Delta Instruments Users Manual CWD 2005 Combustion Calorimeter For high speed measurement of fuel gases

Users Manual CWD 2005 Combustion Calorimeter For high speed measurement of fuel gases 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: 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 LLC 148 Veterans Drive Northvale NJ 07647 Phone : 201-768-7200 Fax : 201-768-5020 Web : DeltaInstrument.com Email : info@DeltaInstrument.com ___________________________________________________________________ 2 Manual CWD2005.doc Manual CWD 2005 Attention: Please read all safety instructions before you connect the CWD 2005 See section 1.1 page 6 ___________________________________________________________________ Manual CWD2005.doc 3 Manual CWD 2005 ___________________________________________________________________ 4 Manual CWD2005.doc Manual CWD 2005 Contents 1. 1.1. 2. 2.1. 2.2. 2.3. 3. 3.1. 3.2. 3.3. 3.4. 3.5. 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. 5. 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. Important Information ........................................................................ 9 Safety Instructions ........................................................................... 10 Introduction ..................................................................................... 13 Output values .................................................................................. 13 Available measurement ranges ....................................................... 14 Response times .............................................................................. 14 Analyzer Overview .......................................................................... 16 Dimensions, weights ....................................................................... 21 Gas connections ............................................................................. 22 Gas consumption ............................................................................ 22 Electrical power supply.................................................................... 24 Measurement ranges ...................................................................... 24 Ambient temperature limits .............................................................. 24 Installation ....................................................................................... 25 Shelter requirements ....................................................................... 27 Room ventilation ............................................................................. 27 Exhaust gas discharge .................................................................... 27 Electrical power connection ............................................................. 28 Gas connections ............................................................................. 29 Process gas filters ........................................................................... 29 Pressure Regulators........................................................................ 30 Sample gas pump ........................................................................... 31 Carrier gas Support ......................................................................... 32 Fast Loop connection ...................................................................... 32 Interfaces ........................................................................................ 33 Commissioning ................................................................................ 35 Software .......................................................................................... 38 Screen and Keypad layout .............................................................. 38 Menu keypad ................................................................................... 39 Trend display ................................................................................... 39 Numeric display ............................................................................... 39 Information field ............................................................................... 39 Menu ............................................................................................... 39 Start/Stop ........................................................................................ 39 Numeric keypad .............................................................................. 40 Burner window ................................................................................ 40 Status display .................................................................................. 40 Arrow and data entry keypad .......................................................... 40 Data input ........................................................................................ 40 Value fields...................................................................................... 40 List fields ......................................................................................... 40 ___________________________________________________________________ Manual CWD2005.doc 5 Manual CWD 2005 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. 6.2.1.2.2. 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. 6.2.1.3.7. 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. 6.2.1.3.7.2.9. 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. 6.2.1.5. 6.2.1.5.1. 6.2.1.5.2. Keypad ............................................................................................ 41 Menu Navigation ............................................................................. 41 Menu Overview ............................................................................... 42 Options ............................................................................................ 44 Input/Output I/O ............................................................................... 45 Analog outputs ................................................................................ 45 Relay output .................................................................................... 46 Display mA ...................................................................................... 47 Digital inputs .................................................................................... 47 Display ............................................................................................ 48 Calibration ....................................................................................... 49 Configure Calibration gas ................................................................ 50 Automatic calibration ....................................................................... 50 Calibrate .......................................................................................... 51 Store Basic Calibration .................................................................... 52 Calibration Limits ............................................................................. 52 System ............................................................................................ 53 General ........................................................................................... 54 Ignition............................................................................................. 55 Update............................................................................................. 55 Load factory configuration ............................................................... 56 Curve Data to CSV File ................................................................... 56 Hold Signal on..off ........................................................................... 56 Settings ........................................................................................... 57 Time/Date........................................................................................ 57 Language ........................................................................................ 58 Change language ............................................................................ 59 Bit maps on…off .............................................................................. 59 Transfer W. D:>C: ........................................................................... 60 Transfer W. C:>D: ........................................................................... 60 Read PCX files ................................................................................ 60 Store PCX files ................................................................................ 60 Delete PCX files .............................................................................. 60 PCX Info .......................................................................................... 60 New dictionary ................................................................................. 60 Change USB ................................................................................... 61 Password ........................................................................................ 61 Color Settings .................................................................................. 62 Hardware 1 ...................................................................................... 62 Service ............................................................................................ 64 Customer specific application .......................................................... 65 Air conditioning room temperature .................................................. 66 Serial Printer ................................................................................... 66 ___________________________________________________________________ 6 Manual CWD2005.doc Manual CWD 2005 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. 7.4. 7.5. 8. 8.1. 8.2. 8.3. 8.4. 8.5. 9. 9.1. 9.2. 9.2.1. 9.2.2. 9.2.3. 9.2.4. 9.2.5. 9.2.6. 9.2.7. 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. Dual Sample Streams ..................................................................... 69 Trend Display .................................................................................. 70 Move cursor .................................................................................... 71 Change time .................................................................................... 71 . Change “y” values ......................................................................... 72 Change signals ............................................................................... 73 Change units ................................................................................... 74 Event List ........................................................................................ 75 Device Info ...................................................................................... 76 Maintenance .................................................................................... 78 Safety instructions for maintenance or repair .................................. 78 Periodic maintenance ...................................................................... 78 Consumables .................................................................................. 78 Replacement I/O Boards ................................................................. 79 Spare parts packages ..................................................................... 79 Troubleshooting .............................................................................. 80 Event list.......................................................................................... 80 Unstable readings ........................................................................... 80 Drift in readings ............................................................................... 80 Incomplete ignition .......................................................................... 81 Software troubleshooting................................................................. 81 Measurement principle .................................................................... 84 Heating Value measurement, an overview ...................................... 84 Thermopile measuring system ........................................................ 85 Specific Gravity measuring cell ....................................................... 87 Operational overview of the measuring cell..................................... 87 Functional diagram .......................................................................... 88 Output signals ................................................................................. 88 Commissioning ................................................................................ 88 Testing and calibration .................................................................... 89 Maintenance .................................................................................... 89 Technical specifications .................................................................. 89 Circuit diagrams .............................................................................. 90 Input-Output card: E/A internal ........................................................ 90 Input-Output Card E/A external ....................................................... 93 Input-Output Card E/A external Type _06 ....................................... 93 Relay outputs .................................................................................. 94 Analog outputs ................................................................................ 95 Digital/ Relay contact inputs ............................................................ 96 Open collector drives or mA outputs ............................................... 97 Serial interface RS232 (Option) ...................................................... 98 Profibus-DP Interface ...................................................................... 99 Appendices ................................................................................... 100 ___________________________________________________________________ Manual CWD2005.doc 7 Manual CWD 2005 11.1. 11.2. 11.3. 11.4. 11.5. 11.5.1. 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. Spare parts list .............................................................................. 100 Pressure regulators ....................................................................... 100 Low sample pressure .................................................................... 100 Gas conditioning ........................................................................... 100 Gas connections ........................................................................... 101 Adjust pressure regulator .............................................................. 101 Calibration gas connection ............................................................ 101 Process gas connection ................................................................ 102 Double Range ............................................................................... 104 Carrier Gas .................................................................................... 105 Fast loop ....................................................................................... 106 Air Consumption (Option) .............................................................. 106 Calculated Air Consumption .......................................................... 106 Air Consumption with CO measurement ....................................... 107 Spare parts.................................................................................... 110 Spares electronics ......................................................................... 110 Spares Electric .............................................................................. 111 Spares gas .................................................................................... 114 Spares measurement system ........................................................ 116 Spares burner ............................................................................... 118 Spares air ...................................................................................... 120 Spares enclosure .......................................................................... 120 Technical Data .............................................................................. 121 ___________________________________________________________________ 8 Manual CWD2005.doc Manual CWD 2005 1. Important Information Important Information Thank you for specifying a Union CWD 2005 Heating Value Analyzer for your online process measurement application. 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 particular system. Union Apparatebau reserves the right to make change without notice both to this publication and the product that it describes. ___________________________________________________________________ Manual CWD2005.doc 9 Important Information 1.1. Manual CWD 2005 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 (> 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. If process 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 Manual CWD 2005 Important Information When planning the installation, local site conditions must be taken into account. 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 process 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. ___________________________________________________________________ Manual CWD2005.doc 11 Introduction Manual CWD 2005 ___________________________________________________________________ 12 Manual CWD2005.doc Manual CWD 2005 2. Introduction 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 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 maintain 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 ___________________________________________________________________ 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. TRE - 7°C < TR < TRE + 7°C TR TRE where dTR dt 2C hour Room temperature 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 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 stepless 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. Dead time 50% time 90% time 99% time Response times 3 sec 7 sec 20 sec 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 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 Manual CWD 2005 Analyzer Overview ___________________________________________________________________ Manual CWD2005.doc 15 Analyzer Overview 3. Manual CWD 2005 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. Figure 1: CWD 2005 components shown above but without doors for clarity ___________________________________________________________________ 16 Manual CWD2005.doc Manual CWD 2005 1 Output thermopile (mV Wobbe Index) 2 Fixing screws thermopile 3 4 PT 100 sensor temperature correction PT 100 sensor temp correction differential temperature 5 PT 100 sensor temp correction differential temperature 6 Cooling air orifice measurement „-“ 7 8 Cooling air orifice measurement „+“ Air pressure sensor differential pressure 9 Ignition electrode 10 Enclosure purging 11 12 Burner Ignition transformer 13 Line filter ignition transformer 14 Air fan 15 16 Power supply for fan air Line filter power supply fan air 17 Terminal block power supply 18 Cable gland signals 19 20 Cable gland signals Cable gland signals 21 Cable gland signals 22 23 Cable gland line power Cable gland signals 24 Electronic - extern output signals digital and analog 25 Safety switch ignition transformer 26 27 PT 100 sensor box inlet temperature Electronic - Intern A/D-converter solenoid valve control 28 Differential pressure Wobbe jet 29 Cap for Wobbe jet 30 31 Precision pressure regulator Pressure sensor gas 32 Jet differential pressure S.G.Cell 33 Gas pre pressure regulator 34 35 S.G.cell Solenoid valve process gas 36 Solenoid valve calibration gas 37 Discharge gas air flow Analyzer Overview ___________________________________________________________________ Manual CWD2005.doc 17 Analyzer Overview Manual CWD 2005 Figure 2: Rear inside view of main door 1 3 5 7 Power supply Blower power supply ETX Board Keypad back side 2 4 6 Port for connections Main Board Blower ETX Board ___________________________________________________________________ 18 Manual CWD2005.doc Manual CWD 2005 Analyzer Overview Figure 3: Front view 1 3 5 7 9 11 Cable gland signals Cable gland signals Cable gland ground M16 Switch on…off Discharge Cover analog signals 2 4 6 8 10 Cable gland signals Cable gland signals PS M20 Filter cover Door lock Display ___________________________________________________________________ Manual CWD2005.doc 19 Analyzer Overview Manual CWD 2005 Figure 4: Enclosure shown from left hand side 1 3 5 7 9 11 Cable gland, signal Cable gland, signals Cable gland, signals Interface connections Carrier gas (SV.X11/3-4)* Calibration gas (SV.X14/1-2) 1 4 6 8 10 12 Cable gland power Cable gland, signals USB Connection Fast loop Calibration gas 2 (SV. X14/3-4)* Process gas (SV. X11/ 1-2) 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 Manual CWD 2005 3.1. Analyzer Overview Dimensions, weights Figure 5: Enclosure dimensions Height: Width: Depth: Weight: Protection: 1020 mm 720 mm 337 mm 50.5 kg IP 54 40.2 inches 28.3 inches 13.2 inches 111 lbs 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. ___________________________________________________________________ Manual CWD2005.doc 21 Analyzer Overview 3.2. Manual CWD 2005 Gas connections Gyrolok ¼” tube (6 mm) gas connections are located on the left hand side of the unit. The process and calibration gases should 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” H 2O). Lower calorific gases (1000 kcal) require a pre-pressure of 40 to 60 mbar (24” H2O). If 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 when 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 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 l/h. Gas consumption 48 * d² Litre / hour Specific Gravity Dimension: Wobbe jet diameter in mm Specific Gravity: Process gas/calibration gas Gas consumption Dimension: Specific Gravity: 1,695 * d² scf / hour Specific Gravity Wobbe jet diameter in mm Process gas/calibration gas ___________________________________________________________________ 22 Manual CWD2005.doc 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/Nm³) or 60000 Wobbe (kj/Nm³) 18.1 liter/h In BTU and cubic feet 0 – 1450 Wobbe (Btu/ft.³) 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/Nm³) or 25000 Wobbe (to kj/Nm³) 53.22 liter/h In BTU and cubic feet 0 – 630 Wobbe (Btu/ft.³) 1.89 ft³/ hour Example 3: Wobbe jet Size: 1.85 S.G Blast Furnace gas: 1.032 The Blast Furnace gas / Coke gas consumption corresponds to a range of Wobbe Index of: 1400 Wobbe (kcal/Nm³) or 6000 Wobbe (kj/Nm³) 152,5 liter/hour In BTU and cubic feet 0 – 150 Wobbe (Btu/ft.³) 5.41 ft³/ hour ___________________________________________________________________ Manual CWD2005.doc 23 Analyzer Overview 3.4. Manual CWD 2005 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 CO2 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 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 Manual CWD 2005 4. Installation Installation Figure 6: Enclosure attachment / Exhaust 1 3 5 Fixing element Draft brake Fixing barcket 2 4 Cover insulation Discharge CWD 2005 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 ___________________________________________________________________ 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. 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 Manual CWD 2005 4.1. Installation 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. If 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 m³/h of air. This air must be delivered from outside the enclosure using suitable ventilation. The fresh air should not be connected directly into the 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: 4.3. 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. Exhaust gas discharge The small quantity of flue gas is mixed with 25 m³ 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 components. 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). ___________________________________________________________________ Manual CWD2005.doc 27 Installation 4.4. Manual CWD 2005 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. Figure 8: Connector block assembly 1 3 5 7 9 Power supply customer Door safety switch Power supply Door switch signal Fan with power supply 2 4 6 8 Main switch: instrument on/off Line filter Ignition transformer Ignition impulse ___________________________________________________________________ 28 Manual CWD2005.doc Manual CWD 2005 4.5. Installation 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 filters 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. Figure 9: Small filter 1 3 5 Input ¼” (6 mm) Gyrolok Removable element cap Filter 20-30 m 2 4 Output ¼” (6 mm) Gyrolok Filter body 316 SS Dirty gases need a filter with a larger volume and this will increase dead time. Figure 10: Filter with drain connection 1 3 5 7 Filter inlet Inlet ¼” (6 mm) Gyrolok Filter 99,8% at 0,1 m Filter housing 316 SS 2 4 6 Filter way Outlet ¼” (6 mm) Gyrolok Filter cap (7) Filter volume: 23 cm³ (0.00081 ft³ or 1.4 cu. inches) ___________________________________________________________________ Manual CWD2005.doc 29 Installation 4.5.2. Manual CWD 2005 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” H2O) depending on type. Gas pressures higher than 6 bars (90 PSI) need a primary regulator to reduce the pressure to the inlet of the pre-pressure regulator. The standard analyzer consists of one process gas inlet and one calibration gas inlet and both inlet ports require a pre-pressure regulator. All connectors are mm or inch. Adjust the process gas and calibration gas regulator outlet pressures to read the same pressure when gases are switched, this is important for measurement stability. The first pre-pressure regulator < 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” H2O) orange 30 mbar (20” H2O) blue. Figure 11: Fisher 912 pre-pressure regulator < 6 bars (90 PSI). 1 3 Inlet ¼(6 mm) Gyrolok tube Control spring 2 4 Outlet ¼(6 mm) Gyrolok tube Vent The next unit is a primary regulator < 250 bars (3600 PSI) type GO PR1 has a 316 SS body and gauges. The outlet (2) pressure is adjustable from 0– 3.4 bar. A prepressure regulator is still necessary and acts as a second stage inlet pressure control for the CWD 2005. ___________________________________________________________________ 30 Manual CWD2005.doc Manual CWD 2005 Installation Figure 12: High-pressure regulator GO PR1 < 250 bar (3600 PSI) 1 3 5 Inlet ¼” (6 mm) Gyrolok tube Gauge high pressure Pressure control wheel 2 4 Outlet ¼” (6 mm) Gyrolok tube Gauge, low pressure The last is a primary regulator < 250 bar (3600 PSI) with a 316 SS body and gauges adjustable outlet pressure from 0 – 3.4 bar and has a gas cylinder CGA connection. Hydrocarbons W 21.8 x ¼“ 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 < 250 bar (3600 PSI) 1 3 5 Inlet connection to suit gas cylinder Gauge high pressure Pressure control wheel 4.5.3. 2 4 Outlet ¼”(6 mm) Gyrolok tube Gauge low pressure Sample gas pump If 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 ___________________________________________________________________ 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 Liter /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 Manual CWD 2005 4.6. Installation 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 3 5 USB Interface mouse Interface Parallel interface 2 4 VGA Display Keyboard interface ___________________________________________________________________ Manual CWD2005.doc 33 Commissioning Manual CWD 2005 ___________________________________________________________________ 34 Manual CWD2005.doc Manual CWD 2005 5. Commissioning 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 when 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. Figure 15: Specific Gravity cell shown locked for transport Figure 16: Specific Gravity cell shown in its operating position ___________________________________________________________________ Manual CWD2005.doc 35 Commissioning Manual CWD 2005 Remove the transport packing from the gas pressure regulator. Polystyrene foam is located beneath the removable regulator cover and must be removed before use. Check the process and calibration gas connections for tightness and correct connection. Check any carrier gas or second calibration gas connection if supplied. Switch on the 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 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. If 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. If 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. ___________________________________________________________________ 36 Manual CWD2005.doc Manual CWD 2005 Software ___________________________________________________________________ Manual CWD2005.doc 37 Software 6. Manual CWD 2005 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 Figure17: Display screen and Keypad 1 2 3 4 5 Menu keypad Trend display Numeric display Information field Return to main menu 6 7 8 9 10 Start/Stop Numeric input keypad Flame status window and LED Operating status display LED‟s Arrow and data entry keypad ___________________________________________________________________ 38 Manual CWD2005.doc Manual CWD 2005 6.1.1. Software Menu keypad The menu keys are described in the software section and the function depends on the menu currently displayed and the function changes 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 < 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 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. ___________________________________________________________________ Manual CWD2005.doc 39 Software 6.1.7. Manual CWD 2005 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. Using 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 . 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 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. ___________________________________________________________________ Manual CWD2005.doc 41 Software Manual CWD 2005 6.2. Menu Overview 6.2 6.2.2. Main Menu Trend 6.2.1.2. 6.2.1.3.7.2.1 Calibration Change language 6.2.1.2.1. 6.2.1. Options Config. calibr. gas Selection 6.2.1.3.7.2.2. Bit maps on /off 6.2.1.3.7.2.3. Transfer D: -> C: 6.2.1.2.2. 6.2.2. Change time Automatic calibr. 6.2.1.3.7.2.4. Transfer C: -> D: 6.2.2.2. 6.2.1.2.3. "Y" values Calibrate 6.2.1.3.7.2.5. Read PCX files 6.2.2.3. Change signals 6.2.1.2.4. 6.2.1.3.7.2.6. Store PCX files 6.2.2.1. Trend 6.2.3. Event list 6.2.4. Store basic calib. Device info 6.2.2.4. Change units 6.2.1.2.5. Calib.limits 6.2.2.5. Move cursor 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 dictionary 6.2.1.3. System 6.2.1.3.7.2.10. Cange drive 6.2.1.3.1. General 6.2.1. Options 6.2.1.1. 6.2.1.3.7.1. I/O 6.2.1.3.2. Date and time Ignition 6.2.1.1. I/O 6.2.1.1.1. Analog output 6.2.1.2. Calibration 6.2.1.3. System 6.2.1.1.2. Relay output 6.2.1.1.3. Disp. mA 6.2.1.3.3. 6.2.1.3.7.2. Update Language 6.2.1.3.4. Load fact. conf. 6.2.1.3.7.3. Password 6.2.1.3.5. Export CSV-file Service 6.2.1.5. Customer application 6.2.1.3.7.4. Color settings 6.2.1.4. 6.2.1.1.4. Digital Input 6.2.1.3.6. Hold signals on/off 6.2.1.3.7.5. Hardware 1 6.2.1.1.5. 6.2.1.3.7. Display Settings menue kurz engl CWD2005_2007_03_30 ___________________________________________________________________ 42 Manual CWD2005.doc Manual CWD 2005 Software The Info field is right ahead 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. V 2.07 version number of soft ware R02. Instrument runs on process gas. During a calibration the indication switches to calibration. Actual date and time 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 ___________________________________________________________________ Manual CWD2005.doc 43 Software Manual CWD 2005 Fr = 42.01 controlled frequency of the fan 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 main menu. leads back to the 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 Manual CWD 2005 6.2.1.1. Software Input/Output I/O 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 and back to the main menu move the marked value right or left. The symbol leads 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. ___________________________________________________________________ Manual CWD2005.doc 45 Software Manual CWD 2005 Signal is a multiple choice scrolling list field with the following text entries: Calorific Value; Wobbe, < Wobbe >, Specific Gravity, CV net . Type 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 /ft3, kJ/Nm3, MJ/Nm3, kWh/Nm3, kcal/Nm3, kJ/Sm3, MJ/Sm3, kWh/Sm3 kcal/Sm3 Specific Gravity: specific to air (1.0), absolute kg/Nm3 “Range from” – “Range to” are value fields for numerical inputs. 6.2.1.1.2. Relay output The relay output configuration 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 < > 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 Manual CWD 2005 6.2.1.1.3. Software 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. . 6.2.1.1.4. Digital inputs Signal and zero position are multiple choice list fields. These inputs can start a calibration cycle, or switch on and off an output hold module. The inputs are polled once a second and any change of status must apply for at least one second to be recognized by the system. Signal Start measurement Zero position Contact high open low high Start calibration Hold signal low CWD 2005 CWD2005 measurement closed CWD2005 measurement stop open closed open closed open closed CWD2005 measurement stop CWD2005 measurement Calibration starts No calibration No calibration Calibration starts high open mA hold low closed open mA online mA online closed mA hold ___________________________________________________________________ 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). 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 Manual CWD 2005 6.2.1.2. Software Calibration 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 configuration, 1 or 2 calibration gases are required. This depends on how far the two measuring ranges overlap. If the overlap is large, a single calibration gas is usually sufficient. This is determined on an application basis during final calibration. All analyzers with the carrier gas option calibrate during operation on carrier gas and again using both carrier gas and process gas to establish correct calibration in all modes against calibration gases. Dual sample stream analyzers usually use a single calibration gas. 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. ___________________________________________________________________ Manual CWD2005.doc 49 Software 6.2.1.2.1. Manual CWD 2005 Configure Calibration gas Calibration gas data is entered as a Wobbe Index and Specific Gravity number. If the gas vendor has only 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 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: Air can become trapped in the gas supply tubing during installation. Purge the lines before first calibration or after changing the calibration gas cylinder. The “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. ___________________________________________________________________ Manual CWD2005.doc 51 Software 6.2.1.2.4. Manual CWD 2005 Store Basic Calibration Store basic calibration 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 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 Manual CWD 2005 6.2.1.3. Software System This menu item contains the following basic analyzer configuration parameters.Two pages open the different items of the menu. The button the other page. swiches from one page to The next line with other three menus. ___________________________________________________________________ Manual CWD2005.doc 53 Software 6.2.1.3.1. Manual CWD 2005 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. 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 Manual CWD 2005 6.2.1.3.2. Software 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 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 If 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. ___________________________________________________________________ Manual CWD2005.doc 55 Software 6.2.1.3.4. Manual CWD 2005 Load factory configuration “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 the 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. ___________________________________________________________________ 56 Manual CWD2005.doc Manual CWD 2005 6.2.1.3.7. Software 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 Set the system time and date, the clock stops when the menu is open. Use CANCEL to exit the menu without making any changes. ___________________________________________________________________ Manual CWD2005.doc 57 Software 6.2.1.3.7.2. Manual CWD 2005 Language The menu language consists of 10 submenus. With the button be reached. all the menus can After the first 4 menus the next 4 menus appear and at least the last 2 ones. ___________________________________________________________________ 58 Manual CWD2005.doc 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. ___________________________________________________________________ Manual CWD2005.doc 59 Software Manual CWD 2005 6.2.1.3.7.2.3. Transfer W. D:>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:>D: This 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-0000.pcx. for entering new signs also chinese. 6.2.1.3.7.2.9. New dictionary If 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 Manual CWD 2005 6.2.1.3.7.2.10. Software 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 0 switches the password system off. A default is available if the password is lost. ___________________________________________________________________ Manual CWD2005.doc 61 Software Manual CWD 2005 6.2.1.3.7.4. Color Settings 6.2.1.3.7.5. Hardware 1 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 all inputs for different ranges and carrier gases. Range No. the number of ranges installed . Maximum number is three. Diam Wjet. The Wobbe Jet diameter in mm. ___________________________________________________________________ 62 Manual CWD2005.doc 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/Nm3. 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 possible non automatic manuel 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. ___________________________________________________________________ Manual CWD2005.doc 63 Software 6.2.1.4. Manual CWD 2005 Service User access to the service menu is not required for normal operation as all the user menus and controls are located outside of this area. The screen shot above shows a 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 Manual CWD 2005 6.2.1.5. Software 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. ___________________________________________________________________ Manual CWD2005.doc 65 Software 6.2.1.5.1. Manual CWD 2005 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 the factory only change parameters after consultation with the manufacturer. 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 Manual CWD 2005 Software . The “Cut paper“ command 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. ___________________________________________________________________ Manual CWD2005.doc 67 Software Manual CWD 2005 “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 outputs 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 (1+2+4+8+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 Manual CWD 2005 6.2.1.5.3. Software 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. 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 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. ___________________________________________________________________ Manual CWD2005.doc 69 Software 6.2.2. Manual CWD 2005 Trend Display 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 state 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. 2 The arrows and the return on the right site of the display window with the same functions and additional functions. After pressing the button ”Trend” the menu enters in the same menu which has been leaving before. The following trend menus are available Move cursor Change time Change “y” value Change signals Change units. ___________________________________________________________________ 70 Manual CWD2005.doc Manual CWD 2005 6.2.2.1. Software Move cursor With the Button and the selection of the three info windows is done. To change the selected line and choose the different physical values the arrows and the return in the circle are active points next physical value. . Every touch of the arrows scrolls to the Available values: Cal Vi 2 Wobbe I 2 free Spec grav 2 Cal Vs 2 cal Vi Wobbe i Wobbe s Spec grav Cal Vs T sec T ein dT T amb Ti T Res 3 p air p Wobbe p density p res 3 mV All three info windows are prepared for all physical values and can be displayed in the diagram. 6.2.2.2. 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. ___________________________________________________________________ Manual CWD2005.doc 71 Software Manual CWD 2005 Every touch of the button makes one step. The meaning of the symbols are: 6.2.2.3. Value linear right 25% x axis Value linear left 25% x axis Value pressed 25% x axis Value stretched 25% x axis . Change “y” values ___________________________________________________________________ 72 Manual CWD2005.doc Manual CWD 2005 Software Value linear up Value linear down 25% 25% y axis y axis Value pressed 25% y axis Value stretched 25% y axis Now the specific gravity window is selected. The three lines Dif y Off y value delta from line to line Position of the offset actual value 15,00 1177,441 1221,266 are important to have a good most significant graph of the specific gravity. 6.2.2.4. Change signals The handling of the menu change signals is the same as before described. ___________________________________________________________________ Manual CWD2005.doc 73 Software 6.2.2.5. Manual CWD 2005 Change units The handling of the menu change signals is the same as before described. Note: The trend data is the only data that will be erased if power is lost to the instrument. ___________________________________________________________________ 74 Manual CWD2005.doc Manual CWD 2005 6.2.3. Software Event List 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 the message “AD calibration” and not “ADU error”. ___________________________________________________________________ Manual CWD2005.doc 75 Software 6.2.4. Manual CWD 2005 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.. ___________________________________________________________________ 76 Manual CWD2005.doc Manual CWD 2005 Maintenance ___________________________________________________________________ Manual CWD2005.doc 77 Maintenance Manual CWD 2005 7. Maintenance 7.1. Safety instructions for maintenance or repair Use the main power switch to remove power for maintenance 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 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 Manual CWD 2005 7.4. Maintenance Replacement I/O Boards If 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 operating experience. The one-year package contains consumables and spare parts for 1 year of normal operation. Process criticality, installation location and country of use should be taken into consideration to determinate what spare parts should always be available locally. Spare parts list: One Year operation 1 3 5 7 (1) Blower power supply (10) Quartz burners jets (2) Paper filters (1) Diaphragm gas pressure regulator 2 4 6 8 (2) Fuse to power supply (2 m) EMV door gasket (2 m) Rubber tube NBR 4x2 mm (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 3 5 7 9 11 13 15 (1) Blower power supply (10) Quartz burner jets (2) Paper filters (1) Diaphragm gas pressure regulator (1) Gasket for heat exchanger (1) Thermopile 1x24 TE (1) Ignition transformer (1) Sensor differential pressure air 2 4 6 8 10 12 14 16 (2) Fuse to power supply (2 m) EMV door gasket (2 m) Rubber tube NBR 4x2 mm (1) Heat exchanger (1) Solenoid valve (1) Ignition electrode (1) Sensor differential pressure gas (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, they 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. ___________________________________________________________________ Manual CWD2005.doc 79 Troubleshooting 8. Manual CWD 2005 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 results in rapid temperature fluctuations. In unprotected installations direct sunlight on the analyzer should always be avoided. 3. Rapid temperature fluctuations Air conditioning systems or heating units with large cooling capacity and large control hysteresis can cause instability. 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 Manual CWD 2005 8.4. Troubleshooting 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 operating 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, 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. ___________________________________________________________________ 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. Caution: The program starts automatically and after finishing the routine (ignore any other screen prompts!) will return 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. 1 2 3 4 5 6 Full Instrument EAintern EAextern Configuration Instrument update backup update update update Backup .int + .ext to To To To full system l ▼ Full update update l ▼ .cfg . par system l ▼ system l ▼ system l ▼ to memory stick I ▼ 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 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 the 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. ___________________________________________________________________ Manual CWD2005.doc 83 Measurement principle 9. Manual CWD 2005 Measurement principle The measurement of process gases by the CWD 2005 is 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 (ZrO 2) 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 BTU 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 Manual CWD 2005 Measurement principle 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 9.2. WobbeIndex Specific Gravity Thermopile measuring system Figure 18: The main components of the calorimeter 1 3 5 7 9 11 13 15 17 Range orifice Cooling air flow Thermopile (cold junctions) Gas flow Pressure sensor Temperature sensor Specific Gravity cell Heat exchanger Temperature sensor 2 4 6 8 10 12 14 16 16 Burner Thermopile (hot junctions) Output signal Pressure regulator Temperature sensor Temperature sensor Cooling air fan Pressure sensor 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 ___________________________________________________________________ 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 Index 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 Manual CWD 2005 9.2.1. Measurement principle Specific Gravity measuring cell The CWD 2005 (The W 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 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. ___________________________________________________________________ Manual CWD2005.doc 87 Measurement principle 9.2.3. Manual CWD 2005 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 Specific.Gravity 0 - 5 Volt U Spec. Gravity / V = 2.5 x Specific Gravity – 0.5 In certain cases, the measuring range is 0.0 – 2.0 Specific Gravity (Air = 1.0) The output signal for the measuring cell is expressed as: U Specific.Gravity 0 – 5 Volt U Spec. Gravity / V = 2.5 x Specific Gravity 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 cell 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. 4-5 l) 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 Manual CWD 2005 9.2.6. Measurement principle Testing and calibration Specific gravity cell function can be tested using 2 gases. The specific gravity of the two gases should differ by more than 0.5 so that the zero and span can be checked. If non-flammable gases are used, such as N2 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. 9.2.7. Maintenance The specific gravity cell requires no regular maintenance. From time to time, the pressure drop across the density cell should be checked. After installation the sensor housing must be able to move freely on the springs. A defective specific gravity cell can be sent in for repair. The output for calorific value can be turned off in the software and the unit will now measure Wobbe Index only. 9.2.8. Technical specifications gas-inlet gas-outlet 1 2 4 LFE 209C 3 ST2 1 9 Insulation Figure 20: Specific gravity measuring cell, heated and insulated 1. 2. Potentiometer 1 Zero Potentiometer 2 Span 3. 4. Suspension springs Insulating discs ST2 PIN terminals 1 2 3 4 5 6 7 8 9 + 15 V - 15 V Location pin Ground Not Connected Location pin +5V Not Connected Ground Power Supply 7 VA Power Supply 7 VA Measurement signal Specific Gravity 0-5 Volt ___________________________________________________________________ Manual CWD2005.doc 89 Circuit diagrams 10. Manual CWD 2005 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 1 2 X10 3 4 3 4 X14 X11 X9 X8 1 2 1 2 1 2 1 2 D9 D10 D11D12 D13 D14 D15 D16 12 7 X15 1 6 3 4 3 4 X16 X17 1 2 1 2 D2 D7 D21 D22 4 6 X2 1 3 4 3 4 1 3 4 X3 6 3 3 4 X7 D3 1 2 D1 4 1 X1 6 3 4 1 X12 X4 6 3 6 1 X5 10 5 6 1 X6 10 5 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 CWD2005.doc Manual CWD 2005 Plug X10 Pin 1 +24V VI Pin 2 -24 V VIS Plug x14 Pin 1 GND Pin 2 +24V Pin 3 GND Pin 4 +24V Plug x11 Pin 1 GND Pin 2 +24V Pin 3 GND Pin 4 +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 -15 V Pin 4 DI Pin 5 DI + Pin 6 +15V Pin 7 N.C. Pin 8 N.C. Pin 9 N.C. Pin10 PE Pin11 Wobbe Pin12 Wobbe + Plug x 16 Pin 1 N.C. Pin 2 N.C. Pin 3 N.C. Pin 4 N.C. Plug x 17 Pin 1 N.C. Pin 2 N.C. Pin 3 N.C. Pin 4 N.C. Plug x 2 Pin 1 PT1+ Pin 2 PT1Pin 3 PE Pin 4 PT2+ Pin 5 PT2Pin 6 PE Circuit diagrams Thermal switch Thermal switch Solenoid valve calibration gas I Solenoid valve calibration gas I Solenoid valve calibration gas II Solenoid valve calibration gas II Solenoid valve process gas Solenoid valve process gas Solenoid valve carrier gas Solenoid valve carrier gas N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. 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 (upper side, front side) Solenoid valve gas (upper side, front side) Solenoid valve air (upper side, back side) Solenoid valve air (upper side, back side) Solenoid valve gas (lower side, front side) Solenoid valve gas (lower side, front side) Solenoid valve air (lower side, back side) Solenoid valve air (lower side, back side) TOB Temperature upper enclosure TOB Temperature upper enclosure Screen TL1 Temperature air 1 TL1 Temperature air 1 Screen ___________________________________________________________________ Manual CWD2005.doc 91 Circuit diagrams Plug x 3 Pin 1 PT6+ Pin 2 PT6Pin 3 PE Pin 4 Pin 5 N.C. Pin 6 N.C. Manual CWD 2005 No Connection No connection Screen N.C.. Plug x 7 Pin Pin Pin Pin 1 2 3 4 No Connection No Connection Signal door closed Signal door closed logical signal to enable ignition impulse logical signal to enable ignition impulse Plug x 1 Pin 1 PT3+ Pin 2 PT3Pin 3 PE Pin 4 PT4+ Pin 5 PT4Pin 6 PE No Connection No Connection Screen No Connection No Connection Screen Plug x 4 Pin 1 P1T5+ Pin 2 IPT5Pin 3 PE Pin 4 P2T5+ Pin 5 IPT5Pin 6 PE T Thermal temperature surface component T Thermal temperature surface component Screen TL2 Temperature air 2 TL2 Temperature air 2 Screen Plug x 5 Pin 1 PE Pin 2 DP2Pin 3 DP2+ Pin 4 AGND Pin 5 +15V Pin 6 PE Pin 7 DP1+ Pin 8 DP1 Pin 9 AGND Pin10 +15V Pin10 PE Plug x 6 Pin 1 PE Pin 2 DP4Pin 3 DP4+ Pin 4 AGND Pin 5 +15V Pin 6 PE Pin 7 DP3+ Pin 8 DP3 Pin 9 AGND Pin10 +15V 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 differential pressure Wobbe jet Supply differential pressure Wobbe jet No Connection Input adapter Input adapter Input adapter Input adapter ___________________________________________________________________ 92 Manual CWD2005.doc Manual CWD 2005 10.2. Circuit diagrams Input-Output Card E/A external The user electrical connections have the following technical dimensions: Connections: Conductor cross section solid 0.14 mm² - 1.5 mm² Conductor cross section stranded 0.14 mm² - 1.5 mm² stripping length: 7 mm 10.2.1. Input-Output Card E/A external Type _06 X7 L10 L9 L8 L4 L7 L1 JP 4 JP 3 JP 8 JP 12 JP 7 JP 6 JP 11 JP10 JP 5 D7 D8 D9 D10 D19 D18 D14 D15 D16 D17 D2 D4 D5 D6 D25 D24 D23 D22 D21 D20 DC/DC OPTION TR9 DC/DC OPTION DC/DC OPTION TR10 DC/DC OPTION TR8 TR4 DC/DC OPTION TR7 DC/DC OPTION DC/DC OPTION TR3 DC/DC OPTION TR6 TR2 DC/DC OPTION DC/DC TR1 X6 X9 X8 TR5 X4 JP 9 X 15 5 1 16 13 X5 12 Relay outputs 1 24 9 X3 8 mA outputs 1 12 Digital inputs / Digital Outputs Open Collector 16 X11 1 6 9 1 24 X14 8 PT100 input / Serial output X1 13 9 X12 X10 1 1 1 1 1 L6 L3 L5 X17 X16 L2 X 16 X15 1 1 1 X13 X2 1 EAextern-06 D1 Serial output Figure 22: Input-Output -E/Aextern_06 Type external with removable terminal blocks. Terminal blocks X3, X5, X11 and X14 are customer connections for contact inputs, relay outputs, analog outputs and RS232 and have removable plugs for wiring. D1 to D25 are status LED`s. ___________________________________________________________________ Manual CWD2005.doc 93 Circuit diagrams 10.2.1.1. Manual CWD 2005 Relay outputs The relay outputs are connected to terminal block X14. The relay contacts have the following specifications Maximum current: 1amp max. 100 Volt, 100V DC/30Watt, 100V AC/60VA If the relay is operational, a red alarm LED is illuminated. The functional position for the relay outputs can be user configured from the menu and the standard factory configuration is shown below. Block X14 on I/O Card EA External type_06 Position Terminals 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC Common norm.open norm.closed Maintenance Function Alarm LED Process D 2 D 4 Filter change D 5 Fault D 6 Wobbe I