CODEL Energy Tech 401 Installation, Operation And Maintenance Manual Download Page 1

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Operating and Maintenance Manual

Monitoring Solutions

Issue: A Revision: 1 Date: 05/07/19 Ref: 100606

EnergyTech 401

CODEL

Energy Tech 401

Cross-Duct IR CO Analyser

Installation, Operation and Maintenance Manual

CODEL International Ltd.

Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom

t : +44 (0) 1629 814 351 f : +44 (0) 8700 566 307 e : [email protected] web : www.codel.co.uk

Summary of Contents for Energy Tech 401

Page 1: ...606 EnergyTech 401 CODEL CODEL Energy Tech 401 Cross Duct IR CO Analyser Installation Operation and Maintenance Manual CODEL International Ltd Station Building Station Road Bakewell Derbyshire DE45 1GE United Kingdom t 44 0 1629 814 351 f 44 0 8700 566 307 e codel codel co uk web www codel co uk ...

Page 2: ...Issue A Revision 1 Date 24 07 19 Ref 100606 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions ...

Page 3: ...aintenance CODEL has set standards both for itself and for the rest of the industry All development and design work is carried out in house by experienced engineers using proven state of the art CAD and software development techniques while stringent assembly and test procedures ensure that the highest standards of product quality synonymous with the CODEL name are maintained High priority is plac...

Page 4: ...Issue A Revision 1 Date 24 07 19 Ref 100606 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions ...

Page 5: ... of Cross Duct Gas Analysers 22 3 INSTALLATION INSTRUCTIONS 27 SAFETY CONSIDERATIONS 27 3 1 ELECTRICAL SUPPLY DATA 27 3 2 3 2 1 AC Supplies 27 3 2 2 Outputs 27 3 2 3 Normalising Inputs 28 3 2 4 Plant Status Input 28 3 2 5 Cable Requirements 29 UNPACKING THE EQUIPMENT 29 3 3 SITING THE EQUIPMENT 30 3 4 3 4 1 Points to Consider 31 DUCT WORK 32 3 5 ISOLATING VALVES 33 3 6 AIR PURGE 33 3 7 TRANSMITTER...

Page 6: ...w Keys 72 5 4 3 Enter Key 72 PROGRAM TREE 73 5 5 OPERATING MODE 74 5 6 PARAMETER MODE 74 5 7 5 7 1 Identification 75 5 7 2 Parameters 75 5 7 3 Averages 75 5 7 4 Output 75 5 7 5 Alarm 76 5 7 6 Plant Status 76 NORMALISATION 77 5 8 5 8 1 Display Format 77 DIAGNOSTIC MODE 78 5 9 5 9 1 Detector Levels 79 5 9 2 Chopper Motor Frequency 79 5 9 3 YVals Gas ppm 80 5 9 4 Calibration Data 80 5 9 5 Fault Condi...

Page 7: ...14 EMERGENCY SHUTDOWN PROCEDURE 104 5 15 ISOLATION PROCEDURE 104 5 16 INTERFACE WITH INTEGRATED EMISSIONS MONITORING SYSTEM 104 5 17 61 MAINTENANCE 106 ROUTINE MAINTENANCE PREVENTATIVE 106 6 1 6 1 1 Cleaning Windows 106 6 1 2 Replacement of the Heater Element 106 6 1 3 Replacement of Chopper Motor Assembly 107 6 1 4 Replacement of Gas Cells 107 RECOMMENDED SPARE PARTS 109 6 2 FAULT FINDING 109 6 3...

Page 8: ...Issue A Revision 1 Date 24 07 19 Ref 100606 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions ...

Page 9: ...d meanings shown below are used throughout these instructions and are intended to ensure your safety while carrying out installation operation and maintenance procedures Please read these instructions fully before proceeding Caution risk of electric shock Caution risk of danger Caution hot surface Earth ground terminal Protective conductor terminal ...

Page 10: ...Issue A Revision 1 Date 24 07 19 Ref 100606 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions ...

Page 11: ...0Ω max Volt free contact 10A 250V Volt free contact 10A 250V Inputs Oxygen Temperature Pressure Plant status Contact 4 20mA 4 20mA 4 20mA Volt free contact Serial Port for remote instrument operation normalising inputs and outputs Path Length 0 5 to 8m Flue Gas Temperature 0 to 650 C Construction cast aluminium fully sealed to IP65 Transmitter electrically heated silicon nitride cylinder Detector ...

Page 12: ...perate on duct widths of less than 8m at flue gas temperatures up to 300 o C The rugged construction makes installation extremely simple and through the use of microprocessor technology they have many advanced features local normalising inputs for compliance with legislation requirements serial data facility to allow communication between analysers and a central data logging station user definable...

Page 13: ...e duct a receiver to measure that radiation a power supply unit to provide the necessary power rails and a signal processor to compute the gas concentration from the signals provided by the receiver unit Each of these units is designed to be rugged and durable They are all fully sealed to IP 65 standards and are suitable for outside mounting without the need for further weatherproof enclosures Fig...

Page 14: ...radiation emitted by the heater is then chopped by a motor driven disc and focused across the duct by a lens The chopper disc is driven by a small DC motor The phase and frequency of the chopper disc are monitored by a radiation detector to provide a reference signal that is utilised by the signal processor unit The system calibration is achieved by a small gas cell containing pure reference gas t...

Page 15: ...mately half the radiation is reflected at right angles directly onto a radiation detector The other half of the radiation is transmitted by the beam splitter through a gas cell containing pure reference gas CO and onto a second radiation detector The detectors used are lithium tantalite pyro electric detectors renowned for their sensitivity stability and ability to operate at normal ambient temper...

Page 16: ...cate with other CODEL analysers and a central data logging unit The power supply unit is housed in a fully sealed cast aluminium enclosure and contains the power supplies for the instrument A switched mode power supply is utilised to provide an extremely stable power source able to cope with large fluctuations in the supply voltage The contact outputs are also taken from this unit data valid and h...

Page 17: ...ough a gas cell filled with pure reference gas CO to provide a reference measurement completely unaffected by the measurement gas The basic expression from which the gas concentration in the gas is determined is Y G K D2 D1 Where D1 the reference output from the detector D2 the live output from the detector G a scaling factor 16000 for CO K a constant known as the zero correction factor set so tha...

Page 18: ...ontaining pure CO is then positioned in the sight path and the two detector outputs are measured again to give readings E1 and E2 From the basic scale shape equation Y G K D2 D1 and from the calibration equation Yo G K E2 E1 at zero Yo Set Cal Value or K G Yo E1 E2 thus substituting in the scale shape equation Y G G Yo E1 E2 D2 D1 The two ratios E1 D1 and E2 D2 being derived each from one detector...

Page 19: ...the quantity or number of molecules of gas within their sight path This measurement is converted into a concentration which is fully compensated for the expansion effects of temperature whilst assuming constant atmospheric pressure This basic measurement is referred to as ppm parts per million However to obtain a true concentration vpm ppm by volume the ppm value must be normalised for pressure us...

Page 20: ...and NO2 as the relationship is fixed in particular processes and typically is 95 NO 5 NO2 NOx 1vpm 2 05 x 100 NO mg m 3 The mass concentration present is calculated as below mg m 3 STP N vpm This value is the mass concentration of the gas at STP Finally the effects of water vapour and oxygen need to be considered Since the vpm measurement is already normalised for temperature and pressure the only...

Page 21: ...d for oxygen then standard O2 O2 measured If no correction is required for water vapour then H2O 0 After all these calculations have been performed the resulting measurement is the effective mass concentration of the pollutant normalised to standard conditions in mg Nm 3 Where measured values are required e g to calculate rates of emissions they need to be recalculated for measured temperature and...

Page 22: ...ted in Figure 3 below However two other common flue gas constituents carbon dioxide and water vapour also absorb energy within this wave band Fortunately at 4 7µm IR absorption by each of these gases is at a minimum Figure 4 demonstrates how the absorption spectra of CO CO2 and water vapour affect wavelengths of between 4 5 and 4 9 µm By using a narrow band pass filter which only passes IR energy ...

Page 23: ...m filter it cannot change and the curve is practically flat at CO concentrations of above 10 000 ppm metres A cross duct monitor effectively measures CO molecules in its optical path so the same concentration of CO will have a greater effect across a large measurement path than a small measurement path The term ppm metres is the concentration of CO within the duct multiplied by the gas path length...

Page 24: ...gh a cell containing pure CO the gas filter shown in This absorbs all the energy capable of being absorbed by CO and provides a reference that is unaffected by any CO in the duct but will be affected by any other material e g dust which reduces the energy received from the transmitter in exactly the same way as the other beam The second beam does not have such a cell in front of it and as such is ...

Page 25: ...count of all opticaland electronic gains G scaling factor Figure 6 shows the parameter Y against the CO concentration This is the calibration curve for the instrument and is opposite in shape to the transmissivity curve shown in Figure 5 Each is fixed by the characteristics of the 4 7µm filter and cannot change CODEL CO analysers make full use of this scale shape to provide an easily attainable ca...

Page 26: ...We can also see from Figure 6 that at high CO levels the parameter Y becomes completely insensitive to variable CO levels in the duct such that Y a when the CO b By making Y a when CO b Y 0 when CO 0 and all these errors are eliminated A gas cell containing pure carbon monoxide can be introduced into the IR beam at the source This cell represents a value of 10 000ppm metres and provides a referenc...

Page 27: ... The instrument may be powered from either 85 132V AC 170 264V AC at 47Hz 440Hz A switch within the power supply unit selects the input voltage and an internal 2A 20mm fuse protects the instrument Voltage fluctuations within the above ranges are tolerated without loss of performance and the total power requirement is less than 50VA Three forms of output are provided a selectable fully isolated cur...

Page 28: ...lant status input facility is available to prevent the rolling average stacks being diluted by measurements made during periods where the plant is shut down It is governed by one of three choices a serial input from an integrated system the logic input terminals PS1 and PS2 in the signal processor and multiple Multiple has four options temperature oxygen water vapour thresholds and logic input It ...

Page 29: ...quired twin twisted pair cable with an overall screen see IEM Communications Manual for further details Doc ID 0006 6 analogue inputs any suitable 2 core cable CODEL instruments have an internal impedance of 240 for these inputs Unpacking the Equipment 3 3 After the equipment has been unpacked unless specifically requested by the customer the following equipment items should be found transmitter w...

Page 30: ...le at both sides of the duct for servicing the transmitter and receiver the site should be as free from extremes of temperature and vibration as possible permissible ambient temperature range 20 o C to 70 o C flue gas temperatures should not exceed 300 o C at the point of measurement at higher temperatures instrument accuracy will deteriorate there must be an uninterrupted sight path available bet...

Page 31: ...ation on lenses too high 70 o C potential instrument problems measurement range minimum range depends upon acceptable measurement uncertainty which is 10ppm metres e g for the level of uncertainty to be below 2 of range the minimum range would be 500ppm metres Note 10 ppm CO 12 5 mg m 3 for increased sensitivity reduced uncertainty of measurement the path length must be maximised maximum range 600...

Page 32: ...ide of the duct to be measured these holes should accept a slip fit with the stand off pipe The stand off pipe should now be welded into each hole and a mounting flange welded to each pipe with the tapped holes four square it may be easier to weld the pipe and the flange together before they are fixed to the duct To avoid vibration and movement it may be necessary to fit spreader plates or bracing...

Page 33: ...ld now be bolted to the isolating valve if used or site flanges with a rigid gasket fitted between them using the four countersunk screws provided The adjustable flange is then offered up to the front flange taking care that the O ring seal and snout locate smoothly into the central aperture This is then re secured by the four locking nuts that screw down onto the adjustable flange The arrangement...

Page 34: ...its can only be attached to the air purge in one position make sure this locates correctly Before mounting the air purges ensure that air is supplied to the air purge unit If this precaution is not observed then the air purge and the optical surfaces may be severely contaminated Figure 9 Analyser Head Arrangement Before mounting the transmitter and receiver ensure that air is supplied to the air p...

Page 35: ...r may be supplied by one of three methods negative pressure duct if the duct across which the instrument is measuring operates at a negative pressure under all firing conditions the air purge inlets may be simply left open and the negative draft in the duct allowed to draw in ambient air For positive pressure ducts they must be supplied with either compressed air or air from a blower compressed ai...

Page 36: ...e the low flow required an air supply of 1 bar is required and the consumption is 1 litre second per purge blower air a blower may be used to provide the air to the air purge customers may specify their own blower it should be able to deliver 5 litres second per purge about 10cfm against the working pressure of the duct CODEL can specify a blower if required ...

Page 37: ...ing the four captive screws unplug the ribbon cable at the connector on the lid PCB Note that the processor case has a hinged lid The case is then secured to a firm support by use of the four mounting holes found in the four corners of the case outside the sealing rim Since the mounting holes are located outside the seal of the case it is not necessary to seal the mounting holes after installation...

Page 38: ...Page 38 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Figure 10 Signal Processor Unit Power Supply Unit Mounting Detail ...

Page 39: ... mount the power supply up to a maximum of 10m from the transmitter A maximum total cable length of 25m may be used to link the power supply to the receiver These are the maximum permitted lengths of cable and must not be exceeded Dimensions and mounting hole locations are identical to the signal processor and are illustrated in Figure 10 ...

Page 40: ...ifferent routes if possible to reduce the risk of cross interference Leave sufficient free end length to make final connections CODEL supplied cables are provided with ferrite beads fitted to all cores to protect against interference and should not be modified without consulting CODEL 3 12 1 Installation and Connection of Cables Wiring should only be undertaken by a qualified Technician DANGER Ens...

Page 41: ...tion 3 Installation Instructions Issue A Revision 1 Date 24 07 19 Ref 100606 Page 41 Overall system connections are illustrated in Figure 11 3 12 2 Connection Schedule Figure 11 System Connection Schedule ...

Page 42: ...gral adjustable mounts gain adjustment adjust the gain within the receiver head and the signal processor operating parameters set the operating parameters within the micro processor for correct instrument operation calibration calibrate to a zero or an estimated gas concentration current output calibration calibrate the analogue current loop output record the set up and calibration data it is stro...

Page 43: ...cation LED illuminates and that the LCD display is functioning at the signal processor Replace the lid of the power supply After the initial power on and while the heated source is reaching temperature the display will show WAITING FOR REFERENCE When the source has reached an adequate temperature for the reference to be detected the message STABILISING REF will be displayed along with the frequenc...

Page 44: ...r purge Then replace the receiver and align using as a guide the detector levels displayed by the signal processor in Mode 5 Finally the transmitter adjustment is fine tuned once again using the detector levels in Mode 5 All these processes are described below Remove the receiver from its mounting flange Adjust the alignment of the transmitter flange until the bright red disc of the transmitter is...

Page 45: ... will move onto the second digit Similarly alter and press ENTER when the desired number is displayed When the fourth digit has been correctly entered the processor will enter Mode 5 Within Mode 5 select the CALIBRATE menu using the arrow keys Press ENTER when calibrate is displayed Once again use the arrow keys to select DISPLAY DETECTOR LEVELS option and press ENTER to access The D1 and D2 detec...

Page 46: ...lange again observing the values of D1 and D2 as appropriate lock the flange in place when a MAXIMUM has been obtained After this procedure has been followed the alignment is completed and there is rarely any need for further adjustments The alignment of the receiver unit is important Take time to ensure that a maximum values of D1 and D2 are obtained NOTE The alignment of the receiver may be cond...

Page 47: ...timum signal to noise ratio the detector levels must be maximised For the best signal to noise ratio the gain of the detector signals within the receiver must be set to a maximum without saturating The gains will have been set by CODEL at a pathlength of 2m If the pathlength is above 4m or below 1 5m this adjustment may be necessary to optimise the detector levels If the pathlength is within this ...

Page 48: ...rim potentiometer s set the gain with the receiver Levels should be measured with a voltmeter set to AC Volts Figure 13 Receiver Trim Pots Figure 14 Receiver Test Points Control board for end detector D2 Front of receiver End detector Voltage indication LED s S0V Green S2 blue S1 white ...

Page 49: ...st point When the detector levels are satisfactory replace the cover After the detector level s at the receiver have been optimised if necessary the levels within the micro processor should be adjusted This adjustment is conducted by means of two trim potentiometers within the signal processor see Figure 15 4 6 2 Signal Processor Gain Adjustment Figure 15 Gain Adjustment Signal Processor If the du...

Page 50: ... pot slightly to reduce the gain until a SAT of 0 is displayed Should saturation be indicated with trim pot turned fully CLOCKWISE reduce the gain in the receiver and repeat the procedure repeat the steps above marked thus for the D1 level using the D1 trim potentiometer The gain of the detector circuitry is now complete If the duct is operating and the opacity levels are high reduce the D2 level ...

Page 51: ... allows adjustments to be made to the intensity of the source Chopper Frequency remove the head from the duct to conduct this process A trim pot in the front of the unit nearest to the lens is accessible after the front flange has been removed achieved by loosening and removing the four screws holding the flange in place Once removed the trim pot is revealed This allows adjustments to be made to t...

Page 52: ...changes to the operating parameters it is recommended that Table 1 Instrument Settings is completed to provide a record of the instrument set up Press the MODE key until the number 5 is displayed in the top left hand corner Enter 0000 for the security code this is the default code set at the factory After the correct code has been entered the six sub modes are accessed by using the ARROW keys and ...

Page 53: ...Press the ENTER key while this display is shown to select it then press the ARROW keys to step through the available options Press the ENTER key enter each option and change the displayed parameter An origin of 0 or 4mA can be set for the current loop output The ARROW keys will toggle between these two options Press the ENTER key to enter the new value Any of the four averaging stacks seconds minu...

Page 54: ... display then defaults to zero thus the span value must be re entered for the unit to function correctly Should a fault condition occur the current output of the instrument may be set to any of the following options Set the output at 0 mA ZERO Adjust the output to the calculated gas concentration even though a fault condition exists MEAS Hold the last calculated gas concentration HOLD Set the outp...

Page 55: ...ng else should be connected to these terminals when the output is being set up The value is adjusted using the two arrow keys the UP arrow will take the current output up and the DOWN arrow will take it down Press the ENTER key when the correct output current is displayed on the ammeter In a similar manner to the above the current output level should now be set to 20mA Set mA Output 4 8 1 6 This i...

Page 56: ...set up information it is important that the security code is changed from the factory setting Each digit is selected with the ENTER key and changed with the ARROW keys If the system is being used as part of an integral monitoring system and the serial input and outputs are being used the central processor requires a Device Identity to identify each instrument This number must be unique for each eq...

Page 57: ...o the processor This value is then used to produce a final value of gas concentration A contact output is available to warn of a high gas concentration This contact output may be triggered from any of the four averaging stacks Select its source with the ARROW key and enter it with the ENTER key Measurement Path 4 8 1 9 Length Alarm 4 8 1 10 The current value entered for the path length will be dis...

Page 58: ...nt is operating under correct conditions There is a choice of three controls for plant status only one can be used to control plant status at any one time logic input serial input and multiple input The multiple input has five sub options temperature threshold oxygen threshold water vapour threshold detector level threshold and logic input Any or all of these five options in the multiple option ma...

Page 59: ... Enter the required value and press ENTER The next option will then be shown similarly select YES or NO and so on After the final option Logic Input has been configured the display will revert to Multiple scroll down using the arrow key and when EXIT is viewed press ENTER The plant status is thus configured A value is set here for the temperature threshold Whilst the temperature taken from the nor...

Page 60: ...e user may set the standard levels to which the measurement is to be normalised and how the instrument reads the value i e fixed keypad input 4 20mA input or on the serial data line After selecting the parameter to be set up the ARROW keys will select between entering the standard levels and how the normalisation data is to be brought into the instrument Each normalising parameter normalises the m...

Page 61: ... inputs All the other analysers must then be set to serial and the normalisation parameters will be transmitted down the serial data highway An analogue input should always be used for temperature correction this ensures that the flue gas temperature is being measured continuously and accurately Connect the analogue output of the temperature transducer into the CODEL analyser and select the analog...

Page 62: ...re data can be taken to the instrument via the serial data line To correct the data to a standard pressure normally 101kPa the pressure at the point of measurement needs to be determined If the flue pressure is relatively constant through all firing conditions then a fixed input may be used If the pressure is not constant it should be measured and brought into the instrument via the 4 20mA input w...

Page 63: ...mpleted these therefore need resetting using this option This process will erase the current average that is held in all of the averaging stacks Select this option by pressing the ENTER key and using the Arrow keys If this option is selected after the instruments first commissioning all data in the averaging stacks is reset and the data for as much as the last 30 days will be lost From this option...

Page 64: ... the calibrate option The basic calibration of the instrument can be calculated from this routine It is preferable to conduct this operation with the plant shut down to ensure a zero gas concentration within the duct If this is not possible however the instrument can calibrate to a known value of the gas concentration the calibration target Set the calibration target either to a known value of the...

Page 65: ... it is not the initial calibration it is recommended that the Cal Factor is recorded from the parameters option before the calibration is run To aid commissioning and to record any subsequent changes to the operating parameters table 1 overleaf displays all of the options available and can be used as a record of the operating parameters The calibration routine must be run during commissioning othe...

Page 66: ...arameter Comm Averages Seconds Minutes Hours Days Output 0 or 4mA base Units Average Fault condition Parameters Path length Alarm source Alarm units Alarm level Normalisation Temperature Standard level o C I P o C 4mA I P o C 20mA Keypad input o C not ideal Serial input Oxygen Standard level Wet or dry gas I P 4mA I P 20mA Keypad input Serial input Pressure Standard level kPa I P kPa 4mA I P kPa 2...

Page 67: ...om Mode 4 diagnostic mode Enter the cal factor into the table below as a record of instrument operation Table 2 Calibration Data Factory settings were obtained under the following conditions 2 m path length Clean conditions 240V 50 Hz supply Detector Outputs Factory Comm D2 D1 E1 E2 Calibration Data Cal factor Span factor Output Calibration Set zero Set span ...

Page 68: ...nter the SET UP MODE CONFIGURE OUTPUT SET ZERO OPTION and adjust the level using the ARROW keys until 0mA is recorded Record the value in brackets on the display in Table 2 Calibration Data Enter the SETSPAN option and adjust the level using the ARROW keys until 20mA is recorded Record the value in brackets on the display in Table 2 Calibration Data The current output is now calibrated This comple...

Page 69: ...lid of the signal processor Once commissioning has been concluded the absorption of IR radiation is measured and a parameter Y is calculated see Principles Modes of Operation This value is used to produce a final concentration of gas that can be normalised to standard conditions and averaged over a time ranging from 10 seconds to 30 days The instrument computes four averages any of which can be us...

Page 70: ...ber in the top left hand corner of the display Mode 1 Operating Mode displays average gas concentrations Mode 2 Parameter Mode displays operating parameters Mode 3 Normalisation Mode displays normalisation data Mode 4 Diagnostic Mode investigates instrument operation Self checks are continually made by the instrument should a complication exist this mode will automatically be selected and the faul...

Page 71: ...Section 5 Normal Operation Issue A Revision 1 Date 24 07 19 Ref 100606 Page 71 ...

Page 72: ...or back to the operating mode if pressed from within a mode Pressing the ARROW keys will do one of two things depending on the position in the program it will increase or decrease the displayed value If the key is held down it will scroll quickly to the desired value it will step through the available options within a mode or sub mode Pressing the ENTER key will do one of two things depending on t...

Page 73: ...dentification Parameters Averages Output Alarm source level Plant status Auto zero 1021 only Temperature Oxygen Pressure Water vapour Detector levels Modulation frequencies Y Z values H2O m 1030 only Cal values Fault condition Set averages Configure O P Parameters Normalisation Reset average Calibrate Check cell gas ppm Mode Mode Mode Mode Mode Modes 1 4 change the display only Operating Mode 1 Pa...

Page 74: ...W keys will now change the highlighted parameter Each push of the ENTER key will select another of the parameters in the following order Concentration Units vpm mg m 3 or mg Nm 3 Measured or Normalised display Averaging Time seconds minutes hours or days Once the display configuration is as required press the ENTER key when the cursor is flashing on the averaging time and the cursor will disappear...

Page 75: ...Section 5 Normal Operation Issue A Revision 1 Date 24 07 19 Ref 100606 Page 75 Press the ENTER key again to exit from each option See ...

Page 76: ...ptions The following parameters are examined from this option selected using the ARROW keys Measurement Path Length the path length currently used to calculate the gas concentration Span Factor from the SET UP MODE CALIBRATE option the sensitivity of the instrument can be adjusted This will originally be conducted by CODEL at the factory using known gas concentrations Output Fault should a fault c...

Page 77: ... 100606 Page 77 Set Up Mode The selected option may be examined here Selecting this option will display the times set for each of the four averaging stacks The base span and averaging of the analogue output are displayed from this option 5 7 3 Averages 5 7 4 Output ...

Page 78: ...ion may be used to ensure data is only collected when the plant is fully operational There are three options that can be used to determine plant status ON or OFF logic input serial input and multiple input The multiple input has four options temperature threshold or oxygen threshold water vapour threshold and logic input The plant status and its governing factor may be viewed from this display 5 7...

Page 79: ...outine and use the ARROW keys to select which of the normalising parameters to display When the required normalising parameter is displayed press the ENTER key to display the normalisation data Press the ENTER key again to exit the parameter For each of the normalising parameters the display will appear similar to that shown below 5 8 1 Display Format Selected parameter Units Standard level requir...

Page 80: ...ode The ARROW keys will now select from the following list press the ENTER key to select the displayed option Enter Press Enter on Exit option Detector levels D1 D2 E1 E2 d1 d2 e1 e2 Saturation count phase correction Modulation frequency of detector D1 Modulation frequency of detector D2 Parameter Y values Instantaneous gas calculation ppm H2O m X value 1030 only Cal values Rx temperature Fault st...

Page 81: ... the micro processor this value should always be zero If a number other than zero is displayed it indicates saturation and the detector gain should be adjusted see Detector Levels Phase is the phase time correction applied for the calculation of the detector levels This will be between 0 1 and 5 9 milliseconds This value is calculated by the instrument and may not be adjusted The chopper blade sho...

Page 82: ...r the corresponding Y values Also displayed by pressing the arrow keys are the Z values These are adjusted Y values used to compensate for cross sensitivities in the measurement range The calibration factors determined during the calibration routine Kcal and the value currently being used Kwkg can be examined from this display Should the two values be different this indicates a change in instrumen...

Page 83: ...within either the receiver or the signal processor is too high for the current duct conditions Low Det Level detector levels are too low 3 000 Mod Freq O R chopper motor frequency is out of range 30Hz or 45 Hz Reference Fail no reference signal from the transmitter unit Cal Fact O R after the calibration routine the calculated Set Cal factor is out of range see Fault Finding By pressing the arrow ...

Page 84: ...c calibration of the instrument Contact serial temp O2 or Det Level Model 1030 only Set up normalisation I P std levels for temp Set up normalisation I P std levels for O2 Set up normalisation I P std levels for pressure Set up normalisation I P std levels for H2O Reset the four stack averages Detector D2 Adjust sensitivity Model 1021 only Conduct a basic calibration Calibrate H2O model 1030 only ...

Page 85: ...four averaging stacks to be reset Calibrate the outputs of the detectors and the basic calibration of the instrument can be set After the correct code has been entered the user may access each of the six sub modes listed above by using the ARROW keys and pressing ENTER when the required option is displayed Once the display is as shown here press the ENTER key to gain access to the set up mode The ...

Page 86: ...ROW keys to select the average time that requires changing and press the ENTER key to change it The value can now be changed using the ARROW keys and input by pressing the ENTER key Set the seconds averaging stack to the required value This is limited to within 10 to 60 seconds in10 second intervals Set the minutes averaging stack to the required value This is limited to within 1 to 60 minutes in ...

Page 87: ...ogue output They are selected by the ARROW keys and entered using the ENTER key The analogue output can represent the gas concentration in units of mg m 3 mg Nm 3 or ppm The ARROW keys will toggle between these three options Press the ENTER key to enter the new value Select the required span using the ARROW keys for each digit The ENTER key is pressed to enter the value of each digit The units wil...

Page 88: ...ss the ENTER key to select it and the operator is prompted to set the current levels at 0 to 20mA When this is displayed the current output should be set to 0mA as measured with a calibrated current meter across the analogue current loop terminals nothing else should be connected to these terminals when the output is being set up The value is adjusted using the two arrow keys the UP arrow will tak...

Page 89: ...horised tampering with the set up information it is important that the security code is changed from the factory setting Each digit is selected with the ENTER key and changed with the ARROW keys If the system is being used as part of an integral monitoring system and the serial input and outputs are being used the central processor requires a Device Identity to identify each instrument This number...

Page 90: ...ntration x path length and in order to obtain a true value of concentration of gas it is necessary to input the correct path length into the processor This value is then used to produce a final value of gas concentration A contact output is available to warn of a high gas concentration This contact output may be triggered from any of the four averaging stacks Select the source with the ARROW key a...

Page 91: ...value may be changed from this mode Used to determine whether the plant is operating under correct conditions If it is not plant status will be OFF and the minutes hours and days averaging stacks will not be updated If data is stored whilst the plant status is OFF diluted overall readings will be registered 5 10 15 Cal Factor 5 10 16 Plant Status Input Do not enter this mode without first recordin...

Page 92: ... YES or NO NO will mean that the temperature threshold is not used to determine plant status If YES is selected the display will enter the display below Configure the instrument for temperature threshold press ENTER when correctly configured and the display will move to the next option Select YES or NO in a similar manner to above After the last option has been set Logic Input the display will ret...

Page 93: ...lant status is OFF For plant status ON the water vapour level must be above the threshold set Select YES or NO and press ENTER For plant status to be ON the logic input PS1 and PS2 must be open circuit for plant status to be OFF the logic input must be closed circuit After this option has been configured the menu will exit to Multiple Use the down arrow to select EXIT and press ENTER Logic Input 5...

Page 94: ...sing inputs are to be changed they are Temperature Oxygen Pressure Water Vapour After selecting the normalising parameter the user may set the standard levels to which the measurement is to be normalised and how the instrument reads the value i e fixed keypad input 4 20mA input or on the serial data line Figure 20 illustrates the program tree for entering the normalisation parameters 5 10 17 Norma...

Page 95: ...ue is stable to about 5 if an INPUT UNIT is being used all normalising data can be transmitted via the serial data line using the 4 20mA inputs within the processor to receive a measurement transducer data The values at 4mA and at 20mA will be requested should this option be selected With an integrated system the lead analyser should have its normalising parameters set to 4 20mA inputs Select the ...

Page 96: ... an estimate of the oxygen at the point of measurement is required If the oxygen level is being continuously measured connect the analogue output of the oxygen analyser into the CODEL analyser and select the analogue input in the normalisation menu This input must be defined as either WET or DRY depending on how the measurement is made After the measurement has been defined as wet or dry the analo...

Page 97: ...nd relatively fixed level set the standard level to DRY and use a fixed value in the keypad option representing the expected water vapour produced for the fuel type If the measurement is not to be normalised for water vapour set the standard level to WET The average values that are currently held in the four averaging stacks can be reset using this option this will erase the current average that i...

Page 98: ...any alterations that are required the filters and gas cells are not moved during this operation See Section Commissioning and Diagnostic Mode for a discussion of these levels detector level and saturation count Instrument sensitivity can be adjusted if a known concentration of measurement gas exists between the transmitter and receiver units and instrument sensitivity is suspected If a problem ari...

Page 99: ...Section 5 Normal Operation Issue A Revision 1 Date 24 07 19 Ref 100606 Page 99 ...

Page 100: ...of cycles over which the calibration factor is determined a minimum of 30 is recommended The calibration should now be run and the display will show a count down during its execution When the calibration is complete the new Cal Factor will be displayed for about 5 seconds and the instrument will exit the calibration routine Do not run the calibration routine unless known conditions exist in the du...

Page 101: ...Section 5 Normal Operation Issue A Revision 1 Date 24 07 19 Ref 100606 Page 101 ...

Page 102: ...default back to Mode 1 if YES is not selected within 5 seconds The check cell must not be inserted before this screen is accessed see Notes for Using a CODEL Check Cell Normal Shutdown Procedure 5 12 The system should not need shutting down unless maintenance is being carried out In this case power down the power supply and thus the signal processor and analyser heads Close the manually operated i...

Page 103: ...ength as programmed in the SPU The value written on Check cells is the ppm m standard The ideal time to perform a check cell test is with the plant off auto zero condition on and the analyser well stabilised at zero Do not insert the check cell in any other mode than Mode 6 The rolling averages of the analyser will not update during use of Mode 6 to prevent false readings being recorded the check ...

Page 104: ...two screws retaining the cover on the check cell holder see Figure 21 Place a rubber check cell gasket over the check cell body onto the base Check Cell Installation 5 13 1 4 Figure 21 Check Cell Holder Figure 22 Check Cell and gasket Gasket Receiver Check cell holder Check cell check cell cover ...

Page 105: ...ce to the instrument operation Wait for the instrument reading to settle 5 to 10 minutes and record the gas measurement with the cell in position Remove the check cell and wait for the analyser to return to zero another 5 to 10 minutes Replace the cover on the check cell holder and press the mode key on the signal processor The instrument now returns to operating mode This test can be done with th...

Page 106: ...on has cleared If the analysers are linked to the Integrated Emission Monitoring package that remotely monitors the system the alarm will be displayed on the IEM system monitor when the condition has cleared the fact that an alarm condition occurred will be recorded by the software The 4 to 20mA output from the analyser will also alter according to the pollution levels detected Emergency Shutdown ...

Page 107: ...Page 107 If the system interfaces with CODEL s bespoke IEM software package via a serial data line central control unit CCU and pc then details of configuration of this system are to be found in the operating manuals OPS 087 Communication Equipment and OPS 016 IEM Software ...

Page 108: ...inuous operation and when replacement does become necessary it can be replaced on site To replace an element proceed as follows switch OFF power remove the rear cover plate from the transmitter by removing the four retaining screws Note that these screws are not captive carefully remove the PCB now revealed by unscrewing the three retaining screws disconnect the two wires from the terminals at the...

Page 109: ... head screws anti clockwise unscrew to loosen assembly carefully lift out the assembly and remove the centre plate from the transmitter body de solder the red and black wires attached to the chopper motor remove the three screws holding the chopper motor to the centre plate replace the chopper motor and reverse the above procedure turn the power ON and check the chopper motor frequency by viewing ...

Page 110: ... and remove the front flange turn the three brass extended head screws anti clockwise unscrew to loosen assembly carefully lift out the assembly and ease the PCB off its supports unscrew the M3 x 6 slotted screw or grub screw on some models at the end of the gas cell assembly prise the gas cell off the stepper motor shaft place the new gas cell in position and reverse the above process turn ON the...

Page 111: ...er M4 x 16 screws completely remove the four M6 bolts from the end detector PCB slide out the gas cell assembly replace the gas cell ensuring that the same orientation is kept the notch in the gas cell assembly should be facing away from the side on which the side detector PCB fits reverse the above process being careful not to over tighten the four bolts if these are too tight the gas cell may fr...

Page 112: ...y Should a recognised fault occur the display switches from its current mode of operation to the diagnostic mode and display the current fault condition see Data Valid LED Out If this fault clears the display will stay in the diagnostic mode and display the All Clear Enter the diagnostic mode from the keypad of the instrument this can be done at any time without interrupting or disturbing the anal...

Page 113: ... outside of the above ranges the Data valid LED will extinguish and the fault condition be displayed see Data Valid LED Out for details If one or more fault conditions occur the data valid LED on the front panel will extinguish the data valid relay will operate and the instrument will automatically enter the diagnostic mode to display the fault condition see section Fault Condition 6 3 2 Data Vali...

Page 114: ...cted during unstable duct conditions poor alignment incorrect detector gain adjustment possible causes poor supply voltage faulty chopper motor incorrect setting within transmitter possible causes chopper motor failure Further information Corrective Maintenance is provided in the fault finding tables in Detector signals 6 3 2 1 saturated Sat over 50 Low detector levels 6 3 2 2 D1 3 000 Cal factor ...

Page 115: ...Section 6 Maintenance Issue A Revision 1 Date 24 07 19 Ref 100606 Page 115 Corrective Maintenance ...

Page 116: ...oms and when the fault has occurred and refer to the appropriate tables If the fault cannot be rectified by the customer then the tables should indicate which of the four units are faulty power supply signal processor transmitter receiver The faulty unit can then be returned to CODEL for repair 6 4 1 Use of Fault Finding Tables Be sure to use the tables from the top down and pay particular attenti...

Page 117: ...ignal processor All LEDs illuminated Supplies OK proceed to next possible cause LEDs not illuminated Proceed to next test Check fuse in signal processor Fuse OK Proceed to next possible cause Fuse blown Replace fuse Connection problem Check wiring between signal processor power supply Wiring OK Proceed to next test Incorrect wiring Correct wiring Check ribbon cable connections in signal processor ...

Page 118: ...Page 118 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions ...

Page 119: ...terminals 2 5 37Hz square wave approx 12V OK Contact your CODEL supplier See above not OK Check rectify wiring continuity between power supply signal processor Chopper motor failure in transmitter Check if chopper blade is rotating No Proceed to next test Yes Contact your CODEL supplier Replace chopper motor Fault clears No further action Fault continues Contact your CODEL supplier Symptom Possibl...

Page 120: ...processor and or Rx Detector levels in range No further action Fault continues Proceed to next possible cause Transmitter failure Check heater cartridge Cartridge open circuit Replace heater cartridge Cartridge OK Proceed to next possible cause Transmitter gas cell drive failure Check drive LED in signal processor LED flashing Proceed to next test LED not flashing Contact your CODEL supplier Check...

Page 121: ...ext possible cause Poor alignment window contamination path obscuration Proceed as for low detector level Cal factor in range No further action Cal factor out of range Proceed to next possible cause Tx gas cell drive failure Proceed as for low detector level Cal factor in range No further action Cal factor out of range Proceed to next possible cause D2 detector circuit failure Check D2 signal leve...

Page 122: ... the detector levels and saturation count Detector levels OK Proceed to next possible cause Detector levels out of tolerance Re commission the instrument and consult the fault finding table again Output circuitry failure Enter set up mode configure output attempt to set zero span Output responds correctly Re commission the instrument and consult the fault finding table again Output does not respon...

Page 123: ...e transmitter see Replacement of the Heater Element up to operation 4 Remove one lead from the heater cartridge and measure the resistance across the two cartridge terminals It should be about 3 5 If it is open circuit the heater cartridge needs replacing Conduct the procedure for adjusting the chopper frequency in the transmitter see 6 5 1 Individual Tests Heater Cartridge 6 5 1 1 Chopper Motor 6...

Page 124: ...rails and equipment operations 5V 15 15 Situated top left of processor Should all be ON indicating that the power supplies to the instrument are functioning correctly M DIR should operate approximately every 4 seconds SOL_MDRV Centre of the board Supply to the solenoid that drives the filter into the optical path within the receiver pulses every time the M DIR changes approximately every 2 seconds...

Page 125: ... This LED should be ON indicating that the power supply unit is functioning correctly This LED will extinguish should the supply voltage drop from 12 to 11V If further checks on instrument operation are required there are various test points within the instrument Many of these are simple DC voltages and so may be checked using a voltmeter set to DC volts otherwise may be investigated using an osci...

Page 126: ... amplification in processor Flattened saw tooth 32 to 45Hz 3 5V pk pk maximum centred on 0V Amplitude may be varied by a trim pot See Detector Levels T3 D1 output to the A D converter within the micro processor offset by 2 5V Flattened saw tooth 32 to 45Hz 3 5V pk pk maximum centred on 2 5V T4 As T1 but for D2 signal T5 As T2 but for D2 signal T6 As T3 but for D2 signal T7 Receiver ambient tempera...

Page 127: ...ue current output 0VB and 12VB Isolated supply for the plant status input F Reference wave from the transmitter unit via the power supply Square wave 30 to 45Hz 5V pk pk centred on 2 5V 0V and 12V Power supply for the instrument 0V 0V for the receiver T1 Detector output without conditioning T2 Detector output after first stage of gain T3 Detector output after both stages of gain S 0V supply to the...

Page 128: ...ss than 999ppm m if it is greater than this use a larger pathlength to reduce the effective ppm m value of the check cell i e select the pathlength such that ppm m pathlength 999 Insert the calibrated check cell in check cell mode mode 6 and leave for 15 minutes to settle When settled note down the reading Go to calibrate in mode 5 go to span adjust make sure the span factor is1000 then insert the...

Page 129: ... chosen thus the effective value of the check cell in 720ppm 2880 4 However in Mode 6 it reads higher 3240 this value is effectively 810ppm at a 4m pathlength 810 is keyed in as the first value in the span factor option The span factor is then adjusted until the second value reads 720 Now press Enter to set the span factor Special Tools and Handling 6 6 Devices None are required to use or maintain...

Page 130: ...Section Recommended Spare Parts lists the recommended spares for maintenance The parts catalogue for CODEL s EnergyTech 401 gas analysers is given below Description Part Number Transmitter 990 210 Receiver 990 211 Signal Processor state model type 990 208 Power Supply 990 207 Purge Assembly 980 051 ...

Page 131: ... PROCESSOR UNIT 38 FIGURE 11 SYSTEM CONNECTION SCHEDULE 41 FIGURE 12 ADJUSTING NUTS ALIGNMENT 44 FIGURE 13 RECEIVER TRIM POTS 48 FIGURE 14 RECEIVER TEST POINTS 48 FIGURE 15 GAIN ADJUSTMENT SIGNAL PROCESSOR 49 FIGURE 17 KEYPAD 72 5 4 1 1 FIGURE 18 PROGRAM OPERATION TREE 73 FIGURE 19 DIAGNOSTIC MODE TREE 78 FIGURE 20 SET UP MODE TREE 82 FIGURE 21 NORMALISATION OPTIONS 92 FIGURE 22 CHECK CELL HOLDER ...

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