nenn nenn nenn nenn nenn nenn anne anne nnnn nennen nenne 17 2 3 Response UMO egner id he nn nee 17 24 lt SBECHCANDNS See ee o 18 di AS PA eee eee 20 SH Dimensions We lQMiSssncinaiainn ee 25 AS COMMS CO Saas eet ee eee a ae 26 3 3 Gas Consum Mt ae ol toi ale o eee 26 3 4 Electrical PpOWer SUITE rite alia Ala Aia 27 3 5 M ASUT MENLTANQE sentence A 27 3 6 Ambient temperature limits 0080 n0nnnnnn nenn nenn nennen nenn nnnn nennen nenne 28 4 AA o ee La alare 30 AW EXNaustagas ISO uo A Sia 32 Ae SNOII T requiem o ace 32 4 3 HOM VENIAN cias 32 4 4 Electrical power connectar ia 32 4 5 GaS COM
33. aintenance or similar on or off All signals together are switched on or off SUN 55 User Manual CWD2005 Plus Software 6 2 1 3 5 Settings Settings are all menu buttons which belong to basic configuration and are only seldom or only from time to time used ne wel gt Main gt Option gt System gt Settings Fig 6 21 Settings 6 2 1 3 5 1 Time Date The clock stops when the menu Time Date is open The symbol fe and increase or decrease the selected value The arrow symbol a and gt select the next field left and right On this menu we can set time date of the system Press OK when after the setting or use cancel to exit the menu without making any changes gt Main gt Option gt System gt Settings gt Time and date change Fig 6 22 Date and time Software User Manual CWD2005 Plus 6 2 1 3 5 2 Language The menu language consists of 10 submenus These submenus can be reached using the button El One can update or correct the language by downloading it into a USB memory stick and then again uploading it to the system in gt Option gt System gt Settings gt Language Fig 6 23 Language menu first layer gt Main gt Option gt System gt Settings gt Lang Fig 6 24 Language menu second layer User Manual CWD2005 Plus Software NT TIA AN AL ELE IAH ARENAS O N m gt Settings gt Language Fig 6 25 Language menu third layer 6 2 1 3 5 2 1
34. ample gas inlet The pump must meet the requirements for flow and installation area classification See Chapter 11 for more details 4 5 4 Fast Loop connection For a more rapid response time a fast loop connection can be provided A T piece with a pressure regulator and a flow meter is inserted before the calorimeter and the excess gas sample is piped to a lower pressure location or a vent header The dead time can generally be reduced by a factor 1 5 and this normally depends on the gas type and the pressure ratios in the sample tubing See section 11 6 for more details Installation User Manual CWD2005 Plus 4 6 Interfaces Many of necessary electronic devices can be connected to the CWD2005 Plus The analyzer can be operated using a plug in mouse and a standard PC keyboard with PS2 connector lt has also USB port for transfer database and graphic Fig 4 9 Interface connection on the left hand side of the main door 1 USB port 2 VGA Display 3 Mouse port 4 Keyboard port 5 Parallel port User Manual CWD2005 Plus Commissioning 5 Commissioning When all electrical and gas connections have been completed and tested in accordance with all instructions codes and regulations then the analyzer is ready to be started up The following work must be carried out during initial operation of the analyzer Remove the transport tie wraps and transport screws on the specific gravity cell The body of the cell must hang free on the springs and m
35. ard analyzer will have only one measuring range therefore will require one calibration gas Variation of specific gravity considered as an error to the measurement For a dual or three measuring ranges configuration 1 or 2 calibration gases are required This depends on how far the two measuring ranges overlap If the overlap is large a single calibration gas is usually sufficient This is determined on an application basis during final calibration All analyzers with the carrier gas option calibrate during operation on carrier gas and again using both carrier gas and process gas to establish correct calibration in all modes against calibration gases Dual sample stream analyzers usually use a single calibration gas 6 2 1 2 1 Configuration of calibration gas V 1 02 Process 25 05 2009 10 13 19 Methan 105 57 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 96 mbar int press 16 75 mbar CGI q V 25 21 V 1 107 O 821 8 kg T1 33 77 17 71 p 4 00 m Fr 66 36 Stab 11 801 Configuration of calibration gases 2 eruera 0 00 0 00 Specific 0 000 gt Main gt Option gt Calib gt Configuration of calibration gases Fig 6 13 Configuration of calibration gas Calibration gas data are entered as a wobbe index and specific gravity number If the gas vendor has only supplied the data in percentage then the user must calculate and enter these three calibration gas variables from the components of the calibration gas 5
36. ay not come into contact with the sides of the bracket Screws should be removed and stored see figures below dy GO dd C Fig 5 2 Specific gravity cell shown in its operating position Remove the transport packing from the gas pressure regulator Polystyrene foam is located beneath the removable regulator cover and must be removed before use Check the process and calibration gas connections for tightness and correct connection Check any carrier gas or second calibration gas connection if supplied Switch on the main power switch After a short delay while the analyzer powers up the main screen will illuminate An information field in th
37. calibration Start calibration Closed 7 a open o calibration ow i Calibration starts high closed mA online Hold signal open mA online Low open gt en Abort calibration high d Calibrati ti close alibration continue Calibration abort ae sini open alibration continue Le Abort calibration Configuration example On the connection board E A external the 3 remote digital contact inputs Start measurement Start calibration and Start hold are connected to terminal block number X3 on terminals 1 to 6 See Chapter 10 for wiring details Software User Manual CWD2005 Plus 6 2 1 1 5 Display gt Main gt Option gt I 0 gt Display configuration Fig 6 10 Display Measuring variable and unit are list fields They determine the numerical display on the user configurable display screen 6 2 1 2 Calibration Fig 6 11 Calibration menu first layer The button swiches from one page to the other page User Manual CWD2005 Plus Software V 1 02 Process 25 05 2009 10 13 08 Methan 105 61 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 94 mbar int press 16 78 mbar 5 6 g V 25 15 V 1 107 O 821 T kg 11 33 78 17 74 p 4 00 m Fr 66 44 Stab 12 240 kWh m3 Dif y 0 180 gt Main gt Option gt Calib Store basic Calib calibration limits Fig 6 12 Calibration menu second layer Calibration data are stored as wobbe index and specific gravity values Stand
38. cate a maintenance condition has occurred Warning Air can become trapped in the gas supply tubing during installation Purge the lines before first calibration or after changing the calibration gas cylinder The calibration command may need to be executed 2 3 times after installation of the analyzer for the first time V 1 02 Process 25 05 2009 10 13 32 Methan 105 54 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 95 mbar int press 16 78 mbar mV 25 29 V 1 197 T1 33 77 17 72 p 4 00 Fr 66 34 Stab 11 207 Frogram Day time Evers AA era as A gt Main gt Option gt Calib gt Konfiguration der Autokalibrierung Fig 6 14 Automatic calibration 6 2 1 2 3 Automatic Calibration 2 There are two situations that trigger the automatic calibration difference between actual ambient temperature and the temperature at the last calibration in C and SUN 51 User Manual CWD2005 Plus Software Minutes after starting up the analyzer in minutes dp air 4 00 mbar W I s Du nn dy WERBEN alt KWVhI Methan 105 53 Volz int press 16 79 mbar 3 5 m mV 25 31 V 1 197 11 33 77717 71 p 4 00 Fr 66 50 Stab 10 942 Program 2 Situation 2 Temp change gt Main gt Option gt Calib gt Configuration auto calibration 2 Fig 6 15 Automatic Calibration 2 6 2 1 2 4 Calibrate This menu starts the manual calibration cycle and will override any programmed auto calib
39. ch of the installed output modules in the information display In the screen example the first output is selected using the Display mA key and indicates 20 mA Up to seven outputs can be installed This feature can be helpful for output signal loop tests to remote equipment V 1 92 Process 25 05 2009 10 12 13 m 1 15 34 Methan 105 96 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 95 mbar int press 16 79 mbar mV 24 3 V 1 107 11 33 757 17 77 p 4 00 Fr 66 47 Stab 13 138 gt Main gt Option gt I 0 Fig 6 8 mA Display User Manual CWD2005 Plus Software 6 2 1 1 4 Digital input Signal and zero position are multiple choice list fields These inputs can start a calibration cycle or switch on and off an output hold module The inputs are polled once a second and any change of status must apply for at least one second to be recognized by the system V 1 02 Process 25 05 2009 10 12 30 Methan 105 82 VolZ dp air 4 900 mbar W I 5 dp wobbe 3 96 mbar 14 695 Wh int press 16 78 mbar Civ sS 11 716 N Fr 66 35 Stab 13 042 gt Main gt Option gt 1 0 gt Configuration of contact inputs D O O Fig 6 9 Digital inputs open en CWD2005 Plus measurement un d CWD2005 PI t st close us measurement sto Start measurement CWD2005 Pl E i open us measurement sto u p CWD2005 Plus measurement open Calibration starts high N librati close o
40. cted separately If a very short response time is required a tube with a smaller diameter 1 8 4 mm can also be used Check that the pressure drop is not too large for every gas that we use Input pressure to the analyzer must be between 20 and 40 mbar 12 H20 Lower calorific gases 1000 kcal require a pre pressure of 40 to 60 mbar 24 H20 If input pressure is too low then it should be boosted with a process gas pump A pump is available as an option and can be mounted on a panel with the necessary pressure gauges and pre pressure regulator A filter is needed in the process gas line and can be ordered as an option from the factory or Supplier A small filter will be sufficient when natural gas is used since this gas is normally clean Larger filters are necessary for dirty gases such as blast furnace gas and coke oven gas The volume of the filter will affect the response time and the filter element should have a large active face retention area and a small dead volume If a process gas with high humidity is at a much higher temperature than ambient temperature decreasing in the process gas line due to low ambient temperature can produce condensation of water and this must be avoided The gas has to be dried or a water separator with a drip leg installed at the lowest point of the process gas line The gas rapidly warms up above ambient inside the analyzer so there is no danger of condensation 3 3 Gas consumption Gas consu
41. d is provided with DC power from the ST2 plug Part of the process gas approx 4 5 flows through the measuring cell this small sample is returned to the main gas stream and no gas is vented to the atmosphere 9 2 5 Testing and calibration Specific gravity cell function can be tested using 2 gases The specific gravity of the two gases should differ by more than 0 5 so that the zero and span can be checked If non flammable gases are used such as No Os or air the ignition cycle will time out The purge time can be set to a high value so that the solenoid valve remains open and the gas will flow Restore any program data after testing and crosscheck the results SUN 79 User Manual CWD2005 Plus Measurement principle 9 2 6 Maintenance The specific gravity cell requires no regular maintenance From time to time the pressure drop across the density cell should be checked After installation the sensor housing must be able to move freely on the springs A defective specific gravity cell can be sent in for repair The output for calorific value can be turned off in the software and the unit will now measure wobbe index only 9 2 7 Technical specification gas inlet gas outlet 1 2 O O O O Q 4
42. d side 24 FIG S S ENCIOSUFE DIMENSIONS sail 25 Fig 4 1 Enclosure attachment Exhaust u022400220002n0e nenn nnne nenne nenn nen nenne nenn nnne nennen 30 Fig 4 2 Mounting the analyzer ee 31 Fig 4 3 GOnnector DIOCK assembly suisse a 33 FI9 4 4 Smalltilier sis ude El Hal 34 Fide4 Or Filer WIR GAIN CONMECHON aia a 34 Fig 4 6 Fisher 912 pre pressure regulator lt 6 bars 90 PS1 35 Fig 4 7 High pressure regulator GO PR1 lt 250 bar 3600 PSl nen 35 Fig 4 8 High pressure regulator GO PR1 lt 250 bar 3600 PSl nennen 36 Fig 4 9 Interface connection on the left hand side of the main door nn 37 Fig 5 1 Specific gravity cell shown locked for transport nenne nnnnn nennen 38 Fig 5 2 Specific gravity cell shown in its operating position nn 38 Fig 6 1 Display screen and keypad ss 40 IQs 16 2 MEenugiagrami sa a E A N 43 o E E een nlnreinieinerelense 44 FOs G SNDU OUID UT aaa ee 45 FOO ODIOS are eek eier 45 FOGG ANIO PU ee ee NER ee 46 Fl 0 7 REAY Os 46 SN AA O O O is Saree Re rani 47 AO e e o 48 FIGs A en ne ni e ele 49 FiG 6 11 Galibrati n menu Met layer aan 49 Fig 6 12 Calibration menu second layer VV 50 Fig 6 13 Configuration of calibration gas 50 FO O tA Automate Cali DI AO Nizza pra rta aa aaa ar 51 Fig 6 15 Automatic Calibration Ltrs
43. dida 78 9 2 2 Funcional lag isso dans 79 9 2 3 OUTDULS gNalSs ea 79 9 2 4 NINA opera llon atacara dan ati aia abi 79 9 2 5 Testing and calibration ss 79 9 2 6 VELIERO ARRE Sn eee 80 9 2 7 Technical specification nenn nenn nenn nenn nennen 80 19 GIGUoR dica 82 101 INPUFOUIRUE SArdE EA Mternal ea aan 82 10 2 lt Inpu Quiput Gard E AFEXENI nile 84 10 2 1 Input Output card E A extern Typ_06 nenne nenn nennen 85 lil APOENA earlier 92 lil Sparepalis ISE AAA 92 112 Pressure regulators ii id bid 92 MES LOW SAMPE pressure ii ed er 92 kiA AS Conditio MN e a 92 1 1290 EEEE E ED ee PA AA EE TOR or 93 11 5 1 Adjust pressure regulator T nano nnn nano nnnnnnennnnnne 93 11 5 2 Adjust pressure regulator ss 93 115 3 PROCESS gas C9nnecl f aaa aaa 94 MAA ser 95 1147 AI CONSUMPUON ODOM ee es ce 96 11 7 1 Galculated a1 CONSUMPHION arr aiaa 96 11 7 2 Air consumption with CO measureMEnt nenne nennen 96 11 7 3 Housing for outdoor installation e 98 User Manual CWD2005 Plus Figures RIO OVE VIEW sra ee roda 20 Fig 3 2 CWD2005 Plus components shown above but without doors for clarity 21 Fig 3 3 Rear inside view of main door nenne nenn anne nenne nenn nnnnenennennnennnnenennnnnn 23 Fig 3 4 Enclosure shown from left han
44. discharge The small quantity of flue gas is mixed with 25 m of air after combustion and is heavily diluted with an exhaust temperature around 8 20 C 15 F above ambient Flue gas must be discharged from a flue gas outlet to ensure that the thermal balance is not disrupted This is particularly important with small enclosure or shelter as air inside may become oxygen deficient and stale if the supply of combustion air is too small The very small quantity of sample gas is equal to several pilot lights of domestic stove and poses no health hazard for most process gases such as natural gas etc It is an advantage to generate a slightly higher pressure in the shelter ventilator or fan so that all flue gases are discharged from the outlet This is particularly a case for corrosive gases Corrosive air in the calorimeter enclosure will result in corrosion of the electronic components In some other cases it is advantageous for an enclosure or shelter to be purged with clean dry air All parts of exhaust system are included with the analyzer 4 2 Shelter requirement The calorimeter shelter is subject to special conditions The quality of measurement extremely depends on how well these conditions are met Room temperature changes must be slow If necessary only well controlled air conditioning systems should be used If an electrical heater is used the controller should be programmed very carefully Maximum ambient temperature should not be
45. e The next unit is a primary regulator lt 250 bars 3600 PSI type GO PR1 has a 316 SS housing and gauges The outlet 2 pressure is adjustable from 0 3 4 bar A pre pressure regulator is still necessary and acts as a second stage inlet pressure control for the CWD2005 Plus 115 mm 4 5 inch Fig 4 7 High pressure regulator GO PR1 lt 250 bar 3600 PSI User Manual CWD2005 Plus Installation 1 Inlet 6 mm Gyrolok 2 Outlet 6 mm Gyrolok 3 High pressure gauge 4 Low pressure gauge 5 Pressure control wheel The last is a primary regulator lt 250 bar 3600 PSI with a 316 SS body and gauges adjustable outlet pressure from 0 3 4 bar and has a gas cylinder CGA connection Hydrocarbons W 21 8 x A left DIN 477 Nr 1 or CGA sized fittings Mixed gas M19 x 1 5 LH DIN 477 Nr 14 or CGA sized fittings A pre pressure regulator is still required after the high pressure calibration gas cylinder regulator for two stage inlet pressure control See Fig 11 2 Chapter 11 5 1 Fig 4 8 High pressure regulator GO PR1 lt 250 bar 3600 PSI 1 Inlet connection to gas cylinder 2 Outlet 6 mm Gyrolok 3 High pressure gauge 4 Low pressure gauge 5 Pressure control wheel 4 5 3 Sample gas pump If the process gas inlet pressure is lower than recommended then a process gas pump should be installed to boost the sample gas pressure Gas at higher pressure can then be regulated so that the recommended gas pressure is maintained at the s
46. e multiple identical outputs for a single measured value can also be programmed For example 3 outputs for wobbe index or 2 outputs for specific gravity etc 3 remote contact inputs and 4 numeric screen displays are provided 6 2 1 1 1 Analog output The symbols 0 and O move the highlighted value left or right The symbol 9 leads back to the main menu UN 45 User Manual CWD2005 Plus Software gt Main gt Option gt I 0 gt Configuration of analog outputs Fig 6 6 Analog Output The following items listed below can be selected from a series of the lists Users can define the allocation order of the analog outputs and other data Example wobbe number 1 or 2 or 3 etc Cal V number 3 or 2 or 1 etc Signal is a multiple choice scrolling list field with the following text entries Calorific value wobbe lt wobbe gt specific gravity CV net lt or gross gt Type is a list field with the following entries O 20 mA or 4 20 mA Unit is a list field with the following contents Calorific BTU ft3 kJ m3 MJ m3 KWh m3 kcal m3 kJ Sm3 MJ Sm3 kWh Sm3 kcal Sm3 Specific gravity specific to air 1 0 absolute kg m3 Range from Range to are value fields for numerical inputs 6 2 1 1 2 Relay output gt Main gt Option gt I 0 gt Configuration of relay outputs Fig 6 7 Relay output Software User Manual CWD2005 Plus The relay output configuration menu consists of signals in
47. e last measured value and the last three calibration values will be displayed Fig 6 38 Status option in Database 66 UN Software User Manual CWD2005 Plus 6 2 2 Trend The CWD2005 Plus has a very powerful trend capability that can be plotted on the screen in configurable time scales as well as in different units of measurement including calorific value wobbe index specific gravity and others Different colors identify the three different trends and numbers state the relationship to the data boxes at the right of the screen z a V 1 92 Process ar ir di dealer dl a 25 05 2009 10 18 53 int press 16 75 mbar 14 637 N Methan 105 41 VolZ mV 26 21 V 1 107 11 33 90 17 73 p 4 00 Fr 66 36 Stab 0 012 Ge BE Be BE Be BEE Tee A AAA PP 20 00 h 120 0 m 9 u Fig 6 39 Trend Change time After pressing the button trend in the main menu 5 different menus are available to display all important functions of the analyzer After scrolling the five menus the first menu is again available and so on To handle the parameters there are two possibilities 1 Buttons on the bottom line with different symbols The symbols change with the menu accordingly D 2 cog The arrows and the return on the right site of the display window with the same functions and additional functions After pressing the button Trend the menu enters in the same menu which has been leaving before The following trend men
48. e output mV wobbe index Thermopile fixing screws PT 100 Sensor temperature compensator PT 100 Sensor cooling air inlet temperature 21 User Manual CWD2005 Plus Analyzer Overview 22 Burner enclosure Burner Cooling air orifice measurement Cooling air orifice measurement Ignition electrode Measuring orifice Enclosure purging Ignition transformer Ignition transformer line filter Air fan Power supply for air fan Power supply line filter for air fan Power supply terminal block Signals cable gland Signals cable gland signals cable gland Signals cable gland Line power cable gland signals cable gland Extern electronic output input signal digital and analog Ignition transformer safety switch Burner window Intern electronic analog digital converter solenoid valve control Differential pressure sensor for wobbe jet Cap for wobbe jet Precision pressure regulator Gas pressure sensor Wobbe jet differential pressure for specific gravity cell Gas pre pressure regulator Specific gravity cell Process gas solenoid valve Calibration gas solenoid valve Flue gas outlet pipe Breather pipe 66 GG Analyzer Overview 7 1 Power supply 3 Power supply fan 5 ETX Board 7 Backside Keypad User Manual CWD2005 Plus Fig 3 3 Rear inside view of main door 2 Port for connections 4 Mainboard 6 Blower ETX Board 23 User Manual CWD2005 Plus Analyzer Overview Fig 3 4 Enclosure shown from left
49. e top right hand corner will show status After a short purge period the gas valve will open and the ignition will start automatically Note this is only possible with the door closed as a safety switch inhibits ignition while the door opens Once the flame is lit the door can be opened without creating a flame out condition 38 UN Commissioning User Manual CWD2005 Plus The device will start up and after short warm up period 20 30 minutes during first initial operation from cold will reach the correct process gas calorific value CWD2005 Plus software measuring ranges and any other specified options have been pre configured at the factory see datasheet and memory stick supplied with the unit Following start up the gas pressure indication on the screen will read 4 mbar and the cooling air differential pressure gauge blue will also show 4 mbar If the gas pressure needs adjustment add or subtract weights from the precision weight loaded regulator The air pressure should need no adjustment by the user since it is controlled by variable speed of air fan Check the specific gravity differential pressure indication on the screen reads 4 mbar and adjust if necessary see section 9 2 4 for more details After the warm up period the analyzer will show the calorific value wobbe index and specific gravity numerically in the display and a visual trend will be developed onscreen The menu system is described in Chapter 6 and this describe
50. ed continuously and the temperature rise from heat of combustion is transferred from the burner to the thermopile via the cooling air supply and is measured by its thermopile sensor as heat rise Measurement is based on the real time wobbe index and specific gravity values of the gas a specific gravity sensor is built into the calorimeter The PC based microprocessor calculates calorific value using the following formula Calorific value Wobbelndex Specific Gravity The CWD2005 Plus is a high speed combustion calorimeter and is usually preferred in control applications since it has fast time response direct measurement and simple to maintain online by gas industrial steel and petrochemical companies lt measures the calorific value of the process gas and simultaneous outputs are available for both upper and lower calorific values as well as wobbe index and specific gravity Petrochemical industries often need to measure flare gases with many unknown gas components and need to meet the uptime requirements of tough environmental regulations The CWD2005 Plus combustion calorimeter responds to all unknown components in the process gas and reports them as heating value or wobbe index 2 1 Output values The connection board PCB provides a series of removable terminal strips where the 0 20 or 4 20 mA DC isolated outputs proportional to the measuring range and eight user programmable alarm contacts are available for customer connection In
51. epending on the properties of the gas Gas consumption varies due to difference of specific gravity and flaming temperature SUN 17 User Manual CWD2005 Plus Introduction In addition to the dead time and response time the sample lag time during flow of process gas through the supply tube and fittings in the unit must be added The gas consumption is based on the total sample volume up to the burner In page 24 two formulas show how to calculate the total response time A fast loop is recommended on long sample lines see section 4 5 4 2 4 Specifications 18 Measured Variables Measurement range Accuracy Hs or Wobbe Accuracy specific gravity Linearity Reproducibility 0 point stability Interfaces Analog outputs Digital outputs Digital inputs Process gas dry gas XH20 lt 1 g kg Gas connection pre pressure Gas consumption Air requirement Calibration gas Calibration interval Calibration gas consumption Ambient conditions Temperature condition Temperature fluctuation Electrical supply Dimensions Higher heating value Hs Lower heating value Hi wobbe index specific gravity air requirement 8 4 13 1 kWh m 30 2 47 2 MJ m 1 measurement value 0 5 full scale 0 2 0 1 0 2 per month RS232 9600 Baud 8 Data bit 1 Stop bit Profibus DP DP Anybus Communicator 4 20mA for Hs Hi wobbe and density 8 Relays and 4 open collectors Start Measure
52. er rectifier L _ measurement chamber Offset reference chamber ambient air at a barometric pressure K set point Offset oscillator phase sensitive ressure membrane rectifier active filter Fig 9 2 Functional diagram of the specific gravity measuring cell 9 2 3 Output signals The standard measuring range is 0 2 2 2 specific gravity air 1 0 The output signal for the measuring cell is expressed as Uspecitic graviy O 5 Volt Uspecific gravity V 2 5 X Specific Gravity _ 0 5 In certain cases the measuring range is 0 0 2 0 specific gravity air 1 0 The output signal for the measuring cell is expressed as Uspecitic gravity O 5 Volt Uspecific gravity V 2 5 X Specific Gravity 9 2 4 Initial operation The specific gravity cell is supplied with a transport lock after installation remove the tie wraps The cell is fitted with tension springs that mechanically decouple the system Vibrations in the unit air fan etc cannot be transferred to the specific gravity cell if the cell can move freely The differential pressure across the specific gravity cell is shown on display It should be approximately 4 mbar 0 5 mbar controlled by pressure regulator adjust the regulator if necessary as a low differential pressure will slow response speed If the regulator is out of range see section 11 5 1 for more details The measuring cell is already connected an
53. erminal block X3 All digital control inputs are protected by internal opto isolators If the control input in question is connected a LED will display its status Control inputs can be user configured from the operating menu and the example shown below is the standard configuration as delivered from the factory Signal Terminal X3 Function Alarm LED Pin Control input 1 1 Start measurement D 25 2 Start measurement 2 3 Start calibration D 24 4 Start calibration 3 5 Hold input signal D 23 6 Hold input signal 4 7 not connected D 22 8 not connected 5 9 not connected D 21 10 not connected 6 11 not connected D 20 12 not connected 7 13 not connected D 19 14 not connected 8 15 not connected D 18 16 not connected Control input Open Collector 300 mA 9 17 Collector D 14 18 Emitter 10 19 Collector D15 Emitter 11 21 Collector D 16 22 Emitter 12 23 Collector D17 24 Emitter 10 2 1 4 Open collector drives or mA outputs Warning To avoid possible damage to the output circuit please ensure that the open collector output is connected correctly OC Open Collector output Rel Relay output mA mA output Output Plug Function Pin SUN 87 User Manual CWD2005 Plus Circuit diagrams OC X17 1 24V Heating solide state relay Optional GND Heating solide state relay Optional OC X16 1 24V Compressor air conditioner solide state relay Optional 2 GND Compressor air conditioner solide state relay Optiona
54. et combination 1 with an air jet Calibr gas Number of calibration gases for the total range The first jet set 1 and the lower set shows number 2 Blending After a range change the change is blended to the new value No Range switch point 1 or 2 Signal Wobbe calorific value or specific gravity Unit Engineering units selected Value Example 1 shows a switch to the second range at 650 5 kcal m3 Switch Range overlap between ranges in Example 5 hysteresis above SUN 6 User Manual CWD2005 Plus Software Change range Range switching can be done manually or automatically If manual is chosen an additional menu appears see section 6 2 1 3 9 for more details none automatic manual Burner time constant a burner specific factor Different burner types have their own specific factor for example natural gas BF gas LPG gas etc Max temp inside tube Shut down immediately if the thermopile temperature is too high 50 C limit Calibration constant off System offset in running time application specific only 6 2 1 3 6 Database This menu shows the database configuration of the system This database menu is for display purpose only To be able to configure one has to do it from menu Service which is password protected lt shows date and time when the data is being recorded and when the data is being exported The time interval is in minute This menu shows dates and times when these data are bei
55. et covering 17 PT 100 Air temperature sensor 6 Wobbe jet gas differential pressure 18 Flue gas outlet tube 7 Burner 19 Output thermopile mV Wobbe index 8 Ignition electrode 20 Specific gravity SG cell 9 Fan power suppy net filter 21 Breather pipe 10 Fan power supply 22 Solenoid valves block 11 AirFan 12 Ignition transformator Sample gas is passed to the burner 7 via a wobbe range orifice 6 at very precisely regulated pressure and burned at atmospheric pressure The gas flow is therefore dependent on the specific gravity of the gas The flue gases are mixed with the cooling airflow The temperature of the overall mix is measured by the thermopile hot junctions At the cold the thermopile measures the temperature of the incoming flow of cooling air The result is a differential voltage 19 at the thermopile that is independent of the cooling air temperature Broadly speaking this is proportional to the Wobbe Index of the gas Airflow and gas flow must be regulated very accurately The gas flow is regulated to a constant level by an extremely precise weighted gas pressure regulator 4 The flow of cooling air is kept constant by using a pressure sensor 14 15 to control the speed of the cooling air fan 11 During heat transport from the burner 7 to the active elements of the thermopile 19 all parts of the system absorb heat Heat for the thermocouples is also lost The heat management of this process is monitored by
56. f industrial process control scene in last few years Some units are valued for their low maintenance requirement rugged durability and simple to be understood and serviced quickly by anyone without needing any special tools Principally in combustion calorimeters a small amount of process gas is burned and then cooled by a controlled fluid usually air The temperature of the burned gas is measured and it corresponds to the heat release The goal of a few manufactures has been to improve response speed of these online units Over the years technical progress and the embodiment of smart design strategies have improved response times from around 5 minutes for the old mechanical water bath based units down to just a few seconds for the newly introduced CWD2005 series The CWD2005 Plus is the successor to the CWD 2005 CWD 2000 CW95 CW85 CW71 and all previous models about 10 000 units supplied during more than 85 years service to the gas industry Compare to CWD2005 the CWD2005 Plus has stability and accuracy over temperature disturbance or fluctuation of the ambient temperature It has also a database system that later can be transferred to USB mass storage and also some other new features The CWD2005 Plus is a high speed combustion calorimeter with a small industrial PC and large digital display mounted with the combustion chamber thermopile and other vital components in a custom wall mounted enclosure A small amount of process gas is measur
57. gases such as BF gas or Coke gas need a larger filter see section 4 5 1 and a mounting plate complete with a filter and bypass valves is an available option Very dirty contaminated gases need a special sample gas conditioning system available as an option to remove Naphtha HS Tar and NH plus coal dust from the sample gas Appendix User Manual CWD2005 Plus Fig 11 3 Process Gas line maximum pressure 60 bar 1 Process gas supply line 2 High pressure regulator 3 Sample gas filter 4 Pre regulator ZN 6 bar 18mbar 5 Pressure gauge 0 60 mbar 6 CWD2005 Plus Fig 11 4 Process Gas line maximum pressure 60 bar 1 Prozessgasleitung 2 Vordruckregler max 60bar 0 3 4 bar 3 Filter 4 Druckregler ZN 6 bar 18mbar 5 Pressure gauge 0 60 mbar 6 CWD2005 Plus The high pressure regulator 2 in the figure above is not necessary if the process pressure is below 6 bars 11 6 Fast Loop The CWD2005 Plus itself has a high speed response time but the installed response speed depends on the volume of the process connections with regulators and filters SUN 95 User Manual CWD2005 Plus Appendix To calculate the volume of the tube with the volume of filters and regulators see Chap 3 3 A fast loop speeds up sample gas delivery to the analyzer The tee piece outlet allows 80 of the gas to flow past the analyzer to a lower pressure area and 20 of the total gas volume is sampled by the analyzer with a 1 4 improvement i
58. in the thermopile in relation to heated air with temperature difference 18 40 C 4 00 mbar air difference pressure Fr 66 38 controlled frequency of the fan Stab 11 870 is the stability defines as standard deviation of the measured value average over 2 min This information is important for a successful calibration A typical value at the end of calibration is less than 0 015 Under this value calibration is finished 6 2 1 Options The Options menu contains all of the following menus Button 5 leads back to the main menu 44 UN Software User Manual CWD2005 Plus V 1 02 Process 25 05 2009 10 11 11 Methan 109 15 VolZ dp air 4 00 mbar W I s dp wobbe 3 98 mbar int press 16 79 mbar mV 23 98 V 1 107 T1 33 73 18 27 p 4 00 Fr 66 30 Stab 12 113 Fig 6 4 Options The free area of the info field is reserved for important information This information belongs to the actual menu level For example communication error indicates that the connected printer cannot communicate with the system Filter change or over temperature are the common information 6 2 1 1 I O Input Output dp uakbe 3 95 mbar 45 088 KW int press 16 78 mbar V 1 02 Process 25 05 2009 10 11 19 Methan 108 65 VolZ mV 24 12 V 1 107 T1 33 73 18 19 p 4 00 Fr 66 31 Stab 12 391 Fig 6 5 Input Output Input and output can be linked together in any order In the softwar
59. ircuit boards which can only be operated with its own unique software configuration data files A configuration file is provided with each analyzer and it is stored on a memory stick for safety If the memory stick is misplaced or the configuration is corrupted due to an incident the device cannot be reconfigured without this memory stick The service memory stick contains several programs that will restore the original configuration reboot the system execute and backup data and also configure the EA external board and the EA internal board This is also important if one of these boards is ever replaced User Manual CWD2005 Plus Measurement principle 9 Measurement principle The CWD2005 Plus measurement is based on dry combustion calorimeter principle with a thermopile that has been proven over many years in every type of industry Physically there are two basic variables to be measured wobbe index W and specific gravity D The processor acquires the data and calculates the calorific value H according to the following equation H WWVD 9 1 Wobbe index measurement 1 I r 1 a e a ce cl E 1 A Fig 9 1 CWD2005 Plus scheme Measurement principle User Manual CWD2005 Plus 1 Gas pre pressure regulator 13 Air purge body 2 Differential pressure SG cell 14 Air differential pressure 3 Gas pressure sensor 15 Air differential pressure 4 Precision pressure regulator 16 Burning body 5 Wobbe j
60. itch Power supply for electronic Door switch signal Fan with power supply Analyzer main switch on off Line filter Ignition transformer Ignition impulse input ON OW 00 A N 4 5 Gas connections Gas connections should be leak tested before use Different type of Gyrolok should be used depending on the type of the process gas Up to 5 inlet connections are possible if all options including process gas two calibration gases carrier gas and fast loop are specified 4 5 1 Process gas filters Two types of gas filters are recommended Natural gas and other relatively clean gases need a filter with small internal volume Filter elements need to be changed occasionally and a pressure gauge can be used to check filter back pressure The mA hold function can be activated before changing the filter to provide a continuous output signal during filter maintenance Be sure to cancel memory hold after use It is possible to order filter with a bypass SUN 33 User Manual CWD2005 Plus Installation 42 mm 1 7 inch 4 63 5 mm 2 5 inch _ Fig 4 4 Small filter 1 Inlet 6 mm Gyrolok 2 Outlet 6 mm Gyrolok 3 Removable element tap 4 Filter housing SS 316 5 Filter 20 30 u Dirty gases need a filter with a larger volume and this will increase dead time 110 mm 3 3 inch Fig 4 5 Filter with drain connection 1 Filter inlet 2 Filter way 3 Inlet 6 mm Gyrolok 4 Outlet 6 mm Gyrolok 5 Filter 99
61. ith several Bus interfaces The system provides float Data in Intel Type and Byte Data They can be connected to the Fieldbus at the serial interface The binary data in Intel Format must be interpreted by the customer The by the manufacturer already programmed Anybus Communicator can be connected with the provided serial Interface Cable see Page 92 Figure 25 The Communicator is powered by common 24 Volt The blocks are interpreted according to following memory pattern Da DARIO RE Ie Float 4 Byte inferior cal val Inferior calorific value unit kJ m 2 Float 4 Byte superior cal val Superior calorific value unit kJ m 3 Float 4 Byte Wobbe i Inferior wobbe index unit kJ m 4 Float 4 Byte Wobbe s Superior wobbe index unit kJ m 5 Float 4 Byte dv Relative specific gravity dimensionless 6 Float 4 Byte Reserve 7 Float 4 Byte Reserve 8 Float 4 Byte Tin Air temperature of the burning chamber inlet unit C Carbon monoxide percentage unit Only for instrument with 9 Float 4 Byte CO CO Module 10 Float 4 Byte Air min Minimum air requirement unit m air pro m gas User Manual CWD2005 Plus 11 Float 4 Byte Reserve 20 Float 4 Byte 12345 6789 21 Byte 1 Byte Operation 22 Byte 1 Byte Filter change 23 Byte 1 Byte Reserve 32 Byte 1 Byte Reserve Circuit diagrams A test number to check the complete protocol Operation events O status stop 1 status process 2 status ignition
62. ized personnel only All instructions for the in situ installation have to be considered Warning During installation of the protective conductor connection please consider the existing rule for instruments with higher leakage current gt 3 5 mA The CWD2005 Plus operates over a specified ambient temperature range Directly exposing the analyzer to temperature outside the range is not recommended There may be damage occurred due to adverse weather conditions if an outdoor shelter is not used x Sum Important Information User Manual CWD2005 Plus One has to be careful working with pressurized flammable gases that will be connected to the analyzer The Installation procedure must conform to all applicable local and national codes All process gas lines have been actually leak tested at 1 5 times the normal operating pressure during assembly at the factory After installation the entire process gas system should be pressurized and tested for leaks before operation When planning the installation local site conditions must be taken into account The analyzer has a small open flame inside Any hazardous area regulations for applicability should be considered There may be requirement of an air purge system to the analyzer s shelter in order to conform hazardous area regulations The air purge system will ensure the LEL inside the enclosure remains well within the allowable limits of a standard defined by local or national authority
63. l OC X15 1 24V Valve hot gas solide state relay Optional 2 GND Valve hot gas solide state relay Optional OC X 4 1 24V 2 GND mA X 6 1 20mA 2 GND OC X 8 1 24V 24 Volt Relay ignition impulse internal signal 2 GND GND Relay ignition impulse internal signal OC X 10 1 24V 2 GND OC X 12 1 24V 2 GND Rel X 9 1 Common 2 normally opened 10 2 1 5 Serial interface RS232 optional The RS 232 interface can be used to transmit measured values to a remote location Parameter selection is made in the menu I O Analog outputs The RS 232 interface is connected to block X11 and to block X1 Interface parameters Transmission rate 9600 Baud Parity bit no Stop bit 1 Data bit 8 Data output format 111111 111 222222 222 333333 333 444444 444 555555 555 666666 666 777777 777 111111 111 value analog output 1 222222 222 value analog output 2 1777 77 777 value analog output 7 Plug X11 Pin Signal MA Analog input 1 Optional MA Analog input 1 Optional mA Analog input 2 Optional mA Analog input 2 Optional PT 100 Air conditioner heating enclosure PT 100 Air conditioner heating enclosure Not connected RI RTS CTS DSR OOONDOOFWDN Circuit diagrams User Manual CWD2005 Plus 12 DTR 13 TXD 14 RXD 15 DCD 16 RS232 GND Plug X1 Pin Signal 1 DCD 2 RXD 3 TXD 4 DTR 5 RS232 DND 6 DSR 7 RTS 8 CT 9 RI 10 2 1 6 Profibus DP interface The CWD2005 Plus can be supplied w
64. ment Start Calibration Hold Signal Calibration Abort e Gases according DVGW Worksheet G260 e Biogas according DVGW Worksheet G262 e Natural gas 15 18 mbar 15 20 I h min spec gravity 0 55 with wobbe jet 0 55mm ca 30 m per hour Air in the installation room with max 50 ppm of flammable components Methane max 0 05 Impurity pureness gt 3 5 Minimum once a day ca 2 5 Liter per calibration 10 20 Minutes pro calibration Installation room required Room temperature between 5 C and 35 C 2 5 C per hour 220 Volt 110 Volt 50 60 Hz AC 50 x 1020 x 320 mm ca 74 5 kg Introduction User Manual CWD2005 Plus User Manual CWD2005 Plus Analyzer Overview 3 Analyzer Overview All major components are shown below and can be replaced if necessary as a spare part ltems marked with an are not visible on this drawing see following drawings Signals cable gland Signals cable gland M16 ground cable gland Switch on off Flue gas outlet Analog signals covering ON OW h 20 9 Fig 3 1 Front view Signals cable gland M20 power supply cable gland Filter covering Door lock Display Ooo R D Analyzer Overview User Manual CWD2005 Plus AA N a 36 35 34 32 31 30 29 28 27 26 25 24 i J T FE ER 14 lea Ja i tral Te VE li 3 m Fig 3 2 CWD2005 Plus components shown above but without doors for clarity Thermopil
65. more as 40 C A higher temperature will not damage the analyzer It will affect only the accuracy of the measurement Direct sunlight from a window should be avoided since the additional radiant heat will disturb the energy balance in the room 4 3 Room ventilation CWD2005 Plus calorimeter requires approximately 30 m h of air This air must be delivered from outside the enclosure using suitable ventilation The fresh air should not be connected directly into the analyzer but should enter the room via a heater or a roundabout route so that the temperature of the air has time to adjust to the internal enclosure air temperature With some careful design and attention to a few simple points the possibility for thermal shock can be greatly reduced or eliminated completely Note Sections 4 1 4 2 and 4 3 are for customer guidance if a shelter has not been ourchased from the factory as part of the original order 4 4 Electrical power connection The electrical power supply connections are wired to the terminal block in the bottom section of the enclosure see Fig 3 2 and Fig 4 3 Check whether the available voltage supply matches the analyzer s requirement voltage Installation User Manual CWD2005 Plus O Dm o gt w r g 2 x OS 9 O E wo z r m SE ES b gt O 230 V AC 110 V AC N LI x z Q 5 2 N Fig 4 3 Connector block assembly Power supply line Door safety sw
66. mple of the menu beyond the password protected area V 1 02 Process S 25 05 2009 10 16 57 Methan 105 47 VolZ dp air 4 00 mbar dp wobbe 3 93 mbar int press 16 76 mbar mV 26 03 V 1 107 11 33 85 17 78 p 4 00 Fr 66 35 Stab 0 072 Off y 12 627 value 13 184 Fig 6 32 Service Note Service menus are only accessible to the technical staff or the manufacturer and contain specialized areas for data calculation compensation for various temperatures operating functions and internal system calibrations Access to this area may void the equipment warranty if data in this area is corrupted by the user A special service manual is required for work in any of the special service areas To enter the service menu press the Service key enter the special service password code number and press OK to confirm Exit the input routine by pressing the escape or exit keys 6 2 1 4 1 Configuration The configuration menu is an important setting of the analyzer Changing the setting on configuration menu could change the analyzer s measurement setting Attention this setting should only be configured by the manufacturer or authority in the company under manufacturer s supervision Software User Manual CWD2005 Plus HE UAE ETE AANT LN a um E o Q A I u o um gt a u n N I E o um gt A A I c um n x A I Fig 6 33 Configuration menu first layer HE
67. mption will depend on the range orifice wobbe jet in the analyzer and the specific gravity of the process gas Natural gases require 15 20 liters of gas per hour Blast furnace gases with low calorific values require up to 200 liters per hour Use the following formula to calculate the gas consumption based on specific gravity and range orifice wobbe jet diameter Quantities expressed in l h or scf h 48d liter Gas consumption VD hour or 2 Gas consumption ea FA VD hour Wobbe jet diameter d in mm Specific gravity process gas calibration gas Analyzer Overview User Manual CWD2005 Plus Example 1 Wobbe jet Size 0 55 S G Natural gas 0 642 The Natural gas consumption corresponds to a range of Wobbe Index of 14000 Wobbe kcal Nm3 or 60000 Wobbe kj NM 18 1 liter h In BTU and cubic feet 0 1450 Wobbe Btu ft 3 0 64 ft9 hour Example 2 Wobbe jet Size 0 85 S G Coke gas 0 422 The Coke gas consumption corresponds to a range of Wobbe Index of 6000 Wobbe kcal Nm or 25000 Wobbe to kj Nm3 53 22 liter h In BTU and cubic feet 0 630 Wobbe Btu ft 3 1 89 ft hour Example 3 Wobbe jet size 1 85 S G Blast Furnace gas 1 032 The Blast Furnace gas Coke gas consumption corresponds to a range of wobbe Index of 1400 Wobbe kcal Nm or 6000 Wobbe kj Nm3 152 5 liter nour In BTU and cubic feet 0 150 Wobbe Btu ft 3 5 41 ft hour 3 4 Electrical power supply
68. n Process 2 normally opened 3 normally closed 2 4 COM Maintenance 5 NO 6 NC 3 7 COM Filter change 8 NO 9 NC 4 10 COM Fault 11 NO 12 NC 5 13 COM Wobbe lt XXX 14 NO 15 NC 6 16 COM Wobbe i gt XXX 17 NO 18 NC 7 19 COM Customer specific pos 20 NO 21 NC 8 22 COM Customer specific pos 23 NO 24 NC 10 2 1 2 Analog outputs The mA outputs are connected to terminal block X5 Circuit diagrams Alarm LED D2 D 4 D5 D6 D7 D8 DQ D 10 The maximum loop resistance for the mA outputs is 500 ohm with signal isolation If more than three current outputs are required additional DC DC isolation modules will be required for each output Seven analog outputs are available up to three are supplied as standard The functional position of the current outputs can be user selected using the analog output menu and the standard delivery configuration is shown below Analog Terminal X5 Function output Pin 1 1 mA wobbe index value 2 mA 2 3 mA specific gravity 4 mA 3 5 mA calorific value 6 mA 4 7 mA user selectable 8 M 5 9 mA user selectable 10 m 6 11 MA user selectable 12 mA 7 13 MA user selectable 14 mA 86 Isolator module No Jumper No open TR1 JP 5 TR2 JP 6 TR3 JP 7 TR4 JP 8 TRS JP 9 TR6 JP 10 TR7 JP 11 Circuit diagrams User Manual CWD2005 Plus 15 n C 16 n C 10 2 1 3 Digital Relay contact inputs The digital control inputs are connected to t
69. n field The info field provides a lot of information Time operating mode software version methane percentage and other variables depending on the menu displayed Additional information is available depending on the specific menu section The lower section of the info field is reserved for internal information The first line is the mV signal from the thermopile V is the signal in Volts from the specific gravity cell T1 is the air temperature in C at the thermopile entrance and the next value is the differential temperature of any change in incoming air temperature The variable p is the differential air pressure Fr is the current frequency of the fan speed controller and this value is helpful to monitor the condition of the air filter Stab signal stability value During calibration the CWD2005 Plus determines the calibration duration based on current stability versus a pre set stability value of lt 0 15 to complete the calibration cycle and this level ensures that a stable calibration endpoint is reached Info field is an important source of information when logging troubleshooting data 6 1 5 Menu The menu key leads the menu display back to main menu regardless of menu or level 6 1 6 Start Stop This key shuts stop the system without switching the main power switch off The air blower can also be programmed for a delayed shutdown or keep running This option can be activated in menu 6 2 1 3 1 The key also stores the data in the s
70. n response time The flow meter control valve customer supplied allows the customer to adjust the by pass ratio 2 3 b calorimeter out gt 0 5 Fig 11 5 Fast Loop 1 Gauge inlet pressure 2 Filter 3 Pressure regulator 4 Gauge analyzer inlet 5 Fast loop outlet pressure 6 Flow controller 11 7 Air consumption Optional It is possible to measure air consumption with a calculation model or with an additional measurement of CO with an integrated IR Card 11 7 1 Calculated air consumption The air consumption can be determined with a correlative formula with the variables of specific gravity and heating value The dimension is m air pro m process gas The air consumption can be displayed on the screen and an output of 4 20 mA is available 11 7 2 Air consumption with CO measurement CO contents in the process gas not allow only a calculation of the air consumption Variable content of CO needs an additional measurement of CO This is the only way to reach exact values of air consumption It is possible to install a CO module in the CWD2005 Plus The module is delivered separately and has to be installed before the analyzer is started The CO measuring cuvette is sensitive and could possibly be damaged if it was installed during transportation The direction of the installation is indicated Parallel to the density measurement the CO part in the process gas is detected with an infrared measurement in the CO module From
71. ng recorded in the system and when these data are exported to USB stick Measured values are recorded according to selectable status All means measured values are recorded non stop on every event Process means measured values are recorded during process event w o Stop means measured values are recorded on every event except stop event DB off database off means measured values will not be recorded in the database On the menu only the last measured value and the last three calibration values will be displayed V 1 02 Process 25 05 2009 10 16 25 Methan 105 41 VolZ dp air 4 90 mbar W I 5 dp wobbe 3 94 mbar int press 16 75 mbar mV 25 91 V 1 197 11 33 84 17 77 p 4 00 Fr 66 61 Stab 0 212 Databases Date tine Tine Status measured 25 05 2009 10 12 5 25 05 2009 07 57 Process altra 25 05 2009 Amos 25 65 2009 esa 7 Event 25 05 2009 10 09 25 05 2009 06 15 Cav ke u ov v va To 15 P Gas P a wrar CE 27 03 26 90 26 99 0 56 0 56 32 1 3 1 3 9 n 0 wei6u 0 56 1 A EEE ESS gt Main gt Option gt System gt Database Configuration gt Main gt Option gt System gt Database Configuration tm uzeaun 2 R Fig 6 31 Database Software User Manual CWD2005 Plus 6 2 1 4 Service Accessing to the service menu is not required for normal operation as all the user menus and controls are located outside of this area The screen shot above shows a sa
72. nt side Solenoid valve gas upper side front side Solenoid valve air upper side back side Solenoid valve air upper side back side Solenoid valve gas lower side front side Solenoid valve gas lower side front side Solenoid valve air lower side front side Solenoid valve air lower side front side Temperature upper enclosure Temperature upper enclosure N C Temperature air 1 Temperature air 1 Screen N C N C N C N C N C N C logical signal to enable ignition impulse logical signal to enable ignition impulse 222222 000000 zz OO 83 User Manual CWD2005 Plus Pin Pin Pin Pin DIS Plug x 5 Pin Pin Pin Pin Pin oRWND Pin Pin Pin Pin Pin 10 Pin 10 0 Y O Stecker x 6 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 0 10 2 Input Output card E A Extern PE P2T5 TL2 IPT5 TL2 PE PE DP2 DP2 AGND 15V PE DP1 DP1 AGND 15V PE PE DP4 DP4 AGND 15V PE DP3 DP3 AGND 15V Circuit diagrams ZZZZ 0000 N C Signal differential gas pressure Signal differential gas pressure Supply differential gas pressure Supply differential gas pressure N C N C N C N C N C N N N N N 00000 N C Signal differential pressure wobbe jet Signal differential pressure wobbe jet Supply differential pressure wobbe jet Supply differential pressure wobbe jet The user electrical connections have the following
73. nteractive menus with user dialog boxes system prompts and activity messages An on screen mimic along the bottom edge of the display adapts to the changing requirements of all the corresponding menus and redefines keypad function Please see Fig 6 1 The menu buttons 1 always leads to the next higher menu level The menu button 5 always returns the user to the start menu regardless of menu level When addressing the software interface please allow one second between keypad 6 1 Screen layout E 3 Wobbe i Heizwert kcal kcal 20 06 2006 00 17 39 111504 67 nm 8570 80 q gt Wobbe 3 Dichte mV 20 52 Ve 0 888 0 551 3 rel pf Ti 24 177 13 43 p s01 li Fr 41 01 Stab 0 277 Fig 6 1 Display screen and keypad 1 Menu keypad 6 Start Stop 2 Trend display 7 Numeric input keypad 3 Numeric display 8 Burner window 4 Info field 9 Status display LED 5 Return to main menu 10 Arrow and data entry keypad 6 1 1 Menu keypad The menu keypad is described in the software section and the function depends on the menu currently displayed and the function changes from menu to menu 40 UN Software User Manual CWD2005 Plus 6 1 2 Trend display The trend display shows the both the trend and the interactive screens of the other menus An area is also dedicated to the display of current measurement variables 6 1 3 Numeric display The numeric display shows the measured values and units of measurement 6 1 4 Informatio
74. ons or trouble please give these data to the manufacturer Every change in the screens which are important for the running is automatically stored in this screen device Data Also important service information is stored in the screen After a service our service people will update this screen For example a change of the range is automatically stored also changes of output data 71 User Manual CWD2005 Plus Maintenance 7 Maintenance 7 1 Safety instructions for maintenance or repair Before doing any maintenance or service please shut down the analyzer using the main power switch Caution The burner ignition electrode and the heat exchanger can be very hot Do not jump out any switches or safety devices Use only original spare parts from the manufacturer for any service or repairs 7 2 Periodic maintenance The maintenance intervals for the analyzer are depending on the ambient air and the process gas conditions found at the job site Inspect the following parts after 6 months operation All connections to the gauges pressure sensors specific gravity cell and the primary air connection to the burner should be checked and changed if necessary The gas pressure regulator diaphragm should be checked If this has become hardened or brittle it has to be replaced since this is very essential for a stable measurement Check the rubber connection on the wobbe jet and air jet for any leakage Both the thermopile and heat exchanger
75. ration for this one time only The next automatic calibration cycle will then start normally as programmed by the user Manual calibration uses the same routine to verify readings as auto calibration but automatically adds a memory hold function that allows manual calibration to be performed by the user at any time without a spike in the output signal If an output signal hold is required during auto calibration the user can select the hold function with the keypad from the main menu a hold signal on message will then appear in the information field to alert the user that this feature is now active 6 2 1 2 5 Store basic calibration The function store basic calibration saves the last calibration to get a fix point for the calibrations The point is important to see the deviation at the next calibration and to have a deviation limit for a signal if the limit hits a programmed limit This deviation will be registered in the event list and monitored according to limit of minimum maximum see next section New basic calibration examines the limit and shows exceeding deviation of is value in red color Software User Manual CWD2005 Plus 6 2 1 2 6 Calibration limits gt Main gt Option gt Calib gt Settings II Fig 6 16 Calibration limit In this menu it is possible to program limits for each value after a calibration cycle to give a signal if a deviation reaches this limit 6 2 1 3 System TONTA TONO TT TT CAE
76. restrictor in designing an outdoor shelter for the analyzer is recommended since it will limit the potential to release in case of any accidental damage of process gas tubing inside Maintenance Maintenance of the unit is only done after disconnecting the main switch The following points have to be considered before maintaining or repairing the electrical or the high voltage equipment After switching off the main switch the capacities of the equipment store up to 5 min high voltage It is important to wait till the voltage brake down to zero Please pay attention to the safety function of the current circuit breaker It is forbidden to manipulate the safety switch in the main door SUN 13 User Manual CWD2005 Plus Important Information Parts of the burner could be very hot during operation more than 200 C Before doing any service at the burner please wait about 15 min to cool down all burner parts During start up or maintenance as well as in not optimal conditions not 100 gas burned there could be a danger of gas components in the exhaust of the system If process gas has toxic components please consider that all actual safety rules have to be fulfilled In case of using non toxic gases there will be no problems since they are highly diluted with cooling air Important Information User Manual CWD2005 Plus User Manual CWD2005 Plus Introduction 2 Introduction Combustion calorimeter has been an important part o
77. rm water The use of a brush to remove any stubborn deposits is recommended Then the heat exchanger should be dried with compressed air before reinstallation 8 4 Incomplete ignition Warning ignition could only be occurred with the door closed 1 Incorrect temperature setting too high the temperature threshold should be reduced The analyzer tries to ignite while the flame is burning and the device does not switch to normal operating mode Troubleshooting User Manual CWD2005 Plus 2 Incorrect temperature setting too low the temperature threshold should be increased The device switches to operating mode although the flame is not burning and then switches back to ignition mode 3 Ignition electrode corroded wear out due to frequent ignition The ignition electrode should be replaced if necessary 4 Gas problems when using poor barely flammable gases a special burner needs to be installed that will provide a stable flame pattern 3 No ignition spark door is still open during ignition cycle or could be a problem with door switch The electrode is corroded or bent or is short circuiting because of fouling or carbon tracking down the body of the insulator Check the cooling airflow on the air pressure gauge as a lack of flow will trip the safety pressure switch Check the ignition transformer primary and secondary for continuity 8 5 Software troubleshooting The CWD2005 Plus has an onboard ETX Board and several printed c
78. s This inherent oscillating signal is amplified and further processed in such a way that a continuous output signal in volts is generated The expansion of the sound waves in the measurement chamber is not only dependent on gas density but also other parameters such as viscosity and heat conductivity The selectivity of the measuring cell to gas density is a question of geometric shape dimensioning and a few other proprietary factors The key to stability is a reference chamber that compares the measurement with atmospheric air at ambient conditions The signal received from the chamber with the reference measurement controls the amplitude of the oscillating transmitter membrane and the density measurement is insensitive to small particles on the oscillating membrane A small heater is used to maintain thermal stability Warning The gas pressure in the measuring cell may not deviate considerably from the ambient pressure in the reference air cell Any spikes in sample pressure may result in apparent density deviations that have nothing to do with a change in sample gas density The sensitivity of the measuring cell to external influences such as mechanical vibration impact or pressures are greatly reduced due to its mounting system relatively high mass and electronic filters Measurement principle User Manual CWD2005 Plus 9 2 2 Functional diagram ER 2 signal output ge pe sample gas 31 A N phase sensitive aktive filt
79. s A flow of gas between 8 l h and 220 I h is required depending on measurement range and speed loop gas consumption 11 4 Gas conditioning Coke oven gas and blast furnace gas contain moisture sulfur tar and dust Dust and moisture in the sample gas must be removed and a sample system is available as an option that cleans and simultaneously removes moisture from these gases Pury 100 W sample gas conditioner details The system consists of a process mounted stainless steel sample probe with filter element and cooling unit that cools the sample gas down to around 4 5 C An optional sample conditioning system with standard filters can be used for less dirty gases as shown in the following drawing All components are mounted on SS mounting plate with a filter bypass that allows you to change the filter element online Appendix User Manual CWD2005 Plus Fig 11 1 Filter unit with bypass valve 1 Filter 2 Ball valve 3 Ball valve 4 Ball valve 5 Manometer 6 Pre pressure regulator 6 bar 18 mbar max 7 Holes for wall mounting 11 5 Gas connections The CWD2005 Plus requires a very stable inlet pressure for correct operation and the factory recommends the following pressure regulators A primary regulator is recommended together with a second regulator in front of the CWD2005 Plus for pressures exceeding 6 bars The second regulator has to be adjusted at 18 30 mbar in accordance with the factory specification 11 5
80. s how the user enters their application specific values into the various menus Be sure to read this chapter to gain some familiarity with the equipment before any ad hoc experimentation or adjustment to the menus If the analyzer should fail to power up open the main door and check inside the door that the power supply ribbon cable connections are firmly attached to the power supply as sometimes these have detached during rough shipment and handling If questions arise during start up contact the factory with serial number for further advice The analyzer is supplied factory calibrated and field calibration should only be attempted by users with a source of calibration gas with known values Check the calibration gas data see section 6 2 1 2 and enter the values in the correct menu If only the gas component percentage is known the correct wobbe index value must be calculated from the individual components The use of cylinders with vendor supplied certified values for BIU and specific gravity is recommended as the accuracy of the calibration depends on the accuracy of the standard calibration gas used for calibration User Manual CWD2005 Plus Software 6 Software Attention this manual is based on software release version V 1 02 The CWD2005 Plus runs on a real time operating system It consists of a number of menu levels which can be accessed using the keypad soft keys All operations are similar and are entered via a series of i
81. the caloric value the density and the CO part of the process gas the air requirement is correlatively calculated 96 UN Appendix User Manual CWD2005 Plus The air requirement is presented as a 4 20 mA signal The CO proportion is displayed in the upper right window of the screen Both values may also be bus interrogated by a bus If a bus interface Profibus DP is activated The CO module is tested with a separate calibration gas combustible 0 Gas with the same wobbe index as the second calibration gas but without CO and adjusted to zero The second calibration gas contains a CO proportion to calibrate the span of the CO module as well as the complete analyzer in the described configuration The calibration procedure is full automatically At delivery the two calibration gases are defined by the factory and the customer will be informed The CO module needs no more adjustments and is completely maintenance free The central processor of the CWD2005 Plus takes care of the calculation of the value lt also detects if a module is installed or not The CO indication is only active when a module is installed The calibration procedure cycle consists of 3 steps After the start the calibration 0 gas is connected to the inlet and the zero cal point for the CO measurement is defined After that the calibration gas with known CO part is connected to the inlet and the span of the CO module is adjusted Following the normal calibration procedure of
82. tional diagram of the specific gravity measuring Cell 79 9 3 Specific gravity measuring cell heated and insulated Renee 80 10 1 Input output card E A internal showing module plug positions 82 10 2 Input output E A extern Typ_06 iii 85 11 1 Filter unit with bypass valve 93 11 2 Galibration gas supp ann a ee 94 11 3 Process Gas line maximum pressure 60 bar 95 11 4 Process Gas line maximum pressure 60 bar 95 11 5 Fast LOOP ein Dealer 96 11 6 CO Module installed in the CWD2005 Plus ccooccccccccncccniconiconiconoconocanonanonanononos 97 Important Information User Manual CWD2005 Plus User Manual CWD2005 Plus Important Information 1 Important Information Thank you for choosing a Union CWD2005 Plus heating value analyzer for your online process measurement application Please read this manual and follow all directions before installation and use of this analyzer All shipping containers should be carefully checked for any included accessories Check the shipment against the packing slip and any system arrangement drawings to ascertain that the shipment is complete The analyzer was carefully inspected and calibrated at the factory Check the shipment for possible damage incurred during transit If there is any sign of visible damage to the crate or hidden damage inside the shipment notify the carrier and the fac
83. tory immediately as the equipment warranty does not cover damage in shipping In the event of trouble during start up please contact a factory representative and inform them of the model and serial number of the unit plus a fully description of the problem Note The factory will not be responsible if the customer attempts to repair the unit during the warranty period without first following any detailed factory instruction All possible care has been taken in the publication of this user manual but Union Instruments its agents and distributors accept no liability for any inaccuracies or omissions that may be found This manual reflects the state of the product at the issue date below but further refinements may mean that the manual does not fully reflect your particular system Union Instruments reserves the right to make change without notice both to this publication and the product that it describes Before start up and use of the CWD2005 Plus please take time to carefully review this manual and its contents Observe all Warnings Cautions and Notes Initial operation All electrical connections to line power must be carried out by qualified responsible technical personnel The internal electrical components of the analyzer are wired in accordance with NEC VDE and International standards Check the power supply voltage details can be found on the technical data label inside the door The gas connections should be installed by author
84. troduction User Manual CWD2005 Plus The combustion calorimeter has system to compensate changes of the ambient temperature During selection of a suitable location please avoid dusty areas locations with strong drafts rapid temperature changes direct sunlight or other sources of thermal radiation dll 2 C TRE 7262 Tp lt Tpet 71 C where dt hour Tp room temperature Tpe room temperature during calibration 2 2 Available measurement range Normally 40 100 of the full scale range can be used depending on the gas composition Gas specification Gas Family Wobbe index Nominal range kWh m kWh m Group H 12 8 to 15 7 15 0 e Natural gas H e Natural gas H LPG Air Max specific gravity 0 75 Max olefin components 10 weight Bio methane 98 100 vol CH 0 5 vol CO Natural gas H bio methane LPG Group L 10 5 to 13 0 Natural gas L Natural gas L LPG Air Max specific gravity 0 75 Max olefin components 10 weight Natural gas L bio methane air Max 15 vol air max 3 vol Os in dry gas line max 0 5 vol O in humid gas line 2 3 Response time Deadtime 3 sec 50 time sec 90 time 20 sec 99 time 45 sec Response times are measured when the gas reaches the burner The values shown above were measured using methane Gases with other specific gravities and rate of flame propagation generate different response times some faster and some slower d
85. us are available Change time e Change y values e Change signals Change units e Move cursor 6 2 2 1 Change time To present the diagrams optimal tools are available to be able to show the graph in an optimal view SUN 67 User Manual CWD2005 Plus Software In the following example the diagram shows over all a window of 5 hour in a distance from line to line of 30 minutes In the middle of the base line always the distance from line to line is shown V 1 02 Process 25 05 2009 10 18 53 Methan 105 41 VolZ dp air 4 80 mbar W I 5 dp wobbe 3 93 mbar int press 16 75 mbar Sl q M mV 26 21 V 1 107 0 8219 kg T1 33 90 17 73 p 4 00 m Fr 66 36 Stab 0 012 al kWh m3 Dif y 0 180 GIA COTTON COTTON CONE ATEN ON na Fig 6 40 Change time Every touch of the button makes one step The meanings of the symbols are Value linear right 25 X axis Value linear left 25 x axis Ay Value pressed 25 x axis A Value stretched 25 X axis 6 2 2 2 Change y values V 1 02 Process 25 05 2009 10 19 19 Methan 105 41 VolZ dp air 4 00 mbar W I 5 dp wobbe 3 93 mbar int press 16 74 mbar mV 26 29 V 1 107 11 33 931 17 77 p 4 00 Fr 66 40 Stab 0 010 kWh m3 Dif y 0 180 Off u 12 627 13 177 AUN Change y values Fig 6 41 Change y values At Value linear up 25 y axis Software User Manual CWD2005 Plus
86. xt gt Confirm the entry of a new item using Enter or the Arrow Keys which lead to the next menu and text field 6 1 12 Keypad The keypad operator matrix is polled by the microprocessor once per second and pressing the button faster than one second will receive no system response 6 1 13 Menu navigation The block diagram shows three different shaped menu areas The simple square areas indicate that there are more menu levels The rectangle with the rounded corner indicates that menu is at the lowest menu level The double square indicates the location of an interactive input screen for value or data fields Software User Manual CWD2005 Plus 6 2 Menu diagram Disp mA 621972 Change language 6 2 1 1 6 2 1 3 7 2 2 1 0 it maps on off 6 2114 6 2 1 3 7 2 3 Transfer Analog Output D gt C 6 2 1 3 7 2 4 6 2 1 1 2 Transfer C gt D Relay Output 6 2 2 2 6 21 3725 ae 62 113 ST y values PCX files 6 2 1 3 7 2 8 Options Displa 6 2 2 5 pay Move cursor PCX Info 6 2 2 3 6 2 1 3 7 2 6 Change aa Store signals 6 2 1 1 4 PCX files Digital Input 6 2 1 3 7 2 7 6 2 2 4 ee Change PCX files 6 2 1 units 6 2 1 1 5 6 2 1 1 6 2 1 3 7 29 1 0 6 2 1 2 New a dictionary Calibration 2137210 e 6 2 1 2 1 Calibration 6 2 1 3 6 2 1 3 1 gt Change drive Config calibr gas 6 2 1 3 G22 O HE RE i 6 2 1 3 7 1 Te System Automatic calibr Date Time O N
87. ystem memory Note A system storing is performed every 15 minutes 6 1 7 Numeric keypad For data input the comma key is the decimal point and escape from a menu 6 1 8 Burner window One can observe the burning flame through the burner window The burner provides heat to the thermocouples of the thermopile The flame status shows as a red LED steady flame ok flashing flame out The system needs a stable symmetric blue flame for a stable measurement 6 1 9 Status display There are 4 LEDs showing the following statuses Power Light for power on Operation In normal operation the LED flashes sum User Manual CWD2005 Plus Software Service Indicates the need to change the filter element The upper or the lower limit of the frequency controller has been reached Disturbance Indicates a fault alarm condition 6 1 10 Arrow and data entry keypad The arrow key moves the cursor in the different menu screens The enter key confirms the given value 6 1 11 Data input Some of dialog boxes have value fields where one can enter numerical number and list where one can choose from the list fields 6 1 11 1 Value fields The numerical values can be given by numeric keypad Using the arrow keys you can move on to the next numerical field Use the escape option to abort changes 6 1 11 2 List fields The list of text based field content can be selected by the user with the menu keys lt back gt lt ne

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