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Users Manual CWD 2005 Combustion

1. 36 Manual CWD2005 doc SUN Manual CWD 2005 Software LUM Manual CWD2005 doc 37 Software Manual CWD 2005 6 Software Attention This Manual is based on software release version 2 30 The Software consists of a number of menu levels which can be accessed using the membrane keypad All operations are similar and are entered via a series of interactive 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 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 commands 6 1 Screen and Keypad layout Wobbe i 11504 67 D DIV Le al ea ie IF 2 ai OC d eos Ih Di od EM BO d Ca ae Figure1 Display screen and Keypad 1 Menu keypad 6 Start Stop 2 Trend display 7 Numeric input keypad 3 Numeric display 8 Flame status window and LED 4 Information field 9 Operating status display LED s 5 Return to main menu 10 Arrow and data entry keypad 38 Manual CWD2005 doc SUN Manual CWD 2005 Software 6 1 1 Menu keypad The menu keys are described in the software section and the function depends on the menu currently displayed and the function chan
2. Return to the main menu regardless of menu or level also updates system memory 6 1 6 Start Stop This key shuts down the system without switching the main power switch off The fan can be programmed for a delayed shutdown This option can be activated in menu 6 2 1 3 1 The key also enters the data in the system memory Note A system update is performed by the system every 15 minutes LUM Manual CWD2005 doc 39 Software Manual CWD 2005 6 1 7 Numeric keypad For data input and escape from a menu the comma key is the decimal point 6 1 8 Burner window The burner provides heat to the thermocouples of the thermopile The flame status uses 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 Status display comprises of 4 LED s Power Light for power on Operation In normal operation the LED flashes 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 Move the cursor in the different menu screens and the yellow center key enters data 6 1 11 Data input There are value fields and list fields which can also appear in each dialog box 6 1 11 1 Value fields In the value field the numerical values can be entered with the number keys Usin
3. The measuring principle is described below Two independent physical measurements are carried out These are Wobbe Index value and Specific Gravity and the computer calculates the Calorific Value using following formula Calorific value WobbelIndex Specific Gravity 9 2 Thermopile measuring system D tL ZL K Weight zA O 16 8 Figure 18 The main components of the calorimeter 1 Range orifice 2 Burner 3 Cooling air flow 4 Thermopile hot junctions 5 Thermopile cold junctions 6 Output signal 7 Gas flow 8 Pressure regulator 9 Pressure sensor 10 Temperature sensor 11 Temperature sensor 12 Temperature sensor 13 Specific Gravity cell 14 Cooling air fan 15 Heat exchanger 16 Pressure sensor 17 Temperature sensor 16 Ignition transformer Sample gas is passed to the burner 2 via a wobbe range orifice 1 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 3 the temperature of the overall mix is measured by the thermopile hot junctions 4 At the cold junctions 5 the thermopile measures the temperature of the incoming flow of cooling air The result is LUM Manual CWD2005 doc 85 Measurement principle Manual CWD 2005 a differential voltage 6 at the thermopile that is independent of the cooling air temperature Broadly speaking this is proportional to the Wobbe I
4. Appendices Manual CWD 2005 11 6 Double Range lf an extended range is necessary for example 20 100 it can t be done with one jet combination of Wobbe jet and air jet For this purpose the CWD 2005 will be equipped with a double orifice for 2 wobbe jets and 2 air jets The jet change will be made with 4 solenoid valves automatically The instrument changes in a predetermined point to the next range The electronic calculates a continuous switch from one range to the other range With similar ranges the air consumption may be very different from one gas to an other gas In this case it is switched the wobbe jet can be kept and the air jet can be changed In connection with carrier gas it is possible to measure if needed with and without carrier gas The change considers the calibration with or without carrier gas The system checks if carrier gas will be considered or not The decision if carrier gas is necessary or not can be made manually or automatically With manual change there is in the system menu an additional point change range Next range change for example carrier gas switch on or off carrier gas ee E as IL Figure 27 Double Range 1 Carrier gas Range change 2 Calibrating gas 3 Process gas 4 Solenoid valve Wobbe jet 1 5 Solenoid valve Air jet 1 6 Wobbe jet 2 7 Air jet 2 8 Wobbe jet 1 9 Solenoid valve Air jet 2 10 Air jet 1 1 Solenoid valve Wobbe jet 2 104 Manual CWD2005 doc Z
5. LUT Users Manual CWD 2005 Combustion Calorimeter For high speed measurement of fuel gases E i CALORIMETER Manual CWD 2005 Union Instruments GmbH Zeppelinstrasse 42 D 76185 Karlsruhe Germany Phone 49 721 95243 0 Fax 49 721 95243 33 Email info union instruments com Web http www union instruments com Represented in China by ane lt u Vinca Technical Service Su Anshan Union Industry and Commerce Company Ltd c3 311 Luse Zhihui Cheng Lishan District Anshan Liaoning 11404 China Tel 0086 412 5814665 0086 412 5921396 Fax 0086 412 5824215 Email uts_wang yahoo com cn Represented in North America by Delta Instrument uc Delta Instrument LLC 148 Veterans Drive Northvale NJ 07647 Phone 201 768 7200 Fax 201 768 5020 Web Deltalnstrument com Email info Deltalnstrument com 2 Manual CWD2005 doc ZUN Manual CWD 2005 Attention Please read all safety instructions before you connect the CWD 2005 See section 1 1 page 6 LUM Manual CWD2005 doc 3 Manual CWD 2005 Manual CWD2005 doc SUN Manual CWD 2005 Contents 1 1 1 2 2 1 2 2 2 3 3 3 1 3 2 3 3 3 4 3 9 3 6 4 4 1 4 2 4 3 4 4 4 5 4 5 1 4 5 2 4 5 3 4 5 4 4 5 5 4 6 sj 6 6 1 6 1 1 6 1 2 6 1 3 6 1 4 6 1 5 6 1 6 6 1 7 6 1 8 6 1 9 6 1 10 6 1 11 6 1 11 1 6 1 11 2 NDOT MTOM MANO EE 9 Sale
6. 3 Ball valve 4 Ball valve 5 Indicator 6 Pre pressure regulator 6 bar 18 mbar max 7 Holes for wall mounting 11 5 Gas connections The CWD 2005 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 CWD 2005 for pressures exceeding 6 bars The second regulator has to be adjusted at 18 30 mbar in accordance with the factory specification 11 5 1 Adjust pressure regulator The pressure regulator 6 is adjustable by the user and a small adjustment may be necessary on the regulator s to allow the small specific gravity differential pressure regulator 23 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 Calibration gas connection 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 CWD 2005 is necessary to show inlet pressure level Calibration gas is clean and a filter is not necessary ZUM Manual CWD2005 doc 101 Appendices Manual CWD 2005 5 CR Kl Ih 4 e A L DEEN 2 1 Figure 24 Calibration gas connection 1 Calibration gas cyl
7. In menu point 7 1 1 2 at position 7 und 8 the values for IR Zero Cal and IR FS Cal are entered In case these values are deleted the CO module will not be calibrated Important Only the calibration gases subscribed by the factory may be used Other gas compositions will result in an incorrect calibration of the instrument LUM Manual CWD2005 doc 107 Appendices Manual CWD 2005 Figure 30 CO Module installed in the CWD 2005 1 CO Measuring cuvette 3 Gas inlet 2 CO Module 4 Gas outlet Gas inlet and gas outlet to the module may be inverted There is no flow direction dictated 108 Manual CWD2005 doc SUN Manual CWD 2005 Spare parts LUM Manual CWD2005 doc 109 Spare parts Manual CWD 2005 12 Spare parts 12 1 Spares electronics Specific Gravity Sensor heated 15V 7VA Range 0 2 2 2 dv Specific Gravity Sensor heated 15V 7VA Range 0 0 2 0 dv Weight 1700 gram Order description Specific Gravity Sensor heated Order number 02402199978 Electronic with pressure sensor CWD2000 2005 for differential pressure air 4 mbar Type cw2000sensor 02 Weight 15 gram Order description Electronic with pressure sensor air 4 mbar air Order number 02402199995 Electronic with pressure
8. 08 p 4 00 Fr 41 55 Stab 0 018 kcal Nm3 100 000 9808 076 kcal Nm3 100 000 9987 739 value 9804 709 kcal Nm3 25 000 The free area of the info field is reserved for important information The information belongs to the actual menu level Filter change or over temperature are common information Communication error is an information that the connected printer can not communicate with the system 44 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 1 Input Output I O Y 2 07 RO2 Process 14 03 2607 17 66 50 4 01 mbar 3 96 mbar int press mV V 18 87 V 1 616 T1 24 653 12 81 p 4 01 Fr 41 97 Stab 0 000 15 78 mbar gt Main gt Option gt I Z0 Analog Output Digital Input Relay Output Display Inputs and outputs can be linked together in any order In the software 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 outputs The symbols 0 and C move the marked value right or left The symbol 5 leads back to the main menu V B Process M NI i 16 03 2007 09 22 46 KN i 1227 2 By 914 07 Sy dp air 4 00 mbar 3 92 mbar 17 57 mbar dp wobbe a m 18 76 V 1 6046 int press T1 25 39 12 71 p 4 00 Fr 42 20 Stab 0 1
9. 4 00 Fr 42 32 Stab 0 118 29 Status operation 51 Status calibration gas 1 44 Basic calibration 44 Status operation 43 Basic calibr deviation density gas 1 43 Calibration deviation density gas 1 43 Basic calibr deviation wobbe gas 1 43 Calibr deviation gas 1 07 Status calibration gas 1 66 Status operation 56 Status calibration gas 1 30 Basic calibration 23 Status operation 22 Basic calibr deviation density gas 1 22 Calibration deviation density gas 1 22 Basic calibr deviation wobbe gas 1 22 Calibr deviation gas 1 41 Status calibration gas 1 09 Basic calibration Show Show Show O start up calibration all The event list stores all events that are important and helpful for operating and servicing the CWD 2005 Up to 1000 events can be stored before the system overwrites events and stores the new information by time and data of occurrence 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 During an update of the CWD 2005 sometimes a message can appear ADU error This message is also shown in the event list This message is not a real error It is only an indication that the AD converter is recalibrated The new version of software shows
10. 6 2 1 5 3 6 2 2 6 2 2 1 6 2 2 2 6 2 2 3 6 2 2 4 6 2 2 5 6 2 3 6 2 4 7 7 1 7 2 7 3 1 4 7 9 8 8 1 8 2 8 3 8 4 8 5 d gol 9 2 9 2 1 9 2 2 9 2 3 9 2 4 02 0 9 2 6 92 1 9 2 8 10 10 1 10 2 10 2 1 10 2 1 1 10 2 1 2 10 2 1 3 10 2 1 4 10 2 1 5 10 2 1 6 11 Dal Salle Sire ANS ages 2 cia lera the alne sheath ees Glee eaieer iat 69 RRE Tab le EE 70 WOW e E 71 GRande le 71 eur e EU 72 EE eebe ee 73 Gi geil go 818 g EE 74 VOM LIS E 19 DEVICE INIO BEE 76 VT ue 78 Safety instructions for Maintenance or repair ccseeeeeeeeeeeeeeeeees 78 Rzdleielei nut at er 78 CONSUIMADIES E 78 REplacement I O BO AVS erren settee cobinctn E E 79 Spareparts eler e E 79 Ree le Le ln Le WEE 80 Se g EE 80 WINSLADE WE AGINGS soiu Eyar a TE aca uel ace ie aver Peat 80 Keigtbe te ele 80 INGOMPICTS ININOM EE 81 SOMWare IROUDISSMOOIUN G BE 81 Measurement principe 84 Heating Value measurement AN OVervieW s nonnnnnenneneennnnnnnnnnn 84 Thermopile measuring system cccceeeceeeeeeeeceeeeeeeeaeeeneeeseeeeaeens 85 Specific Gravity measuring Cell 87 Operational overview of the measuring Cell 87 FUNCHONAl GAC KAM EE 88 Srel elei VE 88 COMMISSIONING WEEN 88 BRE ae kere lee EE 89 PU AIG ele 89 TeCHNICAl SPCCIIG ANIONS E 89 CVC UNE CAG FANS EE 90 Input Output card E A mtermal T 90 Input Output Card E A eviemal n 93 Input Output Ca
11. 7 6 2 1 3 7 1 6 2 1 3 7 2 6 2 1 3 7 2 1 6 2 1 3 7 2 2 6 2 1 3 7 2 3 6 2 1 3 7 2 4 6 2 1 3 7 2 5 6 2 1 3 7 2 6 6 2 1 3 7 2 7 6 2 1 3 7 2 8 EEN ERC 6 2 1 3 7 2 10 6 2 1 3 7 3 6 2 1 3 7 4 6 2 1 3 7 5 6 2 1 4 6 2 1 9 6 2 1 5 1 6 2 1 5 2 Manual CWD 2005 K OVD aa 41 Menu INAVIG E e EEN 41 NEEN 42 inte in 44 OU OUTDUT T O D 45 ANOTOU eee ere e E e E 45 ROV ei fue sea seein tn ane ears aneaeisdah enasanaisacaa wa sedune 46 ISLAY IVA E 47 PIG ITALIA OUTS swnndossienas enscncpenicion snes R 47 DIS ei EE 48 SAIN AO WE 49 CONGUE Calbratlon GaS secisenesan aewt ie eee seein iat ceeded 50 Automate GalIDrallON EE 50 OS le 51 Store BasiG CallDFavlOn D 52 Cal FAtlOl EMMIS osier TR 52 Eeer 53 OTC EE 54 ORIO DEEN 55 W OG ALG EE 55 Load factory CONNU AON ME 56 ouve Data t0 CSV Eeer eet 56 FO ONA LONS EE 56 CUMING ege 57 HEDA eege ee 57 Eege 58 CI VIT STS gad sea ag ph ato Saeed Sao duel ta 59 BMAP ON e E 59 Re Ee D a Nee Ne eee 60 TAASTEN O D aaa any es eee ne enon erent 60 Read POX Eege eee 60 tele 60 Delete POX TIO EE 60 FOAI O E EEEE 60 INGW CICHONALY E 60 chande USB orearen siccorsestc const icaerct a ast esi es es 61 FS SUV OM te WEE 61 E eil Gey 11 Le EE 62 FAOW E DEE 62 SIV CC epea a E E E O Gees 64 Customer specific applcaton 65 Air conditioning room temperature cceececeececeeeeeeeeeeeeeeeeeeeseaees 66 Sel lal PHALCN aara a a 66 Manual CWD2005 doc SUN Manual CWD 2005
12. Please read this manual and follow all directions before installation and use of this gas analyzer Unpacking and initial inspection of this unit requires only normal precautions and procedures applicable to the handling of analytical equipment 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 factory 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 should attempt repair of 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 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
13. Weight 3 gram Order description Gasket to heat exchanger Order number 02401199985 Screen for noise suppression Weight 85 gram Beschreibung Screen for noise suppression Bestellnummer 02401199989 116 Manual CWD2005 doc ZUN Manual CWD 2005 Spare parts Orifice gas or air Material alu Perobunan NBR Diameter x xx mm Weight 5 gram Order description Orifice Order number cw05 s m origas x xx mm Orifice gas or air Material alu Perbunan NBR Diameter x xx mm Weight 5 gram Order description Orifice Order number cw05 s m origas x xx mm Rubber tube to orifice gas or air Material Perbunan NBR 7mmx11mmx23 mm D1xDe2xL Weight 3 gram Order description Rubber tube to orifice gas or air instrum CW85 95 CWD2000 2005 Order number cw00 s m orirutu SUM Manual CWD2005 doc 117 Spare parts Manual CWD 200 12 5 Spares burner Order description Order number Order description Order number Order description Order number Order description Order number 118 Burner Type H with 9 quarz jets to CWD2000 2005 Material Aluminium Stainless Steel Weight 125 gram Burner Type H complete Mat Alu SS to CWD2000 2005 cw00 s b hcalss Single quarz jet with threaded sleeve Weight 2 gram Single quarz jet with threaded sleeve CWXx S b sq Landfill gas burner to CWD2000 2005 Material Aluminium Stainless Steel Weight 110 gram Landfill Gas Burner co
14. based on a thermopile principle that has been proven over many years in every type of industry The thermopile used is of unique construction and the use of a high speed thermopile sets the CWD 2005 apart from all other indirect BTU measuring methods since high speed response is usually preferred in control applications 9 1 Heating Value measurement an overview Analyzers that measure the components of the process gas G C are well known and are sometimes used if only some of the gas components are required to be measured Often in the process industry the inability of the G C columns to detect all of the components leading to errors slow response speed with the long cycle times render it unsuitable for dynamic process control applications due to long blind periods with no measurement response between cycles Some manufacturers use an expanding temperature element to measure temperature rise but the removal of this type of element for cleaning during service is usually an issue and the use of very small pneumatic nozzles in a position sensing control system to maintain element temperature are subject to blockage Other less well known manufacturers measure other parameters than the above to report calorific value by measuring residual oxygen in exhaust gas and pass off the measurement of Combustion Air Requirement Index or CARI as being the same as heat release value Note Indirect measuring methods using Zirconia oxide sensors
15. 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 LUM Manual CWD2005 doc 87 Measurement principle Manual CWD 2005 9 2 3 Functional diagram Figure 19 Functional diagram of the Specific Gravity measuring cell 9 2 4 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 U specitic cravity 0 5 Volt 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 U specitic cravity O 5 Volt 9 2 5 Commissioning 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 de couple 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 c
16. 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 F Higher 100 F or more or lower temperatures will require cooling or heating Maximum and minimum ambient temperatures must be specified prior to commissioning so that the installation location can be modified if required Slow temperature fluctuations are fully compensated by the instrument 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 CWD 2005 can be equipped with an optional onboard temperature controller for better temperature control of the whole system environmental temperature shelter temperature Heating and or cooling can be provided depending on the ambient conditions Cooling is always possible with compressed air A C unit or even water 24 Manual CWD2005 doc SUN Manual CWD 2005 Installation 4 Installation FE CE M 1 ae Sei 2 3 CU Ze 2 6 inch 65mm 840mm i UJ K Ka Ka 4 0 1 inch 1019 JHH DL E p 1511mm 73 2 inch 1859mm J L H 13 4 inch T 340m 59 5 inch UU LU 34 3 inch 870mm 26 inch 660mm 5 Figure 6 Enclos
17. installed upstream of the unit must be added The gas consumption is based on the total sample volume up to the burner and by using the formula in section 3 3 it is possible to calculate the total installed response time A fast loop is recommended on long sample lines see section 4 5 4 14 Manual CWD2005 doc SUN Manual CWD 2005 Analyzer Overview LUM Manual CWD2005 doc 15 Analyzer Overview Manual CWD 2005 3 Analyzer Overview All major components are shown below and can be replaced if necessary as a spare part Items marked with an are not visible on this drawing see following drawings a A 2 oP T LLZ a le S e A dch 1 Se 34 be wm S i d 32 f ee Ji 31 f d Su 10 30 aa 12 99 s ltr H 13 28 d NL 8 ag 7 26 H4 pa PTOL Ka 24 om mm 18 17 16 Figure 1 CWD 2005 components shown above but without doors for clarity 16 Manual CWD2005 doc ZUN Manual CWD 2005 Analyzer Overview 1 Output thermopile mV Wobbe Index 2 Fixing screws thermopile 3 PT 100 sensor temperature correction 4 PT 100 sensor temp correction differential temperature 5 PT 100 sensor temp correction differential temperature 6 Cooling air orifice measurement 7 Cooling air orifice measurement 8 Air pressure sensor differential pressure 9 Ignition electrode 10 Enclosure purging 11 Burner 12 Ignition transformer 13 Line filter ignition t
18. mbar m 18 73 V 1 041 Val OI A S 5550 rel int press 17 61 mbar 74 35 40 12 70 p 3 99 Fr 42 11 Stab 0 062 E SS I BE RRR Z es E KN GE 60 0 m 6 gt Main gt Option gt System Export Hold signal 9 cCSV file on off Settings SUM Manual CWD2005 doc 53 Software Manual CWD 2005 6 2 1 3 1 General Change signal after hold provides in a soft transition to and from the calibration cycle or when switching off the output signal hold module This prevents a sudden rise or fall in the measured value occurring in output signal The transition between values is shown in seconds and this allows the signals to blend together for a smooth transfer Purge time purges the unit with air from the fan prior to ignition The delayed shutdown of the air fan following a shut down removes any residual heat from the system and the shutdown of the fan saves energy and filter life A value of 0 will run the cooling air fan continuously and the unit is ready for immediate use after a restart 1225 5 58 912 84 by ree S G dp air 3 99 mbar dp wobbe 3 93 mbar Vayzi 26 V 1 040 0 5547 rel int press 17 54 mbar 14 25 40 12 69 p 3 99 Fr 42 12 Stab 6 159 General settings Change signals after hold in sec EEN Purge time after fan or instr start up oe Fan delayed shutdown time in seconds Ea Carrier gas Cal ceucles Gn min ol 106 10 8 8 60 8 Calibr
19. 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 zinc die cast body and internal parts are made of steel and elastomers Two control springs are available 12 25 mbar 10 H20 orange 30 mbar 20 H20 blue 155 mm 6 1 inch Figure 11 Fisher 912 pre pressure regulator lt 6 bars 90 PSI 1 Inlet 14 6 mm Gyrolok tube 2 Outlet 4 6 mm Gyrolok tube 3 Control spring 4 Vent The next unit is a primary regulator lt 250 bars 3600 PSI tyoe GO PR1 has a 316 SS body 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 CWD 2005 30 Manual CWD2005 doc SUN Manual CWD 2005 Installation Figure 12 High pressure regulator GO PR1 lt 250 bar 3600 PSI 1 Inlet 2 6 mm Gyrolok tube 2 Outlet 6 mm Gyrolok tube 3 Gauge high pressure 4 Gauge low pressure 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 ha
20. particular system Union Apparatebau reserves the right to make change without notice both to this publication and the product that it describes LUM Manual CWD2005 doc 9 Important Information Manual CWD 2005 1 1 Safety Instructions Before start up and use of the CWD 2005 please take time to carefully review this manual and its contents Observe all Warnings Cautions and Notes Warning Reasons to safe persons allow maintenance only after disconnect the main switch Before maintenance or repair work on the electrical or on the high voltage equipment the following points have to be considered After switching off the main switch the capacities of the equipment store up to 5 min high voltage It is important to wait this time till the voltage brake down to zero At the installation of the protective earth please consider the existing rules for instruments with higher leakage current gt 1 5 mA Please pay attention about the safety function of the person current circuit breaker It is forbidden to manipulate to get a malfunction safty switch in the main door Before the service at the burner system consider that parts of the burner could be very hot more than 200 C Please wait more than 15 min to cool down all burner parts before doing any service At the start up and service or not optimal conditions not 100 burnt gas there is a danger of bad components in the burnt gases of the outlet of the system lf proce
21. sensor for differential pressure gas 4 mbar gas Wobbejet Weight 110 gram Order description Electronic with pressure sensor air 4 mbar gas Order number 02402199966 110 Manual CWD2005 doc ZUN Manual CWD 2005 Spare parts Electronic with pressure sensor pressure gas inlet Weight 28 gram Order description Electronic with pressure sensor gas inlet Order number cw05 s e senpigas 12 2 Spares Electric Power supply ACM92 03 V1 5V 3 0A V2 15V 0 5A V1 15V 0 5A V1 24V 0 5A V1 24V 2 0A V1 24V 0 1A Weight 740 gram Order description Power supply CWD 2000 2005 type ACM92A03 110 240VAC Order number 02402199994 Fan CWD2000 2005 tyoe RDO 110 resp 190 VAC Weight 6000 gram Order description Fan CWD 2000 2005 type RDO 110 resp 190 VAC Order number 02402199988 Fan CWD 2005 type 24 V DC Weight 2300 gram Order description Fan CWD 2005 type24V DC Order number SUM Manual CWD2005 doc 111 Spare parts Manual CWD 2005 Order description Order number Ignition transformer TZI5 100W 230V 50Hz with ignition lead and plug Weight 1600 gram Ignition transformer TZI5 100W 230V 50Hz 02402199985 Ignition transformer TZI5 100N 115V 50 60 Hz with ignition lead and plug Weight 1600 gram Order description Order number Order description Order number Order description Order number Order description Order number 112 Ignition transfor
22. supplied the component then the user must calculate and enter these three calibration gas values from the components of the calibration gas 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 instrument obtains this program This includes most of the gases found in many common process gas streams and this utility will help speed and any necessary calculations 6 2 1 2 2 Automatic calibration 50 Manual CWD2005 doc ZUM Manual CWD 2005 Software Day is a list field Sun Mon Tue etc Time and Cycle are value fields Program 1 Calibration Monday at 15 00 hours Program 2 Calibration every second workday at 12 00 hours Program 3 Calibration every day at 23 00 hours The calibration gas purge time duration is adaptive and automatically selected by the software The instrument looks 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 instrument then calibrates and 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 indicate a maintenance condition has occurred Warning A
23. the factory only change parameters after consultation with the manufacturer CN Y 2 12 Process 15 22 03 2007 13 54 46 W I i 4 kcal lh E ered Se 9553 SNm 6781 Zuel Faas dp air ETE Communication error S G Ee KH A 5038 rel int press 39 mbar 74 24 43 12 45 p 3 68 Fr 41 05 Stab 26 401 Set environmental temperature Cool min 100 Cool max so Senses OO gt Main gt Option gt Customer 2 6 2 1 5 2 Serial Printer The RS232 interface can be connected to a printer and the Star Micronics model TSP 600 is recommended by the factory The analyzers software supports this model of printer The paper empty or interrupt during paper reload function are programmed in the software and the necessary feed back signals come from the printer Other printers can be installed but will need extensive software changes The printer drivers can only be changed by the factory and may be unavailable for use in this operating system from the printer vendor 66 Manual CWD2005 doc ZUN Manual CWD 2005 Software NEE ki SE Ze kcal koala cote acces SE Communication error S G dp air 3 69 mbar e see EES BE EE A 5033 rel int press 904 mbar 74 24 42 12 53 p 3 69 Fr 41 46 Stab 21 725 kcal Nm3 S i kcal Nm3 5 0 pf tt TT 6819 108 gt Main gt Option gt Serial printer menu Config Select printer printer The Cut paper co
24. the screen reads 4 mbar and adjust if necessary see section 9 2 4 for more details After the warm up period the instrument will show the Calorific Value Wobbe Index Value 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 describes 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 lf the unit 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 lf questions arise during start up contact the factory with serial for further advice The unit is supplied factory calibrated and field calibration should only be attempted by users with a source of calibration gas with known values See section 6 2 1 2 for more details Check the calibration gas data 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 BTU and Specific Gravity is recommended as the accuracy of the calibration depends on the accuracy of the gas standards used for calibration
25. to the screen shown below remove memory stick and turn the Power switch off then on again The software starts normally with a basic configuration or with individual configurations if the memory stick contains this data Fat ronnt Eamon Senn Peng reet spite rn mmm mmm mmm e KE ee ee ea 2 stick v v vy v vy v Full update This program should only be initiated after consulting the factory This program updates the complete software with standard factory data or the last stored data Attention Before executing this program run the program instrument backup so that individual calibration data is loaded from the computer to the memory stick so that the customer specific configuration is retained after the Full update The menu item 6 should always be executed when the customer changes configuration parameters 82 Manual CWD2005 doc SUN Manual CWD 2005 Troubleshooting Instrument backup full update This program provides the possibility of a program update without loss of the data and parameters stored in the system Here first all system relevant and customized parameters on the inserted memory stick become secured Afterwards all secured data with the new software in the system are installed EA intern update This program generates the calibration data of the EA intern board when the board is replaced in a CWD 2005 system with a new one The data is provided and delivered with th
26. 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 Wherever possible calibration gas should be purchased by the customer in cylinders from a local supplier The gas can also be purchased from the manufacturer with all necessary fittings Note International and Federal regulations prohibit air transport of compressed gases 78 Manual CWD2005 doc SUN Manual CWD 2005 Maintenance 7 4 Replacement UO Boards lf a replacement board E A internal or E A external becomes necessary special updated software is required delivered with the new board Boards of old style and new style are similar and exchangeable for more details see section 10 2 Exchange Switch off line power and change out the board The new style board has additional 4 open collector drivers See section 10 2 2 4 for more details 7 5 Spare parts packages A number of different spare parts packs are available depending 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 op
27. 0 2005 200 x 200 x 95 mm Weight 510 gram Order description Air filter for CWD2000 2005 200 x 200 x 95 mm Order number 02401199996 12 7 Spares enclosure 4 5 EMV sealing to CWD2000 2005 case length e 2 Meter Wire netting Typ Laird BE 4011 1107 1 oo BE Weight 42 gram Order description EMV sealing to CWD2000 2005 case length 2 Meter Order number 02401199995 120 Manual CWD2005 doc ZUN Manual CWD 2005 13 Technical Data System CWD 2005 Process computer Measuring Range Dual Range Low Range High Range Accuracy Specific Gravity Linearity Repeatability Response Time Outputs Relay output Contact rating Digital output Digital Input Communication System Details Gas Pressure Gas Consumption Gas Connection Ambient Temperature Power Dimensions Weight LUM Manual CWD2005 doc Technical Data Technical Data PC104 486 66MHz 8MB disk on chip flash memory Real time processing system with multi tasking ability 40 to 100 F S 20 to 100 F S 75 to 150 BT U scf 700 to 1400 kcal Nm3 1600 to 3200 BTU scf 15000 to 30000 kcal scf 1 0 F S CV or Wobbe Index 0 8 F S Specific Gravity 0 2 0 5 50 7 seconds 90 30 seconds 99 45 seconds 4 20 mA DC isolated 600 ohms max load Up to 7 mA outputs 1 or 3 normally supplied RS232 8 relays 1 0 amp at 100 volt 4 Open collector 3 Contact closures RS232 6 to
28. 05 doc ZUN Manual CWD 2005 Circuit diagrams Plug X10 Pini 24V VI Pin2 24V VIS Plug x14 Pini GND Pin2 24V Pin3 GND Dm A 24V Plug x11 Pini GND Pin2 24V Pin3 GND Dm A 24V Plug x 9 Pin 1 Pin 2 Pin 3 Pin 4 Plug x 8 Pin 1 Pin 2 Pin 3 Pin 4 Plug x15 Pin 1 PE Pin 2 GND Pin 3 15V Pin 4 DI Pin 5 DI Pin 6 15V Pin 7 N C Pin 8 N C Pin 9 N C PiniO PE Pini1 Wobbe Pint12 Wobbe Plug x 16 Pini N C Pin2 N C Pin3 N C Pin4 N C Plug x 17 Pini N C Pin2 N C Pin3 N C Pin4 N C Plug x 2 Pin 1 PT1 Pin 2 PT1 Pin 3 PE Pin 4 PT2 Pin 5 PT2 Pin 6 PE Thermal switch Thermal switch Solenoid valve calibration gas Solenoid valve calibration gas Solenoid valve calibration gas Il Solenoid valve calibration gas ll Solenoid valve process gas Solenoid valve process gas Solenoid valve carrier gas Solenoid valve carrier gas Screen S G cell supply S G cell supply S G cell signal S G cell signal S G cell supply Screen Signal 30 mV Signal Solenoid valve gas Solenoid valve gas Solenoid valve air Solenoid valve air upper side front side upper side front side upper side back side upper side back side Solenoid valve gas Solenoid valve gas Solenoid valve air Solenoid valve air lower side front side lower side front side lower side back side lower side back side TOB Temperature upper enclosure TOB Temperature upper enclosure Screen TL1 Temperature ai
29. 14 18 Not connected 10 19 Not connected D15 20 Not connected 11 21 Not connected D16 22 Not connected 12 23 Not connected D17 24 Not connected 96 Manual CWD2005 doc SUN Manual CWD 2005 Circuit diagrams 10 2 1 4 Warning To avoid possible damage to the output circuit please ensure that the open collector output is connected correctly Open collector drives or mA outputs OC Open Collector output Rel Relay output mA mA output Output Plug Function Pin OC X17 1 24V 500mA Heating solid state relay 2 GND 500mA Heating solid state relay OC X16 1 24V 500mA Compressor air conditioner solid state relay 2 GND 500mA Compressor air conditioner solid state relay OC X15 1 24V 500mA Valve hot gas solid state relay 2 GND 500mA Valve hot gas solid state relay OC X 4 1 24V 500mA 2 GND 500mA mA X 6 1 20mA 2 GND OC X 8 1 24V 500mA 24 Volt Relay ignition impulse internal signal 2 GND 500mA GND Relay ignition impulse internal signal OC X10 1 24V 500mA Heating solid state relay for Z purge enclosure 2 GND 500mA Heating solid state relay for Z purge enclosure OC X12 1 24V 500mA 2 GND 500mA Rel X 9 1 Common 2 Closed LUM Manual CWD2005 doc 97 Circuit diagrams Manual CWD 2005 10 2 1 5 Serial interface RS232 Option The RS232 interface can be used to transmit measured values to a remote location Parameter selection is made in the menu I O Analog outputs The RS232 interface is connected to bloc
30. 15 H2O 15 to 37mbars 0 5 to 7 scfh 15 to 200 ph application dependant Tube fitting Compression or 6mm 5 to 40C Rate of change 5C per Hr 115 volt 50 60Hz 330 VA or 220 volt 50 60 Hz 165VA 30 W x AH x 13 D 111Ib 50 5 kg 121
31. 2 8 Technical specifications V Ges O 2544 Ase S co lt p 2 JE Uy dy O0O00000000 Insulation Figure 20 Specific gravity measuring cell heated and insulated 1 Potentiometer 1 Zero 3 Suspension springs 2 Potentiometer 2 Span 4 Insulating discs ST2 PIN terminals 15V Power Supply 7 VA 15V Power Supply 7 VA Location pin Ground Not Connected Location pin 5V Measurement signal Not Connected Ground Specific Gravity 0 5 Volt O OO JO Om GO gt SUM Manual CWD2005 doc 89 Circuit diagrams Manual CWD 2005 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 E A internal X1 X1 1 amp 6 X17 21 1 2 O ILO Q O 1 O o o 0 0 OOOO OO Ca co E ES E SS ES D11D12 D13D14 D15D16 H i D2 D7 p2ip24U00U0 HD A 0000 oo o pol OO oo oooo 0000 Bo oooo oo S 0 o 0000 UUDUDU Cw2000EAintern 07_2007_02_26 Figure 21 Input output card E A internal showing module plug positions Note This card requires no customer connection D1 to D16 are status LED s 90 Manual CWD20
32. 2005 is supplied without the Specific Gravity cell is fitted 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 in the presence of a modulated acoustical field 9 2 2 Operational overview of the measuring cell 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 gas 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
33. 61 0 5547 rel Steet of amatos outputs Ne Sisnal_ Unit Range tron REN 20 men 250 00 BIU t3 The following items listed below can be selected from a series of multiple choice lists and the user 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 SUM Manual CWD2005 doc 45 Software Manual CWD 2005 Signal is a multiple choice scrolling list field with the following text entries Caloritic Value Wobbe lt Wobbe gt Specific Gravity CV net lt or gross gt Pe is a list field with the following entries 0 20 mA or 4 20 mA Unit is a list field with the following contents Calorific BTU D km Mu Nm kWh Nm kcal Nm kJ Sm MJ Sm kWh Sm kcal Sm Specific Gravity specific to air 1 0 absolute kg Nm Range from Range to are value fields for numerical inputs 6 2 1 1 2 Relay output 1226 5 btu oi 3 54 btu 16 03 2007 09 22 57 S G dp air 4 00 mbar dp wobbe 3 93 mbar U 78 69 V 1 0H0 0 5547 rel ist press 17 52 mbar T1 25 38 12 71 pn 00 Fr 41 99 Stab 0 172 Configuration of relay outputs Signal Oprtr Unit Value 1 Value 2 Zero pos SS f ns w Filter change E tw a a RSC Operation Aan Operation delayed J 1 Aan BEER ER ER ER EES EE EE gt Main gt Option gt I 0 gt Configuration of relay outputs The relay output co
34. UN Manual CWD 2005 Appendices 11 7 Carrier Gas When a carrier gas is necessary both combustible and non combustible gases can be suitable for carrier gas depending on process gas used in the application Normally blast furnace gas with a low content of CO and H2 needs a carrier gas option The amount of CO and H2 in the process gas determines if Oxygen or CH4 is Suitable as a carrier gas A wide ranged flare gas will usually use Methane as a carrier gas See section 6 2 3 8 for a list of carrier gas configuration details 9 e A Se Figure 28 Carrier gas module 1 Mounting bracket S S 2 Difference pressure gauge 3 Pressure regulator 4 Orifice block 5 Orifice carrier gas with cap 6 Inlet carrier gas max 6 bar Ta Inlet pressure gauge range 60 mbar 8 Pre pressure regulator 9 Outlet connection carrier gas to CWD2005 LUM Manual CWD2005 doc 105 Appendices Manual CWD 2005 11 8 Fast loop The CWD 2005 itself has a high speed response time but the installed response speed depends on the volume of the process connections with regulators and filters 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 instrument The tee piece outlet allows 80 of the gas to flow past the instrument to a lower pressure area and 20 of the total gas volume is sampled by the instrument with a 1 4 improvement in response time The flow m
35. ZrO were only developed for applications where the gases are stable and remain in the same family usually Natural gas and may require many calibration gases to curve fit the results of waste flare or other unknown gases into a useable linear output Errors from CO H2 or O2 In process gas can be up to 100 per of component For example 5 fuel based O2 produces a potential 5 error that would only be noticed if the user happened to use a series of calibration gases that reflected this effect as the unit will always repeat if the same calibration gas is used This and the fact they are really measuring fuel air ratio and not BIU has kept these units out of mainstream use on process fuel gas applications Conductivity catalytic or optical sensors have surfaced over the years but for various reasons they have been withdraw or not been accepted by the market The water bath combustion calorimeter was for many years the gas industry standard with its many moving parts submerged in water Slow response weekly calibration with an open hydrogen flame lack of product development and its orphan status by a large corporate owner ensured its demise as the industry looked for new features The CWD 2005 combustion calorimeter responds to all components contained in the process gas and reports them online as heating value and the measurement is fast direct and simple to maintain online 84 Manual CWD2005 doc SUN Manual CWD 2005 Measurement principle
36. a second measuring range which can be supplied as an option This dual range option can extend the measurement range from 20 to 100 and moving from one measuring range to the next provides a step less transition and is displayed as one continuous output Two calibration gases are required for the dual range option If one calibration gas is in the transition zone from one measuring range to the next a single calibration gas can be sufficient for both measuring ranges This must be tested on an application basis by the factory Measuring ranges that are too far apart or contain vastly different components can only be combined into a single measuring range under very specific circumstances Another more radical triple range option is available for process gas streams with very wide ranges A carrier gas option can provide a usable range of 0 100 displayed as one continuous output a continuous supply of Natural Gas or Hydrogen is required for this option 2 3 Response times Dead time 3 sec 50 time 7 sec 90 time 20 sec 99 time 45 sec Response times are measured when the new gas reaches the burner and the values shown above were measured using Methane Gases with other specific gravities and flame speeds generate different response times some faster and some slower depending on the properties of the gas In addition to the dead time and response time the sample lag time for the flow of sample gas through the supply tube and fittings
37. ain online by Gas Industrial Steel and Petrochemical companies 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 CWD 2005 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 output values depend on the model CWD 2005 or W 2005 and these values can be shown on the instruments alphanumeric display The connection board PCB LUM Manual CWD2005 doc 13 Introduction Manual CWD 2005 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 See section 10 2 for details The combustion calorimeter is designed to measure very small temperature changes When selecting a suitable location avoid dusty areas locations with strong drafts rapid temperature changes direct sunlight or other sources of thermal radiation d 2 C t hour Tpe C lt Tp lt Jost 7 C where Tp Room temperature To Room temperature during calibration 2 2 Available measurement ranges Normally 40 100 of the full scale range can be utilized depending on the gas composition The measurement range can be wider for gases with a very high flame speed and the analyzer is designed for
38. at 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 Te Float 4 Byte Reserve 8 Float 4 Byte Tin Air temperature of the burning chamber inlet unit C o Flaat 4 Byte cO e percentage unit Only for instrument with 10 Float 4 Byte Air min Minimum air requirement unit m air pro m gas 11 Float 4 Byte Reserve 20 Float 4 Byte 12345 6789 A test number to check the complete protocol 21 Byte 1 Byte Operation Operation Event 22 Byte 1 Byte Filter change Service needed changing filter 23 Byte 1 Byte Reserve 32 Byte 1 Byte Reserve For the Anybus Communicator there is a separate manual available LUM Manual CWD2005 doc 99 Appendices Manual CWD 2005 11 Appendices 11 1 Spare parts list A list of recommended spareparts for 1 year and 2 3 years operation can be found in chapter 7 under the heading Consumables lf 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 approve
39. ation valve delay o Min internal pressure mbar Geng Warning level internal pressure mbar Bec gt Main gt Option gt System gt General settings D ADC calibration cycle When selecting Delayed shutdown the air fan can be switched off after the time shown in seconds In the example the air fan will run for a further 30 seconds after process gas shutdown before the fan shuts down automatically With a delayed shutdown value of 0 the air fan to run continuously Time until power down display determines the time before entering the screen saver mode after a period of keypad inactivity 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 54 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 3 2 Ignition yY 2 08 Process H 16 63 2007 09 23 58 dp air R dp wobbe nV 18 74 V 1 0460 int press 17 64 mbar 11 25 46 12 70 p 3 99 Fr 42 13 Stab 0 122 gt Main gt Option gt System gt Configuration 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 speaking an ignition cycle should last between 15 and 20 seconds When the ignition
40. av Cal Vs T sec T ein dT T amb Ti T Res 3 p alr p Wobbe p density pres 3 mV All three info windows are prepared for all physical values and can be displayed in the diagram 6 2 2 2 Change time To present the diagrams optimal tools are programmed which can show the graph in an optimal solution In the following example the diagram shows over all a window of 60 minutes in a distance from line to line of 6 minutes In the middle of the base line always the distance from line to line is shown LUM Manual CWD2005 doc I Software Manual CWD 2005 2 08 Process M 16 03 2007 69 21 45 air Bo ade dp wobbe i RS EC KC RT Et La int press 17 55 mbar 1 25 39 12 65 993 98 Fr 42 16 Stab 6 694 Every touch of the button makes one step The meaning of the symbols are Value linear right 25 xX axis Value linear left 25 xX axis Value pressed 25 xX axis Value stretched 25 xX axis 6 2 2 3 Change y values SEI 5 E o 5 08 btu 16 03 2007 09 21 05 dp ai 4 66 mbar S G air E Feiere S To me mV 18 73 V 1 042 A S 5550 rel int press 17 56 mbar 74 25 38 12 67 p 4 00 Fr 42 19 Stab 0 048 ee BE Ell Ss fe E S gt Main gt Trend 5 Change y values 72 Manual CWD2005 doc ZUN Manual CWD 2005 Software vit Value linear up 25 y axis Ceci Value linear down 25 y axis Wer Value pressed 25 y axis Wi Value stretched 25 yaxis Now the specific gravit
41. button starts the copy of the complete dictionary in english and german language Standard from C to the memory stick Corrections can be made and reloaded to the disc of the instrument 6 2 1 3 7 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 7 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 7 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 7 2 8 PCX Info PCX info writes a txt file Every word has a number to identify the expression Under this number the system creates PCX file in the format str O000 pcx for entering new signs also chinese 6 2 1 3 7 2 9 New dictionary lf a new language is introduced or an old language is corrected copy a full language file on the hard disc Copy as above described the language to a memory stick correct all or paste the new language and copy back all files to the system 60 Manual CWD2005 doc SUN Manual CWD 2005 Software 6 2 1 3 7 2 10 Change USB The USB port is also available for a floppy disc The switch can be made here 6 2 1 3 7 3 Password A password can be selected if required by the user If selected no system changes can be made without entering the pass code When unlocked system access is denied after 30 minutes and will ask for the password Entering O s
42. condensation 3 3 Gas consumption Gas consumption will depend on the range orifice Wobbe jet in the instrument 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 scf h or I h 48 d Gas consumption Litre hour Specific Gravity Dimension Wobbe jet diameter in mm Specific Gravity Process gas calibration gas d2 Gas consumption A scf hour Specific Gravity Dimension Wobbe jet diameter in mm Specific Gravity Process gas calibration gas 22 Manual CWD2005 doc SUN Manual CWD 2005 Analyzer Overview 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 Nm or 60000 Wobbe uh 18 1 liter h In BTU and cubic feet 0 1450 Wobbe Btu tt 0 64 ft3 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 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 corr
43. 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 aen Zero postion Contact oz righ Sia ae iesse righ Start calibration low eS ag Hold signal ow mA hold SUM Manual CWD2005 doc 47 Software Manual CWD 2005 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 gt Main gt Option gt 1 0 gt Configuration of contact inputs 6 2 1 1 5 Display Physical value and Unit are list fields They determine the numerical display on the user configurable display screen In the example Wobbe Index Calorific Value Specific Gravity and pressures are displayed on screen 48 Manual CWD2005 doc ZUM Manual CWD 2005 Software 6 2 1 2 Calibration Wit i e NZ op Process M SE 16 63 2607 09 25 50 1225 1 Hu int press 17 66 mbar a Fr 42 09 Stab 0 018 BIU t 10 000 944 270 912 482 Config calibr gas Calibration for CWD 2005 Calibration data is entered as Wobbe Index and Specific Gravity values The standard analyzer will have one measuring range and will require one calibration gas For a dual or three measuring ranges conf
44. d 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 lf the process pressure cannot always be expected to reach 30 mbar 12 H20O 60 mbar 24 H20 with low calorific gases then a sample gas pump is required The boosted pressure is then reduced to required inlet pressure The pump should be suitable for the volume gas type and area code requirements and gas consumption see Chapter 3 or details A flow of gas between 8 Uh 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 Ask for Pury 100 W sample gas conditioner details The system consists of a process mounted SS sample probe with filter element and cooling unit that cools the sample gas down to around 4 5 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 100 Manual CWD2005 doc SUN Manual CWD 2005 Appendices Figure 23 Filter unit with bypass valve 1 Filter 2 Ball valve
45. e e non e automatic e manuel e calculate Calculate calculates 2 calibration gases in one line Under Range No third line range cfg enter 1 for suppressing the third range Now the instrument is prepared for calibrating with 2 calibration gases The input line 3 calibr gas is without any influence Now every calibration takes 2 calibration gases automatically It is necessary to up date the screen in menu 7 2 1 3 8 with the values of the two calibration gases After finishing the new screen inputs the instrument calibrates always at every time with the two calibration gases one after another 2 calibration gases have to be connected Burner time constant This is a burner specific factor Different burner types for Natural gas BF gas LPG gas etc have there own specific factor 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 LUM Manual CWD2005 doc 63 Software Manual CWD 2005 6 2 1 4 Service W I i Bach CW i kcal EEN 9916 83 7031 0 Nre dp air 4 00 mbar dp wobbe 4 18 mbar 18 75 V 1 S G 3 nV 18 75 V 1 019 0 5026 rel int press 13 99 mbar 14 24 03 12 74 p 4 00 Fr 41 52 Stab 0 015 2 500 kcal Nm3 Dif y 62 500 gt Hauptmenue gt Service VW Config Serv mode Diagnostic Gas valve mode User access to t
46. e board by the manufacturer An operation error is impossible because the memory stick supplied in this case only executes program 3 EA extern update This program generates the calibration data of the EA extern board when that is replaced in a CWD 2005 system with a new one The new data file is provided and delivered with the board by the manufacturer An operation error is impossible because the memory stick supplied in this case only executes program 4 Config update This program generates the configuration data in the CWD 2005 that can be saved to disk as a backup from program 6 Instrument backup This program copies the customer specific data to a memory stick 1 int for the EA internal board 2 ext for the EA external board 3 cft for the central unit and the pressure sensors 4 par for the measurement range switching After the CWD 2005 operates on the process and all parameters such as measurement range units calibration cycle filtering etc are finalized initiate program 6 The memory stick contains the current data and it can be used to reboot by running program 1 after an incident which eventually might damage the data in the device It is recommended to always make a copy of the memory stick supplied with the unit so that an unmodified original is always available LUM Manual CWD2005 doc 83 Measurement principle Manual CWD 2005 9 Measurement principle The measurement of process gases by the CWD 2005 is
47. e the relationship to the data boxes at the right of the screen After pressing the button trend in the main menu 5 different menus are available to display all important functions of the instrument 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 lt P Ofe 2 The arrows and the return lt 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 menus are available e Move cursor e Change time e Change y value e Change signals e Change units 70 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 2 1 Move cursor 1223 0 btu oi 0 57 btu 16 03 2007 09 21 35 4 66 mbar S G E hanno tata US i ee 0 r 5548 rel int press 17 59 mbar 74 25 39 12 66 p 4 00 Fr 41 93 Stab 0 066 With the Button 0 and C the selection of the three info windows is done To change the selected line and choose the different physical values the arrows and the Gr return in the circle are active points next physical value Every touch of the arrows scrolls to the Available values Cal Vi 2 Wobbe 2 free Spec grav2 CalVs2 cal Vi Wobbe i Wobbe s Spec gr
48. el int press 17 61 mbar 71 25 40 12 69 p 3 99 Fr 42 08 Stab 0 056 BIU f t 15 900 W HERAN gt Main gt Option gt System gt Options gt Language Change Bitmaps Transfer Transfer language on off D gt C C gt D After the first 4 menus the next 4 menus appear and at least the last 2 ones BEEN BEER Ce Ee 50 btu btu Weg So 1224 7 912 21 Hi mn ne 7 E e 23 moar m 18 65 V 1 046 A p 5547 rel int press 17 62 mbar Zeiss TE emm BIU ft Ja CITT WER SS gt Main gt Option gt System gt Options gt Language Read Store Delete PCX Files PCX Files PCX Files PC Info 58 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 3 7 2 1 Change language The analyzer has German and English display capability 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 1100 words 6 2 1 3 7 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 ZUM Manual CWD2005 doc 59 Software Manual CWD 2005 6 2 1 3 7 2 3 Transfer W D 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 6 2 1 3 7 2 4 Transfer W C gt D This
49. ell is shown on display 53 It should be approximately 4 mbar 0 5 mbar controlled by regulator 23 adjust the regulator if necessary as a low differential pressure will slow response speed If the regulator 23 is out of range see section 11 5 1 for more details The measuring cell is already connected and is provided with DC power from the ST2 plug Part of the process gas approx 4 51 flows through the measuring cell this small sample is returned to the main gas stream and no gas is vented to the atmosphere 88 Manual CWD2005 doc SUN Manual CWD 2005 Measurement principle 9 2 6 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 lf non flammable gases are used such as Nog or air the ignition cycle will time out so set the purge time to a high value so the solenoid valve remains open and the gas will flow Restore any program data after testing and crosscheck the results 9 2 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
50. erating 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 determinate what spare parts should always be available locally Spare parts list One Year operation 1 1 Blower power supply 2 2 Fuse to power supply 3 10 Quartz burners jets 4 2 m EMV door gasket 5 2 Paper filters 6 2 m Rubber tube NBR 4x2 mm 7 1 Diaphragm gas pressure regulator 8 1 Ignition electrode The 2 3 years operation pack contains the same parts as a 1 years operation pack but with an extended supply of consumables as well as electrical and electronic components which based on experience can fail first in Corrosive environments or under other severe operating conditions Spare parts list for 2 3 years operation 1 1 Blower power supply 2 2 Fuse to power supply 3 10 Quartz burner jets 4 2 m EMV door gasket 5 2 Paper filters 6 2 m Rubber tube NBR 4x2 mm 7 1 Diaphragm gas pressure regulator 8 1 Heat exchanger 9 1 Gasket for heat exchanger 10 1 Solenoid valve 11 1 Thermopile 1x24 TE 12 1 Ignition electrode 13 1 Ignition transformer 14 1 Sensor differential pressure gas 15 1 Sensor differential pressure air 16 1 Sensor prepressure gas This spare parts pack serves as a source of local stock If components in the unit fail that are not contained in the spare parts pack th
51. esponds to a range of Wobbe Index of 1400 Wobbe kcal Nm 3 or 6000 Wobbe eh 152 5 liter hour In BTU and cubic feet 0 150 Wobbe Btu ft 3 5 41 ft hour LUM Manual CWD2005 doc 23 Analyzer Overview Manual CWD 2005 3 4 Electrical power supply CWD 2005 power consumption is as follows 230 Volt 50 60 Hz 250 VA 115 110 Volt 50 60 Hz 250 VA The instrument is supplied for operation on 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 the correct equipment suitable for 115 volts 3 5 Measurement ranges The measurement range can be utilized between 20 and 100 of full scale and is dependant on the gas composition A typical range is between 45 100 The Hydrogen component in the gas increases the available range area and inert gases like N2 O2 or COzg reduce the flame speed and the available range The unit is capable of supporting a second range and this must be specified as an optional extra at the time of order In the event of gas change the unit switches to the 2nd measuring range automatically depending on where it is in the first range The computer calculates the transition between the first and second range so that one continuous 4 20 mA DC output signal and display is available over the entire range 3 6 Ambient temperature limits The CWD 2005 should be installed
52. ess gas components with a value around 80 of the analyzers range CWD 2005 gas consumption is between 8 and 200 liters per hour and the quantity will depend on the characteristics of the process gas When designing an outdoor shelter the use of a gas flow restrictor is recommended since it will limit the potential to release in case of any accidental damage to the sample gas tubing inside An air purge system will ensure the LEL inside the enclosure remains well within the allowable limits of the standards defined by local or national electrical codes LUM Manual CWD2005 doc 11 Introduction 12 Manual CWD 2005 Manual CWD2005 doc SUN Manual CWD 2005 Introduction 2 Introduction Combustion calorimeters have been an important part of the process industry control scene for a number of years Some units are valued for their low maintenance requirement rugged durability and ability to understood and serviced quickly by just about anyone without needing any special tools Combustion calorimeters burn a small sample of gas and measure the temperature rise of a fluid usually air through the system and report this as 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
53. eter control valve customer supplied allows the customer to adjust the by pass ratio calorimeter Figure 29 Fast loop schematic 1 Gauge inlet pressure 2 Filter 3 Pressure regulator 4 Gauge instrument inlet D Fast loop outlet pressure 6 Flow controller 11 9 Air Consumption Option It is possible to measure air consumption with a calculation model or with an additional measurement of CO with an integrated IR Card 11 9 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 Nm air pro Nm process gas The air consumption can be displayed on the screen and an output of 4 20 mA is available 106 Manual CWD2005 doc SUN Manual CWD 2005 Appendices 11 9 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 lt is possible to install a CO module in the CWD 2005 The module is delivered separately and has to be installed before the instrument 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 t
54. ey can be ordered from the factory by stating the 5 figure 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 LUM Manual CWD2005 doc 79 Troubleshooting Manual CWD 2005 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 Events include Start Stop Ignition Calibration Low cooling airflow Flame out etc Using the list it is possible to identify which operations have occurred and when This offers an initial clue when problem solving The list can be downloaded and sent to the factory for analysis in the event of a problem 8 2 Unstable readings 1 The pre pressure regulator is unable to maintain constant pressure Process pressure is insufficient This can be the case with Blast Furnace gas A sample gas pump must be installed 2 Direct sunlight resul
55. g the arrow keys you can move on to the next numerical field The position can be changed in the field menu line by using the arrow keys Use the escape option to delete any unwanted changes 6 1 11 2 List fields In list field the multiple choice text based field content can be selected by the user with the menu keys lt back gt lt next gt Confirm the entry of a new item using Enter or the Arrow Keys which lead to the next menu and text field 40 Manual CWD2005 doc SUN Manual CWD 2005 Software 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 LUM Manual CWD2005 doc 41 Software 6 2 Options 6 2 2 Trend 6 2 3 Event list 6 2 4 Device info 6 2 1 Options 6 2 1 2 Calibration 6 2 1 4 Service 6 2 1 5 Customer application 42 Menu Overview 6 2 Main Menu 6 2 1 6 2 2 Trend 6 2 2 1 Change time HOr 6 2 2 2 Y values 6 2 2 3 Change signals 6 2 2 4 Change units 6 2 2 5 Move cursor 6 2 1 1 3 D
56. ges from menu to menu 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 operating information 6 1 3 Numeric display The numeric display is for the display of measured values and units of measurement 6 1 4 Information field The info field provides a lot of information Time operating mode solenoid status and also software version 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 The next value is the differential temperature of any change in incoming air temperature The next value is p for 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 CWD 2005 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
57. he CO module From the caloric value the density and the CO part of the process gas the air requirement is correlatively calculated 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 instrument 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 CWD 2005 takes care of the calculation of the value It 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 the CWD 2005 is started
58. he instrument this key allows a return to factory default by running the standard configuration as supplied by the factory Note Without a memory stick in the slot an error message appears Unable to open file 6 2 1 3 5 Curve Data to 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 6 Hold Signal on off The Button switches all signals 4 20 mA during the maintenance or similar on or off All signals together are switched on or off y 2 68 Process M 16 03 2007 09 24 08 1224 o Hu oz 57 Ay EE i p monne m 18 73 V 1 041 A 5550 rel int press 17 Ei mbar E 56 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 3 7 Settings Settings are all menu buttons which belong to basic configuration and are only seldom or only from time to time used 6 2 1 3 7 1 Time Date a gt Main gt Option gt System gt Options gt Time and date change 5 GC set the system time and date the clock stops when the menu is open Use CANCEL to exit the menu without making any changes ZUM Manual CWD2005 doc 57 Software Manual CWD 2005 6 2 1 3 7 2 Language The menu language consists of 10 submenus With the button all the menus can be reached 1925 EN 912 se 16 03 2007 09 24 29 S G dp air 3 99 mbar EE Cn ee L 0 5548 r
59. he 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 sample of the menu beyond the password protected area Note Service menus are only accessible to the technical staff of 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 64 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 5 Customer specific application Several different menus described below These options are pre programmed by the factory as required Restart power to the unit after an option is selected to enable it 23 Jr _festsnration ze service L Kal gas Druck gt Hauptmenue gt Optionen gt Service gt Konfig ZUM Manual CWD2005 doc 65 Software Manual CWD 2005 6 2 1 5 1 Air conditioning room temperature A PID controller is available as an option for use with variable room temperatures and can control high and low room temperatures The parameters are programmed at
60. hen commissioning the unit Remove the transport tie wraps and transport screws from the specific gravity cell The body of the cell must hang free on the springs and may not come into contact with the sides of the bracket The screw should be removed and stored and the following diagram illustrates the process KE O G 4 O G EFFE EE E W ia ag KL Ue lly Figure 16 Specific Gravity cell shown in its operating position SUM Manual CWD2005 doc 35 Commissioning Manual CWD 2005 Remove the transport packing from the gas pressure
61. iguration 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 Calibration for W 2005 The W 2005 is supplied without a density cell and does not require a specific gravity input Enter 0 in the density field display because if there is a number entered the software will try to calculate the specific gravity and calorific value using this number Note This feature can also be useful when measuring process gases with very steady specific gravity using the W 2005 Instead of entering the specific gravity as 0 enter the expected specific gravity of the process gas The W 2005 will then display the current correct Wobbe index measurement and the customer entered fixed value of specific gravity and use this to calculate a calorific value based on the real Wobbe index value LUM Manual CWD2005 doc 49 Software Manual CWD 2005 6 2 1 2 1 Configure Calibration gas Calibration gas data is entered as a Wobbe Index and Specific Gravity number If the gas vendor has only
62. inder 2 Regulator two stage 3 Flexible metal braided gas hose 4 Pre regulator 6 bars to 18 mbar 5 Pressure gauge 0 60 mbar 6 CWD 2005 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 fig 9 The use of a pressure gauge 0 25 H2O 0 60 mbar is recommended between the pre regulator and the input of the CWD 2005 Steel industry gases such as BF gas or Coke gas need a larger filter see section 4 5 1 fig 10 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 H2S Tar and NH3 plus coal dust from the sample gas 102 Manual CWD2005 doc SUN Manual CWD 2005 Appendices Figure 25 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 18mbar 5 Pressure gauge 0 60 mbar 6 CWD 2005 Figure 26 Process Gas line maximum pressure 60 bar 1 Process gas supply line 2 High pressure regulator 60 bars 3 4 bar 3 Sample filter 4 Pre regulator ZN 6 18mbar 5 Pressure gauge 0 60 mbar 6 CWD 2005 The high pressure regulator 2 in figure 27 is not necessary if the process pressure is below 6 bars ZUM Manual CWD2005 doc 103
63. introduced CWD 2005 series The CWD 2005 is the successor to the CWD 2000 CW95 CW85 CW71 and all previous models about 10 000 units supplied during more than 85 years service to the gas industry The CWD 2005 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 measured 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 WobbeIndex Specific Gravity The W 2005 model measures Wobbe Index values of process gas and is supplied without a Specific Gravity sensor Most of the CWD 2005 units are supplied to customers that need to measure the Calorific Value of their process gas and simultaneous outputs are available for both upper and lower Calorific Values as well as Wobbe index and Specific Gravity The CWD 2005 is a high speed combustion calorimeter and is usually preferred in control applications as the response time is fast the measurement is direct and is simple to maint
64. ir can become trapped in the gas supply tubing during installation Purge the lines before first calibration or after changing the calibration gas cylinder The Start calibration command may need to be executed several times 6 2 1 2 3 Calibrate This menu starts the manual calibration cycle and will override any programmed auto calibration for this one time only The next auto 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 V 2 08 Cal R 1M ean 16 03 2007 09 26 30 SET 5 dit St P 92 btu Hold signal S G dp air 3 99 mbar dp wobhe 3 93 mbar 3y 79 79 v 1 040 0 5548 rel int press 17 60 mbar 14 25 744 12 69 p 3 99 Fr 42 12 Stab 0 020 BIU f t3 15 000 15 000 1177 441 1225 580 Ee KI LEI A Dif y 10 000 944 270 912 893 St Calibrate calibratio LUM Manual CWD2005 doc 51 Software Manual CWD 2005 6 2 1 2 4 Store Basic Calibration store basic calibra
65. isp mA 6 2 1 1 4 Digital Input 6 2 1 1 5 Display 6 2 1 2 Calibration 6 2 1 2 1 Config calibr gas 6 2 1 2 2 Automatic calibr 6 2 1 2 3 Calibrate 6 2 1 2 4 Store basic calib 6 2 1 3 1 General 6 2 1 3 2 Ignition 6 2 1 3 3 Update 6 2 1 3 4 Load fact conf 6 2 1 3 5 Export CSV file 6 2 1 3 6 Hold signals on off 6 2 1 3 7 Settings Manual CWD 2005 6 2 1 3 7 2 1 6 2 1 3 7 2 2 Bit maps on otf 6 2 1 3 7 2 3 Transfer D gt C 6 2 1 3 7 2 4 Transfer C gt D 6 2 1 3 7 2 5 Read PCX files 6 2 1 3 7 2 6 Store PCX files 6 2 1 3 7 2 7 Delete PCX files 6 2 1 3 7 2 8 PCX info 6 2 1 3 7 2 9 New dictionar 6 2 1 3 7 2 10 Cange drive 6 2 1 3 7 1 Date and time 6 2 1 3 7 2 Language 6 2 1 3 7 3 Password 6 2 1 3 7 4 Color settings 6 2 1 3 7 5 Hardware 1 menue kurz eng CWD2005_2007_03_30 Manual CWD2005 doc SUN Manual CWD 2005 C V i Y 2 07 RO dp wobbe d int press 15 89 mbar Software 2 Process 14 03 2607 17 04 45 924 12 Su mY 19 00 V 1 616 T1 24 61 12 82 p 3 99 Fr 42 01 Stab 0 002 BIU f t3 3 97 mbar 15 89 mbar 10 000 1064 270 s value 924 093 Y 2 07 Ro Z Process 14 63 2667 17 04 45 m 19 00 1 616 T1 24 61 12 82 pr 27 Fr 42 01 Stah 6 662 BIU ft3 Dif y 15 600 1282 441 1282 441 The Info field is right ahead
66. k X 11 and to block X 1 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 7 77 77 777 value analog output 7 Block X 11 Pin Signal Not connected Not connected Not connected Not connected PT100 air conditioner heating enclosure PT100 air conditioner heating enclosure Not connected RI RTS 10 CTS 11 DSR 12 DTR 13 TXD 14 RXD 15 DCD 16 RS232 GND Block X 1 O o JO Om PS GO Pin Signal RS232 GND DSR RTS CT RI OO JO Om PS GO 98 Manual CWD2005 doc SUN Manual CWD 2005 Circuit diagrams 10 2 1 6 Profibus DP Interface The CWD 2005 can be supplied with 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 Comunicator can be connected with the provided serial Interface Cable see Page 92 Figure 25 The Communicator is powered by common 24 Volt The blocs are interpreted according to following memory pattern t Cen Float 4 Byte inferior cal val Inferior calorific value unit kim 2 Float 4 Byte superior cal val Superior calorific value unit kim 3 Flo
67. l inputs for different ranges and carrier gases Range No the number of ranges installed Maximum number is three Diam Viet The Wobbe Jet diameter in mm 62 Manual CWD2005 doc ZUN Manual CWD 2005 Software 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 Number 6 Range with jet combination 1 combustible carrier gas with an air jet Number 2 Jet 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 Nm Switch Range overlap between ranges in Example 5 hysteresis above 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 A 2 point calibration is an additional function for 2 point calibration with 2 calibration gases In the screen page 58 in the line change range are 4 different indications possibl
68. lied 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 Block X5 Analog Terminals Function Isolator module Output Pin Jumper No open 1 1 M Wobbe Index Value TR1 JP 5 2 M 2 3 MA Specific Gravity TR2 JP 6 4 mA 3 5 MA Calorific Value TR3 JP 7 6 mA 4 7 MA User selectable TR4 JP 8 8 mA 5 9 MA User selectable TR5 JP 9 10 mA 6 11 MA User selectable TR6 JP 10 12 mA 7 13 MA User selectable TR7 JP11 14 mA 15 N C 16 N C LUM Manual CWD2005 doc 95 Circuit diagrams Manual CWD 2005 10 2 1 3 Digital Relay contact inputs The digital control inputs are connected to terminal block X 3 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 Block X 3 Digital Terminals Function Alarm LED Pin 1 1 Start measurement D25 2 Start measurement 2 3 Start calibration D24 4 Start calibration 3 5 Hold output signal D23 6 Hold output signal 4 7 Not connected D22 8 Not connected 5 9 Not connected D21 10 Not connected 6 11 Not connected D20 12 Not connected 7 13 Not connected D19 14 Not connected 8 15 Not connected D18 16 Not connected 9 17 Not connected D
69. mber 02403199998 Solenoid valve CWD 2000 2005 type 24V DC M25 X 1 Solenoid valve valve seat Weight 365 gram Order description Solenoid valve CWD 2000 2005 Order number 02402199996 Precision gas regulator Compatible to Union instruments CWD2005 Pin max 50 mbar Pout 4 mbar Weight 950 gram Order description Precision gas regulator to type CWD2005 Order number 114 Manual CWD2005 doc ZUN Manual CWD 2005 Spare parts Diaphragm for precision gas regulator D 96 mm Material NBR Weight 10 gram Order description Diaphragm to precision gas regulator Order number CW XX S G PRECDIA Neoprene tube 6 x 2 mm black lenght m Weight 30 gram Order description Neoprene tube 6x2 1m Order number CWXxx S g rutu6x2 Pressure regulator gas type RV12LM Pin max 100 mbar output 10 30 mbar Material zinc Inlet outlet G1 8 Weight 45 gram Order description Pressure regulator RV12LM 10 30mbar Order number cw00 s g prrv12lm10 3 SUM Manual CWD2005 doc 115 Spare parts Manual CWD 2005 12 4 Spares measurement system Thermopile with 24 thermoelemnts diameter 1 0mm Weight 700 gram Order description Thermopile with 24 thermo elements diameter 1 0mm Order number 02403199997 Heat exchanger 0 2mm with clamp collar Weight 60 gram Order description Heat exchanger 0 2mm with clamp collar Order number 02401199994 Gasket to heat exchanger Material ISOPLAN 750 94x84x2mm
70. mer TZ15 100N 115V 50 60 Hz 02402199986 Ignition electrode Type ZE 6 44 30 Weight 20 gram Ignition electrode 02402199987 Plug in relay 24 V serial 40 31 with 1 changer Weight 17gram Plug in relay 24 V serial 40 31 with 1 changer 98402199991 LED with free wheeling diode 6 24 V Weight 3 gram LED with free wheeling diode 6 24 V 98402199988 Manual CWD2005 doc ZUN Manual CWD 2005 Spare parts plug in relay 110 V series 40 31 with 1 changer Oia moo amp d N Te K pI L Weight 17gram Order description plug in relay 110 V series 40 31 with 1 changer Order number 98402199993 bat ed plug in relay 230 V series 40 31 with 1 changer f Mie a Ch me amp LA Weight 20 gram Order description plug in relay 230 V series 40 31 with 1 changer Order number 98402199981 LED with free wheeling diode 110 230 V Weight 3 gram Order description LED with free wheeling diode 110 230 V Order number 98402199992 Finder relay socket series 95 1 changer with clip Weight 35 gram Order description Finder relay socket series 95 1 changer with clip Order number 98402199980 SUM Manual CWD2005 doc 113 Spare parts Manual CWD 2005 12 3 Spares gas Solenoid valve block with 2 valves Material Aluminium anodized Input output tube fitting 6mm Gyrolok SS316 Solenoid valves 24V DC 9 VA Weight 2100 gram Order description Solenoid valve block with 2 valves Order nu
71. mmand cuts the printer paper During the procedure any data is stored and printed afterwards The service LED on the screen flashes as a warning to change the printer roll During this procedure any data is stored and printed afterwards During the instrument start up the printer will be unavailable during the warm up period and the printer will start at the selected time cycle Configure the printer options from the table below and 5 different parameters are available W I i CM i 2a Process kcal a kcal T E lee Spo EE le ar EE Communication error dp air 3 71 mbar S G Ee DEER 0 3 5036 rel int press 14 00 mbar T1 24 42 12 54 p 3 71 Fr 41 50 Stab 11 783 gt Main gt Option gt Serial printer menu gt Changern 2 2 LUM Manual CWD2005 doc 67 Software Manual CWD 2005 W I i C Vii SE 47 kcal Kealll 1 221 12 25 0 P 3 9640 8 Nme 6840 9 rad 121 22510 Po ieee Communication error dp air 3 76 mbar S G EE OL A A 5034 rel int press 97 mbar 74 24 44 12 54 p 3 76 Fr 41 44 Stab 0 904 time period min gt Main gt Option gt Serial printer menu gt Serial printer D ga Time interval select the print time in minutes This is an average of the time interval and the minimum and maximum value of this interval is also displayed The daily value gives an average over one day The example prints out at midnight Outputs are prepared in a bit code of the output
72. mple Mat Alu SS316 to CWD2000 2005 cw00 s b mcalss Wire sieve for Landfill gas burner to CWD2000 2005 Material Brass Stainless steel Weight 8 gram Wire sieve for landfill gas burner Mat Brass SS316 CWxx S b mws 5 Manual CWD2005 doc ZUN Manual CWD 2005 Spare parts Order description Order number Order description Order number Order description Order number Order description Order number Burner type LM for low BTU gas with Aluminium head for CWD 2000 2005 Material Aluminium SS316 Burner head 36 holes diameter 1 9 mm Weight 115 gram Burner LM for low BTU gas with ALU head for CWD2000 2005 cw00 s b Ilmcalss Burner head type LM for CW85 95 CWD2000 2005 Material Aluminium 36 holes diameter 1 9 mm Weight 17 gram Burner head LM for low BTU ALU head for CW85 95 2000 2005 Cwxx s b Imbh Burner type L for low BTU gase with Aluminium head for CWD2000 2005 Material Aluminium SS316 Burner head 36 holes diameter 2 5 mm 1 hole diameter 4 2 mm Weight 115 gram Burner type L for low BTU gas with ALU head for CWD2000 2005 cw00 s b lcalss Burner head type L for CW85 95 CWD2000 2005 Material Aluminium 36 holes diameter 1 9 mm 1 hole diameter 4 2 mm Weight 17 gram Burner head L for low BTU ALU head for CW85 95 2000 2005 Cwxx s b lbh SUM Manual CWD2005 doc 119 Spare parts Manual CWD 2005 12 6 Spares air Air filter for CWD200
73. nce and other work Caution The burner ignition electrode and the heat exchanger can be very hot Do not jump out any switches or safety devices Please use only factory original spare parts for any service or repairs 7 2 Periodic maintenance Inspect the following parts after 6 months operation The maintenance intervals for the instrument are depending on the ambient air and the process gas conditions found at the job site All hose connections to the gauges pressure sensors specific gravity cell and the primary air connection to the burner should be checked and changed if necessary during annual maintenance The gas pressure regulator diaphragm should be checked If this has become hardened or brittle it has to be replaced as this is essential for stable measurement Check the rubber connection on the Wobbe jet and air jet for any leakage Both the thermopile and heat exchanger should be removed and cleaned Combustion by products can form crystals and these can be washed away with warm water and when these parts have been thoroughly dried they can be re installed Note The heat exchanger is mounted on a gasket that remains in place and 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
74. nd signal Cable gland signals Cable gland signals Interface connections Carrier gas SV X11 3 4 Calibration gas SV X14 1 2 Cable gland power Cable gland signals USB Connection Fast loop Calibration gas 2 SV X14 3 4 Process gas SV X11 1 2 ck ON OW MNOOO A 1 J The above drawing shows a standard instrument or instruments equipped with one or two calibration gases or carrier gas Instruments with the option of two process gases have a different inlet arrangement and this will be labeled on the instrument The items marked with a are available as an option at the time of order and are not supplied as standard 20 Manual CWD2005 doc SUN Manual CWD 2005 Analyzer Overview 3 1 Dimensions weights 720mm 28 3 inch 38mm 13 3 inch 1020mm 40 2 inch 320 mm 12 6 inch Figure 5 Enclosure dimensions Height 1020 mm 40 2 inches Width 720 mm 28 3 inches Depth 337 mm 13 2 inches Weight 50 5 kg 111 Ibs Protection IP 54 NEMA 12 The analyzer is supplied for wall mounting brackets are included All 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 ZUM Manual CWD2005 doc 21 Analyzer Overview Manual CWD 2005 3 2 Gas connections Gyrolok A tube 6 mm gas connections are located on the left hand side of the unit The process and calibration gases sho
75. ndex of the gas Airflow 3 and gas flow 7 must be regulated very accurately The gas flow is regulated to a constant level by an extremely precise weighted gas pressure regulator 8 The flow of cooling air is kept constant by using a pressure sensor 9 to control the speed of the cooling air fan During heat transport from the burner to the active elements of the thermopile 4 all parts of the system absorb heat Heat for the thermocouples is also lost The heat management of this process is monitored by a number of thermal elements 10 11 12 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 because the specific gravity of the gas is taken into account in this measurement For this reason the Specific Gravity 13 of the sample gas is measured and calculated with the Wobbe Index in the process calculator to get calorific values in BTU or other units 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 86 Manual CWD2005 doc SUN Manual CWD 2005 Measurement principle 9 2 1 Specific Gravity measuring cell The CWD 2005 The W
76. nfiguration menu consists of signals in 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 Signal is a list field Wobbe Calorific Value and alarm messages can be selected Operation will show lt gt if an alarm value is programmed Unit and Value 1 and Value 2 fields contain configurable operating data Note Zero position low no power applied to relay coil in normal operation Zero position high power applied to relay coil normal operation Eight normally open or normally closed contacts are available See section 10 2 1 46 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 1 3 Display mA This menu displays the mA output of each 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 Y 2 08 Process M W I i C V i 16 03 2007 09 41 18 1221 7 909 81 UL ms 20 00 Sie dp air 3 99 mbar dp wobhe 3 93 mbar Ry 18 73 V 1 039 0 5545 rel int press 17 58 mbar T1 25 25 12 68 p 3 99 Fr 41 72 Stab 0 194 6 2 1 1 4 Digital inputs Signal and zero position are multiple choice list fields These inputs can start a calibration
77. ng mode although the flame is not burning and then switches back to ignition mode 3 Ignition electrode corroded Normal wear following heavy use The ignition electrode should be replaced if necessary 4 Gas problems With poor barely flammable gases a special burner needs to be installed that will provide a stable flame pattern 5 No ignition spark Door is open during ignition cycle 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 CWD 2005 has an onboard ETX Board and several printed circuit boards which can only be operated with its own unique software configuration data file A configuration file is provided with each instrument 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 The memory stick contains six different program routines
78. nnections for contact inputs relay outputs analog outputs and RS232 and have removable plugs for wiring D1 to D25 are status LED s SUM Manual CWD2005 doc 93 Circuit diagrams Manual CWD 2005 10 2 1 1 Relay outputs The relay outputs are connected to terminal block X14 The relay contacts have the following specifications Maximum current lamp max 100 Volt 100V DC 30Waitt 100V AC 60VA lf 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 Position Terminals Function Alarm LED 1 1 COM Common Process D 2 2 NO norm open 3 NC norm closed 2 4 COM Maintenance D 4 5 NO 6 NC Se COM Filter change D 5 8 NO 9 NC 4 10 COM Fault D 6 11 NO 12 NC 5 13 COM Wobbe lt XXXX D 7 14 NO 15 NC 6 16 COM Wobbe lt XXXX D 8 17 NO 18 NC 7 19 COM Customer specific pos D 9 20 NO 21 NC 8 22 COM Customer specific pos D 10 23 NO 24 NC 94 Manual CWD2005 doc SUN Manual CWD 2005 Circuit diagrams 10 2 1 2 Analog outputs The mA outputs are connected to terminal block X 5 The maximum loop resistance for the mA outputs is 500 Ohms with signal isolation lf more than three current outputs are required additional DC DC isolation modules will be required for each output A maximum of seven analog outputs are available up to three are supp
79. on all screens It shows actual information Additionally actual measuring data are indicated which belong to the actual menu In every individual screen different information are available The description is made in the special section in this manual e V 2 07 version number of soft ware e R02 Instrument runs on process gas During a calibration the indication switches to calibration e Actual date and time e 19 00 mV signal of the thermopile 1 016 volt signal specific gravity cell T1 24 61 12 82 input Temperature in the thermopile in relation to heated air differential temperature 12 82 C 3 99 mbar differential pressure air SUM Manual CWD2005 doc 43 Software Manual CWD 2005 e Fr 42 01 controlled frequency of the fan e 10 Stab 0 002 Stab stability 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 The free area of the info field is filled up with useful information in different menus for example filter changing over temperature etc 6 2 1 Options The Options menu contains all of the following menus Button D leads back to the main menu V 2 12 P 15 BEEN EH 22 03 2007 14 26 06 9808 3 kcal 6963 E kcal t 221 2725 0 P 1000 e Nm Nm Communication error S G p air amp O 5040 rel int press 13 93 mbar 11 24732 12
80. ount The instrument has a small open flame inside so consult any hazardous area regulations for applicability If supplied the analyzer shelter may require an air purge system to conform to hazardous area regulations Note A purge system can also be useful for installations in very dusty areas A small source of air for combustion is necessary generally you must ensure that flue gas is not allowed to accumulate the inside of the shelter CO H2 and H2S may be present and that any combustion heat is discharged so that the analyzers 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 fitted with numerous safety features and instrument ignition can only occur with the door closed In the event of failure of gas or cooling air supply the gas solenoid valve will close and after a short interval the solenoid will reopen and the instrument will enter an ignition cycle If the ignition cycle or online measurement function is aborted due to flame out or power failure the gas supply solenoid reverts to its normally closed position and the small amount of sample 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 proc
81. r 1 TL1 Temperature air 1 Screen LUM Manual CWD2005 doc Circuit diagrams Manual CWD 2005 Plug x 3 Pin 1 PT6 Pin 2 PT6 Pin 3 PE Pin 4 Pin 5 N C Pin 6 N C Plug x 7 Pin 1 Pin 2 Pin 3 Pin 4 Plug x 1 Pin 1 PT3 Pin 2 PT3 Pin 3 PE Pin 4 PT4 Pin 5 PT4 Pin 6 PE Plug x 4 Pin 1 P1T5 Pin 2 IPT5 Pin 3 PE Pin 4 P2T5 Pin 5 IPT5 Pin 6 PE Plug x 5 Pin 1 PE Pin 2 DP2 Pin 3 DP2 Pin 4 AGND Pin D 15V Pin 6 PE Pin 7 DP1 Pin 8 Di Pin 9 AGND mi 15V PintO PE Plug x 6 Pin 1 PE Pin 2 DP4 Pin 3 DP4 Pin 4 AGND Pin 5 15V Pin 6 PE Pin 7 DP3 Pin 8 DPS Pin 9 AGND mi 15V 92 No Connection No connection Screen N C No Connection No Connection Signal door closed Signal door closed logical signal to enable ignition impulse logical signal to enable ignition impulse No Connection No Connection Screen No Connection No Connection Screen T Thermal temperature surface component T Thermal temperature surface component Screen TL2 Temperature air 2 TL2 Temperature air 2 Screen No Connection Signal differential gas pressure Signal differential gas pressure Supply differential gas pressure Supply differential gas pressure No Connection Signal differential pressure air Signal differential pressure air Supply differential pressure Supply differential pressure No Connection No Connection Signal differential pressure Wobbe jet Signal differential pressure Wobbe jet Supply differen
82. ransformer 14 Air fan 15 Power supply for fan air 16 Line filter power supply fan air 17 Terminal block power supply 18 Cable gland signals 19 Cable gland signals 20 Cable gland signals 21 Cable gland signals 22 Cable gland line power 23 Cable gland signals 24 Electronic extern output signals digital and analog 25 Safety switch ignition transformer 26 PT 100 sensor box inlet temperature 27 Electronic Intern A D converter solenoid valve control 28 Differential pressure Wobbe jet 29 Cap for Wobbe jet 30 Precision pressure regulator 31 Pressure sensor gas 32 Jet differential pressure S G Cell 33 Gas pre pressure regulator 34 S G cell 35 Solenoid valve process gas 36 Solenoid valve calibration gas 37 Discharge gas air flow LUM Manual CWD2005 doc 17 Analyzer Overview Manual CWD 2005 Figure 2 Rear inside view of main door Port for connections Main Board Blower ETX Board Power supply Blower power supply ETX Board Keypad back side N O10 OAN 18 Manual CWD2005 doc SUN Manual CWD 2005 Analyzer Overview 8 10 8 11 LEED 8 8 11 Figure 3 Front view 1 Cable gland signals 2 Cable gland signals 3 Cable gland signals 4 Cable gland signals PS M20 5 Cable gland ground M16 6 Filter cover 7 Switch on off 8 Door lock 9 Discharge 10 Display Cover analog signals ZUM Manual CWD2005 doc 19 Analyzer Overview Manual CWD 2005 Figure 4 Enclosure shown from left hand side Cable gla
83. rd E A external Type Op 93 SU geif ue 94 PAMVell OGPOWI E 95 Digital Relay e ae Re 96 Open collector drives or MA outputs ss sssnensseeennsnnneenrrrenrnrreernne gt 97 Serial interface RS232 Option cceceeccseececeeeeeeeeeseeeeseeeeeeeeeeees 98 PrOMDUS OF ue 99 POD CNGICES EE 100 LUM Manual CWD2005 doc 7 RES 11 2 11 3 11 4 eos TESA 11 5 2 11 5 3 11 6 11 7 11 8 11 9 11 9 1 11 9 2 12 12 1 12 2 12 3 12 4 12 5 12 6 12 7 13 Manual CWD 2005 SPED E 100 Pressure TOQUNALOIS raseeris e E E E EE de 100 OWS ANIC ORCS E 100 GaS CONG ONIN EE 100 aS e let Eet 101 Adjust pressure regulator ccccceeecceeeeceeeeceeeeceueeceueeseeeeseeeesees 101 Calibration gas Connector 101 Process gas CONNCCHON ME 102 DOUDE RaNGE EE 104 camer GaS tte eet 105 FASE e Tee EE 106 All Consumption Le e TEE 106 Calctilated sAir Gonsuimpuon ME 106 Air Consumption with CO measurement ssessesssesereeenererrreereee 107 PED keener ean ee are ee ane ee eee eee 110 Seege e 110 Spares lS eeereedte eege Een 111 Sal EE 114 Spares measurement svslem 116 SPales DUNGI mosie tinue aionm uu eusaiune eee ateasee 118 opde S Al eee nee 120 SPales Enclos TE 120 TECANICANDAl WE 121 Manual CWD2005 doc SUN Manual CWD 2005 Important Information 1 Important Information Thank you for specifying a Union CWD 2005 Heating Value Analyzer for your online process measurement application
84. 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 power switch After a short delay while the unit powers up the main screen will illuminate An information field in the 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 with the door open Once the flame is lit the door can be opened without creating a flame out condition The device will start up and after short warm up period 20 30 minutes during first commissioning from cold will reach the correct process gas calorific value All software measuring ranges and any other specified options have been pre set 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 as control is by the variable speed air fan Check the specific gravity differential pressure indication on
85. s In some cases it is advantageous for an enclosure or shelter to be purged with clean dry instrument air All parts of exhaust system are included with the instrument All dimensions are in mm Connect an exhaust tube not supplied as shown 1 LUM Manual CWD2005 doc 27 Installation Manual CWD 2005 4 4 Electrical power connection The line power supply electrical connections are wired to the terminal block in the bottom section of the enclosure see drawing figures 1 and 8 Check whether the available voltage supply matches the analyzers rated voltage Le e GA rc A A ee mmm vm mmm mmm mm zl N N a L L AC ST 110 240 V N re m GHEMEN 3 _ LA 3 z E HHE gt 230 V AC 24VDC 110 VAC gt gt N N z Q z Q o S o g y ER an i Figure 8 Connector block assembly Main switch instrument on off Line filter Ignition transformer Ignition impulse Power supply customer Door safety switch Power supply Door switch signal Fan with power supply O JO GO 00 AN 28 Manual CWD2005 doc ZUN Manual CWD 2005 Installation 4 5 Gas connections All gas connections should be leak tested before use Tube compression fittings are normally supplied and up to 5 gas connections are possible if all options including process gas 2 calibration gases carrier gas and fast loop are specified 4 5 1 Process gas filters Two types of gas fil
86. s 1 7 Output 1 1 Output 2 2 Output 3 4 Output 4 8 Output 5 16 Output 6 32 Output 7 64 For all outputs enter code 127 14 2 4 84 16 32 64 Example Sum of outputs 1 to 7 Output 1 and 2 is the code 3 1 2 Output 1 2 and 3 1 2 4 is code 7 Logging state is the output of all state changes These states are also available in the event list and stored Yes or no switches this function on or off Logging temperature logs the room temperature if the sensor is connected to the system This is very helpful for locating problems if the measurement of the CWD 2005 is unstable 68 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 5 3 Dual Sample Streams As an option the instrument can be configured to measure two different process gas streams in sequence Each process gas can be measured on line for a specified time period Each gas stream has a dedicated 4 20 mA output signal Y 2 12 Process 1 22 03 2007 13 56 68 W I i a DEA G i 6850 8 palf 1 21 2725 P 10 Communication error CN dp air 3 78 mbar S G E EE A 5035 rel int press 31 mbar 74 24 44 12 55 p 3 78 Fr 41 44 Stab 0 629 Dual sample dialog Purge time 1 In the screen shot above process gas 1 and process gas 2 measure for 10 minutes and the purge time for process gas 1 and 2 is 1 second to smooth the transition time to the new stream After a purge time of 1 minute the process gas shows the new
87. s a gas cylinder CGA connection Hydrocarbons W 21 8 x 1 4 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 Figure 13 High pressure regulator GO PR1 lt 250 bar 8600 PSI 1 Inlet connection to suit gas cylinder 2 Outlet 1 6 mm Gyrolok tube 3 Gauge high pressure 4 Gauge low pressure 5 Pressure control wheel 4 5 3 Sample gas pump lf the process gas inlet pressure is lower than recommended then a sample 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 LUM Manual CWD2005 doc 31 Installation Manual CWD 2005 sample gas inlet see section 3 2 The pump must meet the requirements for flow and installation area classification See Chapter 11 for more details 4 5 4 Carrier gas Support Process gas with a high level of inert gas will not burn with a stable flame and these poor quality gases need a carrier gas support for combustion Typical carrier gases include Natural gas Methane LPG gas or Hydrogen These gases have a steady calorific value that is calculated as a scaling factor Oxygen is a non flammable carrier gas that supports combustion without adding calorific value Typical flow of carrier gas is 3 5 Li
88. ss gas has toxic components please consider that all actual safety rules have to be abode Non toxic gases are without problems They are very high diluted with cooling air All electrical connections to line power must be carried out by a qualified electrician The analyzers internal electrical components 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 have to be installed only from fort his work qualified persons All for this job actual laws and rules have to be considered The CWD 2005 operates over a specified ambient temperature range Installing the instrument directly outside is not recommended since damage to the analyzer may occur from the adverse weather conditions if an outdoor shelter is not used Caution Caution is necessary during installation because pressurized flammable gases are connected to the instrument and any installation work performed by the customer must conform to all applicable local and national codes All internal sample gas components have been leak tested at 1 5 times the normal operating pressure during assembly at the factory After installation the entire sample gas system should be pressurized and tested for leaks before use 10 Manual CWD2005 doc SUN Manual CWD 2005 Important Information When planning the installation local site conditions must be taken into acc
89. stream value and this is a standard configuration In the example above the values for the two gases are shown the last measured gas stream is displayed as a fixed value in the left hand display screen and the right hand display is the online value The information window at the top right indicates process gas 2 is online Note A small dual stream sample module with gauges regulators and filters including a calibration gas connection is available as an option This module can be wall mounted near the CWD 2005 gas inlet connections The following screen shows a typical dual sample stream trend with 10 minutes on each sample stream with process gas 1 currently online LUM Manual CWD2005 doc 69 Software Manual CWD 2005 6 2 2 Trend Display 3 Y 2 12 Process 2 W I i C V i 22 03 2007 14 22 20 10028 Kea 6736 8 Keal 1 21 5725 0 P gt 1000 WI i 2 dp a He Sete wobbe mV 18 33 V 1 022 9798 l 1 keal pE pna 14 04 mbar T1524 36 12 48 p 3 98 kcal Nm3 100 000 9745 493 16028 200 __ kcal Nm3 100 000 9987 739 9797 055 kcal Nm3 Dif y 25 000 8674 270 6736 559 Off y value The CWD 2005 has a very powerful trend capability that can be plotted on the screen in user configurable time scales and in different units of measurement including Calorific Value Wobbe Index and Specific Gravity and others Different color levels identify the three different trends and numbers stat
90. t It ee EE 10 aide el leie WEE 13 OUMBUEN UE 13 Available measurement ranges n nnnnnnnnennennnnnnnrennrenrnnnnnrnereeneo 14 RESPONSE nn 14 Analyzer Overvi W ccccccccecccsscccenceceuceceuceceuseceusecsusessueesausesueenaaes 16 DIMENSIONS WEINI si2crsiarcdcesdextd aaen aee ETENEE 21 GaS ee leede 22 GaS COM SUMO NON EE 22 Electrical power Supp 24 Meas rement En Let 24 Ambient temperature Iumite 24 JEC UE Le EE 25 ohNekterreguemenl Sessan 27 ROOM Ri dl le N as a dendededdushudedssepuduse 27 Exnaust SEET serana a a 27 Electrical power Conpechon 28 GaS CONNEC UONE osaa heehee hat aa hat haar 29 Process gas E 29 PRESS Uk Carve CUI ee 30 Sampl Gas HUMD WEE 31 CAINE GAS SUD OOM E 32 FASUOOND CONMECIIOM REN 32 Ier e 33 COMMISSIONING DE 35 SOW AIC enge 38 screen and Keypad layVOul voice siothenestetheeetechsxeite tees Segen gege Sege 38 Menu KEY DAG DE 39 Re CIS OU AY estes eect eae a 39 NUMERIC elen UE 39 eegne Tale EE 39 Ve LE 39 AUTO E 39 NUMENC KEV DAG NEE 40 BUNOT WIIG OW E 40 ER le E 40 Arrow and data entry Keypad cccccceeccceeeeceeeeceeeeseeeesaeeeseneesaeees 40 Re 40 vValue elds 2 vedi een eRe eee ae 40 EA E E EE 40 LUM Manual CWD2005 doc 3 6 1 12 6 1 13 6 2 6 2 1 6 2 1 1 6 2 1 1 1 6 2 1 1 2 6 2 1 1 3 6 2 1 1 4 6 2 1 1 5 6 2 1 2 6 2 1 2 1 GE 6 2 1 2 3 6 2 1 2 4 6 2 1 2 5 6 2 1 3 6 2 1 3 1 6 2 1 3 2 6 2 1 3 3 6 2 1 3 4 6 2 1 3 5 6 2 1 3 6 6 2 1 3
91. ter h The software is configured at the factory See Section 6 2 1 3 8 For mechanical installation see section 11 5 3 The carrier gas support option needs to be installed at the factory as it is difficult to retrofit the system after delivery 4 5 5 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 5 3 for more details 32 Manual CWD2005 doc SUN Manual CWD 2005 Installation 4 6 Interfaces A range of electronic devices can be connected to the CWD 2005 The analyzer can be operated using a plug in mouse and a standard PC keyboard with PS2 connector Figure 14 Interface connection on the left hand side of the main door 1 USB Interface 2 VGA Display 3 mouse Interface 4 Keyboard interface 5 Parallel interface LUM Manual CWD2005 doc 33 Commissioning Manual CWD 2005 34 Manual CWD2005 doc SUN Manual CWD 2005 Commissioning J Commissioning When all electrical and gas connections have been completed and tested in accordance with all instructions codes and regulations then the instrument is ready to be powered up The following work must be carried out w
92. ters are recommended Natural gas and other 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 the filter change to provide a continuous output signal during filter maintenance Be sure to cancel memory hold after use CG 42 mm 1 7 inch _ 63 5 mm 2 5 inch _ Figure 9 Small filter 1 Input 6 mm Gyrolok 2 Output 6 mm Gyrolok 3 Removable element cap 4 Filter body 316 SS 5 Filter 20 30 um Dirty gases need a filter with a larger volume and this will increase dead time Figure 10 Filter with drain connection 1 Filter inlet 2 Filter way 3 Inlet 2 6 mm Gyrolok 4 Outlet 1 4 6 mm Gyrolok 5 Filter 99 8 at 0 1 um 6 Filter cap 7 Filter housing 316 SS 7 Filter volume 23 em 0 00081 fte or 1 4 cu inches LUM Manual CWD2005 doc 29 Installation Manual CWD 2005 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 pressures higher than 6 bars 90 PSI need a primary regulator to reduce the pressure to the inlet
93. the message AD calibration and not ADU error LUM Manual CWD2005 doc 79 Software Manual CWD 2005 6 2 4 Device Info This Info Menu shows all important data of each instrument In case of questions 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 informations are 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 CWD2005 Device data Type CWD 2005 db Un CG CO Wien UNION Apparatebau GmbH i 2 Gas type Flare gas Distributor Measurement ranges 76185 Karlsruhe GERMANY Tel 49 0 721 95243 0 Fax 4 49 09721 95243 33 Email info union apparatebau de Wobbe 250 1200 Density 300 1500 Configuration Jet W I Wobbe 0 55 Dir Additional options no additional options installed cali i deviation max 16 03 2007 69 38 22 38 32 Z Analog outputs 4 20m BTU Ft3 250 00 866 60 D 20mA Specific 0 200 2 200 4 20m BTU Ft3 250 00 866 66 Press any key to return to CWDZ005 menu 76 Manual CWD2005 doc ZUN Manual CWD 2005 Maintenance LUM Manual CWD2005 doc 17 Maintenance Manual CWD 2005 S Maintenance 7 1 Safety instructions for maintenance or repair Use the main power switch to remove power for maintena
94. threshold is reached ignition ceases The Ignition threshold is the degree count that the thermopile recognizes the flame is burning Flame temperatures are gas composition dependant so the factory will preset 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 6 2 1 3 3 Update lf a new update is required a CWD 2005 software memory stick has to be inserted in the left side of the door Start by pressing the Update menu key and the update starts automatically After the copy procedure to the disk on chip is finished remove the memory stick copy time is about 1 minute The CWD 2005 boots automatically and starts the measurement operation Note An error message appears Unable to open file if the key is activated without a memory stick in the USB port SUM Manual CWD2005 doc 59 Software Manual CWD 2005 6 2 1 3 4 Load factory configuration 4225 ck btu O13 19 bul 2007 09 23 39 dp air R dp wobbe w EE V 1 040 o 5549 rel int press 17 56 mbar 11 25 39 12 70 p 3 99 Fr 42 11 Stab 0 176 190 000 944 270 913 186 Load factory configuration loads the standard data input as supplied by the factory or installed at the last service If the customer has changed several menu items and problems arise because of malfunction with t
95. tial pressure Wobbe jet Supply differential pressure Wobbe jet No Connection Input adapter Input adapter Input adapter Input adapter Manual CWD2005 doc SUN Manual CWD 2005 Circuit diagrams 10 2 Input Output Card E A external The user electrical connections have the following 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 10 2 1 Input Output Card E A external Type _06 00000 90000000000000000000000000000000 o O 1 1 00000 0000000000000000000000000000000 O X13 X7 Co IT 10 a 00 ro S S ab 00000000 000000 00 II 18 H cn mmm mme deeg Se ee E SSS SS See OO eem mmm wem A e EH i E CH Oin g o S e e S G 5 OU Ss 0 1 rs UD Se Siw X16 ssssesssssss 5 Se ge S O et ef x lt O OO z 29 O O 38 a 38 Oo Ol Le oO 88 SES 29 29 O i o H oO Ee a oc Z O oO oo SG ae O OD a OO O e O X O D7 D8 D D10 D19 D18 D14 D15 D16 D17 OS 0O 0 0 D i I EEN D25 D24 D23 D22 D21 D20 On Hz 13 24 9 16 13 24 OoO0000000 0000 oooo0oo0oo0oo0oo0ojooo0o000000000 X14 Relay outputs mA outputs Digital inputs PT100 input Serial Digital Outputs Serial output output Open Collector Figure 22 Input Output E Aextern_06 Type external with removable terminal blocks Terminal blocks X3 X5 X11 and X14 are customer co
96. tion stores 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 6 2 1 2 5 Calibration Limits C V i NZ op Process M 16 03 2007 09 26 20 1225 5 u 912 95 bu ap Sobbe ET I anar KLL DAN ER ege A R 5549 rel int press 39 mbar 74 25 44 12 69 p 3 99 Fr 42 09 Stab 0 019 Calibration limit wobbe gas 3 Z Calibration limit CG gas LUS 0 00 Calibration limit CG gas 2 Z Calibration limit wobbe gas 2 Z o oo Calibration limit CG gas 3 2 o og gt Main gt Option gt Calib gt Settings II D Here it is possible to program limits for each value after a calibration to give a signal if a deviation reaches this limit 52 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 1 3 System This menu item contains the following basic analyzer configuration parameters Two pages open the different items of the menu The button swiches from one page to the other page 1225 8 SU 913 19 ou Wiss Cnn ee eee m V 18 66 V 1 0406 T1 25 39 12 76 p 3 99 Fr 42 11 Stab 0 176 BIU f LIT III WEARRURRS gt Main gt Option gt System Load General Ignition Update config The next line with other three menus S S Y 2 68 Process M U I i C V i 16 03 2007 09 24 08 1224 94 912 57 Sy Se KE dp wobbe 3 93
97. ts 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 8 3 Drift in readings Readings drift upwards in one direction and calibration no longer restores the calibration value Air fan frequency control is at its maximum value Heavy air filter contamination that can no longer be corrected for by the speed of the air fan The filter element must be replaced Reading drift downwards The heat exchanger is worn out With Propane and Butane this can occur if the flame burns with insufficient primary air Yellow flame and the heat exchanger can become clogged with soot and carbon deposits Remove and wash the heat exchanger with warm water the use of a brush to remove any stubborn deposits is recommended The heat exchanger should then be dried with compressed air before reinstallation 80 Manual CWD2005 doc SUN Manual CWD 2005 Troubleshooting 8 4 Incomplete ignition Warning Ignition only operates with the door closed 1 Incorrect temperature setting The temperature threshold should be reduced The unit tries to ignite while the flame is burning and the device does not switch to normal operating mode 2 Incorrect temperature setting The temperature threshold should be increased The device switches to operati
98. uld be connected separately If a very short response time is required a tube with a smaller diameter 1 8 4 mm can also be used depending on sample gas but check that the pressure drop is not too large The input pressure to the instrument 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 lf the input pressure is too low the pressure should be boosted with a sample gas pump A pump is available as an optional extra and can be mounted on a panel with the necessary pressure gauges and pre pressure regulator The process gas tubing will need a sample gas filter and this can be ordered as an option from the factory or supplied by the customer A small filter will be sufficient wnen Natural gas is used because 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 effect the response time and the filter element should have a large active face retention area and a small dead volume If the process gas is at a much higher temperature than ambient and the humidity of the process gas is high water can condense in the lower temperature sample tubing runs 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 instrument so there is no danger of
99. ure attachment Exhaust 1 Fixing element 2 Cover insulation 3 Draft brake 4 Discharge CWD 2005 5 Fixing barcket 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 SUM Manual CWD2005 doc 25 Installation Manual CWD 2005 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 7 to meet exactly the holes vertical distance on the back of the analyzer 660 4x 8 5 N cy st Figure 7 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 26 Manual CWD2005 doc EUN Manual CWD 2005 Installation 4 1 Shelter requirements The calorimeter shelter is subject to special conditions How well these conditions are met is of extreme importance for the quality of the measurement Room temperature changes must be slow If necessary only well controlled climate systems should be used lf an electrical heater is used the controller should be programmed very carefully Direct sunlight from a window should be avoided since the additional radiant heat will disturb the energy balance in the room 4 2 Room ventilation A calorimeter requires approximately 30 mb of air This air must be deli
100. vered from outside the enclosure using suitable ventilation The fresh air should not be connected directly into the unit 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 parts of 4 3 are for customer guidance if a shelter has not been purchased from the factory as part of the original order 4 3 Exhaust gas 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 10 C 15 F above ambient Flue gases must be discharged from a flue gas outlet to ensure that the thermal balance is not disrupted This is particularly important with small enclosures or shelters 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 on a domestic stove and poses no health hazard for most process gases such as Natural gas etc With corrosive gases 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 Corrosive air in the calorimeter enclosure will result in corrosion in the electronic component
101. which can be executed in the CWD 2005 drive and are explained in the following text The memory stick must be removed after the completion of the selected program and the unit has to be rebooted Only programs 1 and 6 are of user interest if the unit works correctly Programs 2 to 5 contain board specific calibration data for the normal operation and after delivery are of no interest If the boards are replaced or software updates are required a memory stick with configuration data for the new board is supplied with the boards After inserting the memory stick in tne USB port and rebooting the CWD 2005 the following information will appear on the screen The arrows on the lower part of the screen refer to the keys below the screen LUM Manual CWD2005 doc 81 Troubleshooting Manual CWD 2005 Note After several minutes of loading files the screen will return to the start menu with the six vertical arrows power down the unit remove memory stick and restore power The unit will now run through the normal short start up routine This is a recovery memory stick With this memory stick you can reboot or repair the system after a crash You can reformat the Disk on Chip for regenerating the system You can install different updates and you can save any instrument specific data Each command name points with an arrow to a push button The program starts automatically and after finishing the routine ignore any other screen prompts will return
102. witches the password system off A default is available if the password is lost ZUM Manual CWD2005 doc 61 Software Manual CWD 2005 6 2 1 3 7 4 Color Settings CM i NZ op Process M 912 enbl wanes dp air 4 00 mbar 3 92 mbar e oc G ei mV 18 75 V 1 040 0 l 5548 rel int press 17 65 mbar T1 25 42 12 69 p 4 00 Fr 42 10 Stab 0 020 Color settings S G Menu background 6 2 1 3 7 5 Hardware 1 CM i 2 08 Process M NI 16 03 2007 69 25 46 1225 42M 912 75 bu dp air 4 00 mbar 3 93 mbar 0 5547 rel ici 17 60 mbar T1 35 43 12 68 u00 Fr 42 16 Stab 0 018 eo of 2 eo o 1 S G puer 752 00 o oo Change range Burner time constant 200 Max temp inside tube deg C 50 00 Calibration constant off gt Main gt Option gt System gt Options gt Configuration hardware 1 D 2 Q This menu contains data parameters for dual range and carrier gas options The amount of dual range overlap can be selected Burner time constant Wobbe jet and range conf 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 match the process gas if the customer decides to change ranges or carrier gas type contact the factory for new data The previous screen shot shows al
103. y window is selected The three lines e Dif y delta from line to line 15 00 e Off y Position of the offset 1177 441 e value actual value 1221 266 are important to have a good most significant graph of the specific gravity 6 010 9 610 0 550 o 059 10 000 944 270 909 609 6 2 2 4 Change signals The handling of the menu change signals is the same as before described SUM Manual CWD2005 doc 73 Software 1224 l 0 btu oi S 03 btu 16 03 2007 09 21 15 dp air 4 00 mbar dp wobbe 3 93 mbar m 18 65 V 1 642 0 59592 rel int press 17 56 mbar 11 25 38 12 67 p 4 00 Fr 42 17 Stab 0 046 E SE SS es To T ITT EERE CC Hit te eT gt Main gt Trend 5 Change signals 6 2 2 5 Change units The handling of the menu change signals is the same as before described 2 08 Process M 16 03 2007 09 21 25 SoG dp air 4 00 mbar dp wobbe 3 93 mbar ny ig 74 V 1 042 int press 17 57 mbar T1 25 39 12 67 p 4 00 Fr 42 84 Stab 0 051 BIU t3 8 gt Main gt Trend 5 Change units Manual CWD 2005 Note The trend data is the only data that will be erased if power is lost to the instrument 74 Manual CWD2005 doc ZUN Manual CWD 2005 Software 6 2 3 Event List Y 2 08 Process M W I 16 03 2007 09 21 56 1220 52 909 03 BY dp wobbe 3 93 mbar W aizi ES Vi OI 0 5547 rel int press 17 58 mbar 14 25139 12 65 p

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