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CODEL Energy Tech 401 Installation, Operation And Maintenance Manual

Cross-duct ir co analyser
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EnergyTech 401
CODEL
Operating and Maintenance Manual
Monitoring Solutions
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
Issue: A
Revision: 1
Date: 05/07/19
Ref: 100606

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  • Page 1 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 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...
  • Page 2 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...
  • Page 3 Operating and Maintenance Manual Monitoring Solutions CODEL International Ltd is a UK company based in the heart of the Peak District National Park at Bakewell, Derbyshire. The company specialises in the design and manufacture of high-technology instrumentation for the monitoring of combustion processes and atmospheric pollutant emissions.
  • Page 4 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 5: Table Of Contents

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Contents SPECIFICATION ..............................11 GENERAL DESCRIPTION ............................ 12 ..............................13 YSTEM ESCRIPTION 2.1.1 Infrared Transmitter Unit ..........................14 2.1.2 Infrared Receiver Unit ..........................15 2.1.3 Signal Processor Unit ........................... 15 2.1.4 Power Supply Unit ............................
  • Page 6 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions ..............................47 ETECTOR EVELS 4.6.1 Receiver Gain Adjustment........................... 47 4.6.2 Signal Processor Gain Adjustment ......................49 ..........................51 RANSMITTER DJUSTMENTS ............................ 52 PERATING ARAMETERS 1 – I ........................66 ABLE NSTRUMENT ETTINGS 4.10...
  • Page 7 5.11 ............................. 100 HECK 5.12 ........................100 ORMAL HUTDOWN ROCEDURE 5.13 ..............................101 OUTINE HECKS 5.13.1 Notes for Using a CODEL Check Cell ....................101 5.14 ........................104 LARMS MERGENCY ONDITIONS 5.15 ........................ 104 MERGENCY HUTDOWN ROCEDURE 5.16 ............................104...
  • Page 8 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...
  • Page 9 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions IMPORTANT The warning signs (and 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.
  • Page 10 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 11: Specification

    Section 1 Specification 1 Specification Span* selectable from 0-100ppm to 0-10,000ppm, within the range 200 to 6,000ppm. metres at STP Display Units mg/m (measured) mg/Nm (normalised) Averaging four averages selectable from 10 seconds to 30 days Accuracy ± 2% of measurement or ±...

  • Page 12: General Description

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 2 General Description Rapid advances in the design of ‘across the duct’ infrared gas analysers have led to the general acceptance of this technique for the monitoring of gas levels in flue gases of power generation boilers and large industrial process steam boilers.

  • Page 13: System Description

    Section 2 General Description System Description The EnergyTech 401 monitor consists of four items (see Figure 1): an infrared transmitter unit to project a beam of infrared radiation across the  duct a receiver to measure that radiation  a power supply unit to provide the necessary power rails, and ...

  • Page 14: Infrared Transmitter Unit

    Monitoring Solutions 2.1.1 Infrared Transmitter At the heart of this unit is a small heater assembly designed by CODEL engineers Unit to give a high intensity uniform source of infrared energy over a long lifetime, in excess of two years continuous operation, with a power consumption of only 26 watts.

  • Page 15: Infrared Receiver Unit

    The precision and reliability with which the transmitted can be measured governs the performance of the complete instrument. For this reason, CODEL have concentrated their design efforts into producing an extremely simple and robust receiver unit. It contains no moving parts, is fully sealed and designed to give many years of trouble-free and maintenance-free operation.

  • Page 16: Power Supply Unit

    , temperature and pressure, if required. This data can also be entered via the keypad or via the serial data port. A serial communication facility within the processor, allows the instrument to communicate with other CODEL analysers and a central data logging unit. 2.1.4 Power Supply Unit The power supply unit is housed in a fully-sealed cast-aluminium enclosure and contains the power supplies for the instrument.

  • Page 17: Principles / Modes Of Operation

    Section 2 General Description Principles Modes Operation Gas levels are determined by measuring the absorption of infrared radiation, 2.2.1 Calculation of transmitted through the flue gas, in a wave band sensitive to absorption by the Gas Concentration measurement gas. The EnergyTech 401 has two detectors; one measuring the radiation directly to provide a live output, sensitive to the measurement gas, while a second detector measuring the radiation after passing through a gas cell filled with pure reference gas (CO), to provide a reference measurement,...

  • Page 18: Error Compensation

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 2.2.2 Error Compensation The accurate determination of gas concentration depends upon the measurement of the radiation levels received by the detectors. Any error in that measurement caused by detector drift will produce errors in the determination of the gas level.

  • Page 19: Calculation Sequence

    CODEL EnergyTech 401 gas analysers are cross-duct type and thus measure the quantity (or number of molecules) of gas within their sight path. This...
  • Page 20 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 22.4 (standard volume of an ideal gas) The conversion factors for the analysers are given below : Conversion factors (N) 2.2.4.3 Molecular mass (RMM) = 12 + 16 = 1 vpm 28/22.4 =...
  • Page 21 Section 2 General Description 20.9% is taken as the level of free oxygen in dry air. If the measured O % is a wet measurement the measured O concentration must be corrected to a dry measurement. This is performed automatically by the software if the measured O concentration is defined as a wet measurement;...
  • Page 22 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 2.2.5 Principles of Cross-Duct Cross-duct analysers work on the basic principle that infrared (IR) energy is Gas Analysers absorbed by particular gases in a manner very specific to the gas. Although cross-duct analysis will differ from gas to gas, the basic principles are similar for all measured gases.

  • Page 23: Figure 4 : Comparison Of Spectra

    Section 2 General Description Figure 4 : Comparison of Spectra 2.2.5.3 Transmissivity of CO The transmission through the gas of the IR energy at about 4.7µm is affected by Within the 4.7µm Band the concentration of CO. Figure 5 illustrates how the energy within the selected band varies with CO concentration.
  • Page 24 Operating and Maintenance Manual Monitoring Solutions 2.2.5.4 Carbon Monoxide CODEL CO analysers make two measurements of IR energy in the narrow band Calculation around 4.7µm. Both measurements are made after the beam has passed through the gas to be measured. One, however, also passes through a cell containing pure CO (the gas filter shown in ).

  • Page 25: Figure 6 : Calibration Curve

    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 calibration point.
  • Page 26 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions It is not necessary to calculate K because we know that when the constant K is correct : Y is 0 when the CO level is 0. If there is any drift in the measurement it can only be due to a change in some optical or electronic gain and can always be corrected by setting Y to zero when the CO level is zero.

  • Page 27: Installation Instructions

    Section 3 Installation Instructions 3 Installation Instructions Safety Considerations The mains power is supplied to the whole system via the power supply. During installation, DO NOT connect the system to the mains until all units are in place and fully wired up. Keep the isolating valves, if used, CLOSED. The compressed air (to be supplied to the air purges) must be turned OFF until the full installation is complete.

  • Page 28: Normalising Inputs

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 3.2.3 Normalising Inputs Pressure, temperature, and oxygen values can be held to normalise the calculated gas value to standard conditions. These values may be read by the instrument using the following methods: fixed value from the keypad ...

  • Page 29: Cable Requirements

    (if required) - 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...

  • Page 30: Siting The Equipment

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Siting the Equipment The equipment is designed for mounting on boiler ducting or stacks in positions open to the weather. It is fully sealed and requires no further enclosures or protection.

  • Page 31: Points To Consider

    Section 3 Installation Instructions 3.4.1 Points to Consider path length  too long (>8m) - low energy available too short (<0.5m) - optical problems flue gas temperature  too low (<dewpoint) - potential water droplets too high (>300 C) - reduced sensitivity. ambient temperature ...

  • Page 32: Duct Work

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Duct Work The transmitter and receiver units are mounted on a site mounting flange on opposite sides of the duct. To protect operators, it is recommended that an isolating valve is used for ducts that operate at a higher than atmospheric pressure.

  • Page 33: Isolating Valves

    Section 3 Installation Instructions Isolating Valves If isolating valves are used they mount directly onto the site mounting flanges. Air Purge The purges mount onto the isolating valves. They are mounted by separating the front flange from the air purge by unscrewing the four locking nuts. A ‘snout’ and ‘O’...

  • Page 34: Transmitter & Receiver Units

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Transmitter & Receiver Units The transmitter and receiver attach to the rear face of the air purges with a flexible gasket fitted between them, using the M6 x 20 hexagon head screws provided (see Figure 9).

  • Page 35: Air Supply

    Section 3 Installation Instructions Air Supply The purpose of the air purges is to keep the windows of the transmitter and the receiver clean. Air 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...
  • Page 36 - 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: 36...

  • Page 37: Signal Processor Unit

    Section 3 Installation Instructions 3.10 Signal Processor Unit Enough cable is supplied to mount the signal processor up to 10m from the receiver. To mount the signal processor (see Figure 10), first remove the cover by loosening the four captive screws, unplug the ribbon cable at the connector on the lid PCB.

  • Page 38: Figure 10 : Signal Processor Unit

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

  • Page 39: Power Supply Unit

    Section 3 Installation Instructions 3.11 Power Supply Unit Enough cable is supplied to 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.

  • Page 40: Electrical Connections

    Power cables should be installed separately, using different 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.

  • Page 41: Connection Schedule

    Section 3 Installation Instructions 3.12.2 Connection Schedule Overall system connections are illustrated in Figure 11. Figure 11 : System Connection Schedule Page: 41 Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 42: Commissioning

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Commissioning Introduction Commissioning the instrument can take up to a couple of hours and consists of the following operations : power supply voltage selection - select from either 110 or 220V supply ...

  • Page 43: Safety Considerations

    Section 4 Commissioning Safety Considerations The mains power is supplied to the whole system via the power supply unit. If any servicing or re-wiring is to be performed ensure that the power supply is isolated. For commissioning, the system needs power, compressed air to the air purges and the isolating valves (if used) to be open.

  • Page 44: Alignment

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Allow 30 minutes before conducting the alignment procedure; this ensures that the source temperature has stabilised. Alignment In order for the instrument to operate satisfactorily, the transmitter and receiver units need to be aligned. A degree of optical redundancy is built-in and normal duct movements do not affect the operation of the instrument.
  • Page 45 Section 4 Commissioning Replace the receiver on its purge. The next adjustment is done using the  detector levels as viewed from the signal processor. To change mode on the signal processor the MODE key needs to be pressed  once to access each mode.
  • Page 46 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Use this guide to ensure that the MAXIMUM possible values of both D1 and D2  are reached. After alignment has been achieved, lock the flange into position using the locking nuts.

  • Page 47: Detector Levels

    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 bank, this section may be ignored unless there is insufficient or too much gain.

  • Page 48: Figure 13 : Receiver Trim Pots

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Control board for end detector D2 Figure 13 : Receiver Trim Pots Trim potentiometer(s) set the gain with the receiver. Levels should be measured  with a voltmeter set to AC Volts.

  • Page 49: Figure 15 : Gain Adjustment Signal Processor

    Section 4 Commissioning Connect the voltmeter to the S0V and S1 test points, as in figure 19. A voltage of  4Vrms is the target. Increase the gain using the trim pot at the END DETECTOR, until the voltage is a maximum of 4Vrms. Repeat the above procedure for the SIDE DETECTOR, measuring across S0V and ...

  • Page 50: Receiver Gain Adjustment

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions *Set the gain to a minimum by turning the D2 – detector trim potentiometer  within the signal processor fully CLOCKWISE – it is a 20-turn pot. *Enter the DIAGNOSTIC MODE – DETECTOR LEVELS option, and display the ...

  • Page 51: Transmitter Adjustments

    Transmitter Adjustments WARNING!!! It is recommended that CODEL is consulted before making any adjustments within the transmitter Two trim potentiometers within the transmitter unit allow adjustments to be made to the intensity of the source and the frequency of the chopper motor.

  • Page 52: Operating Parameters

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Operating Parameters Operating parameters must be set in the instrument for it to function correctly. All operating parameters are set within the signal processor during the set-up mode, where they are held in non-volatile memory and so retained in the event of a power loss.
  • Page 53 Section 4 Commissioning Set the seconds averaging stack to the required value. This is limited to within 10  to 60 seconds in 10-second intervals. Set the minutes averaging stack to the required value. This is limited to within 1 ...
  • Page 54 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 4.8.1.4 Output Span 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 will be displayed as either...
  • Page 55 Zero mA should be set up no matter what has been selected as the base of the current output. This is factory set by CODEL. In a similar manner to the above, the current output level should now be set to 20mA.
  • Page 56 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions The next menu is to be configured is the Parameters menu – options are given  below. Select this option by pressing the ENTER key. The ARROW keys will now display the available options from within this sub-mode, when the option that requires changing is displayed, press the ENTER key.
  • Page 57 The transmissivity of a sample of any gas depends both on the concentration and Length. on the path length through which the radiation is transmitted. Similarly, the output of the CODEL gas monitor also depends upon the path length of the flue gas through which the radiation is transmitted. NOTE The current value entered for the path length will be displayed for 1 second then the display will default to zero.
  • Page 58 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Select the units for the alarm – these may be different to the units selected for the analogue output. After the source has been selected, the instrument requires a level at which the output will be triggered.
  • Page 59 Section 4 Commissioning 4.8.1.13 Logic Input If the PS1 and PS2 terminals are linked in the signal processor the logic contact is made and the plant status is OFF. These terminals may be linked manually during a plant shut down, or they may be wired to a switch/contact outside the unit e.g.
  • Page 60 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 4.8.1.17 Logic Input Either selected as YES or NO – depending on whether the logic contacts (PS1 and PS2) will be used to indicate plant shut down. 4.8.1.18 Normalisation All of the normalisation inputs and parameters are set up from this mode.
  • Page 61 Connect the analogue output of the temperature transducer into the CODEL analyser, and select the analogue input option. This value is used to normalise the gas concentration measurement, and to correct for the effects of temperature on the IR absorption spectrum.
  • Page 62 To correct the data to standard levels of oxygen, 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.
  • Page 63 Section 4 Commissioning 4.8.1.24 Water Vapour An ‘across the duct’ monitor measures the gas concentration under wet conditions, that is, unlike a sampling system, the gas has not been preconditioned in any way before the measurement is made. To normalise it to dry conditions, when the water vapour present is of a known and 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.
  • Page 64 If a problem arises with this, then please consult CODEL. NOTE The Span Factor will be adjusted at the factory by CODEL, do not adjust it unless the instrument sensitivity is suspected, and it is recommended that before adjustments are made, the original value is recorded.
  • Page 65 Section 4 Commissioning calibration is complete the new "“Cal Factor” will be displayed for about 5 seconds and the instrument will exit the calibration routine. WARNING!!! The calibration routine must be run during commissioning, otherwise the instrument will not be able to calculate the true level of gas within the duct.
  • Page 66 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Table 1 – Instrument Settings Parameter 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...
  • Page 67 Section 4 Commissioning a few seconds after a calibration has been conducted, it can also be interrogated from Mode 4 (diagnostic mode). Enter the cal factor into the table below, as a record of instrument operation. Table 2 – Calibration Data Detector Outputs Factory Comm.

  • Page 68: Current Output Calibration

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 4.10 Current Output Calibration WARNING!!! This is set at the factory and should not be altered without due consideration. The current output should now be set up using a calibrated milliammeter set to DC current, 20mA max.

  • Page 69: Normal Operation

    Section 5 Normal Operation 5 Normal Operation Introduction After the instrument has been commissioned, it will measure the gas levels between the transmitter and receiver and produce an output proportional to the gas levels. An integral 32-character display also shows the calculated levels. The instrument allows the operator to interrogate the micro-processor to observe the system parameters and to change them if required.

  • Page 70: Normal Start-Up Procedure

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Normal Start-Up Procedure Power-up the system and wait for 30 minutes. This allows time for the infrared source to heat up. Once the receiver is detecting a signal a reading will be seen on the signal processor display.
  • Page 71 Section 5 Normal Operation Page: 71 Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 72: Key Operation

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Key Operation Figure 16 : Keypad Each mode is accessed sequentially by each push of the MODE key. Figure 16 illustrates the display and keys of the signal processor. After a mode has been selected, the ARROW keys will select the various options within these modes.

  • Page 73: Program Tree

    Section 5 Normal Operation Program Tree Figure 17 illustrates the main program of the instrument. When an operating mode is complex, an extra program tree is given in this section. Enter Press Enter on Exit option or Enter on the final option Operating Mode - 1 Concentrati on units Measured or normalised...

  • Page 74: Operating Mode

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Operating Mode From this mode of operation the averaging time of the displayed gas concentration may be altered to one of the other averaging stacks, and the measured/normalised gas measurements observed. When in this mode, the display will appear similar to that shown below.
  • Page 75 Section 5 Normal Operation Press the ENTER key again to exit from each option. Page: 75 Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 76: Identification

    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 condition occur, the analogue output can be set ...

  • Page 77: Averages

    Section 5 Normal Operation Set-Up Mode. The selected option may be examined here. 5.7.3 Averages 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 5.7.4 Output option.

  • Page 78: Alarm

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 5.7.5 Alarm A changeover relay contact output is available to indicate a high gas concentration. The level at which this output is operated, and the averaging stack from which the gas value is obtained, may be examined from this display.

  • Page 79: Normalisation

    Section 5 Normal Operation Normalisation Press the MODE key until the number 3 is seen in the top left corner of the display. From this mode, the normalisation parameters currently being used can be displayed. Press the ENTER key to enter the routine and use the ARROW keys to select which of the normalising parameters to display.

  • Page 80: Diagnostic Mode

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Diagnostic Mode The detector levels, chopper blade frequency, ‘Y’ parameter and the fault condition may be examined from this mode. Press the MODE key until number 4 appears in the top left corner of the display and press ENTER to enter the mode.
  • Page 81 Section 5 Normal Operation 5.9.1 Detector Levels Detector levels from the detector are displayed here. D1 is the reference level and should always be less than D2 for NO and CO monitors. SO monitors will have similar values for D1 and D2. The level of D2 for all monitors should be between 10,000 and 20,000.

  • Page 82: Yvals & Gas Ppm

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 5.9.3 YVals & Gas ppm A parameter ‘Y’ determines the calculation of the gas concentration (see section Principles of Cross-Duct Gas Analysers). As a check on the program operation, this parameter and the resulting raw gas calculation, may be interrogated here.

  • Page 83: Fault Condition

    Section 5 Normal Operation 5.9.5 Fault Condition To display the current fault condition, press the ENTER key while this is displayed. This display mode is automatically selected by the instrument, should a fault condition occur. The following fault conditions are recognised by the instrument *ALL CLEAR* –...

  • Page 84: Set-Up Mode

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 5.10 Set-Up Mode All operating parameters – averaging times, output settings, normalisation parameters, path length, calibration, etc. – can be changed from this mode. To prevent any unauthorised changes, the user must enter a four number code...

  • Page 85: Security Code Entry

    - see section Parameters for further details. NOTE The code number will be set to 0000 by CODEL at the factory and should be changed by the user from within the set- up mode. Page: 85...
  • Page 86 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 5.10.2 Set Averages Four separate averages are calculated within the instrument. These are defined in units of seconds, minutes, hours and days. Any of the four averaging stacks can be used to provide the analogue output of the instrument. Each averaging time can be set within predefined limits.

  • Page 87: Output Units

    Section 5 Normal Operation 5.10.3 Configure O/P The analogue current loop output is set up from this mode. 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 to enter each option and change the displayed parameter.

  • Page 88: Fault Indication

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 5.10.8 Fault Indication Should a fault condition occur, the current output of the instrument may be set to one of the following options : set the output at 0mA – ZERO ...

  • Page 89: Parameters

    Section 5 Normal Operation In a similar manner to the zero level, the current output level should now be set to 20mA. 5.10.10 Parameters Select this option by pressing the ENTER key. The ARROW keys will now display the available options from within this sub- mode;...

  • Page 90: Alarm

    The transmissivity of a sample of any gas depends both on the concentration and on the path length through which the radiation is transmitted. Similarly, the output of the CODEL gas monitor also depends upon the path length of the flue gas through which the radiation is transmitted.

  • Page 91: Cal Factor

    Section 5 Normal Operation Select the units for the alarm – these may be different to the units selected for the analogue output. After the source has been selected, the instrument requires a level that the output will be triggered. Set the desired level with the ARROW keys. 5.10.15 Cal Factor During the calibration routine, the instrument calculates a ‘Cal Factor’...

  • Page 92: Temperature

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions There is a choice of three controls for plant status, logic input, serial input and multiple input, but only one can be used to control plant status at any one time.
  • Page 93 Section 5 Normal Operation Set and used in a similar manner to the temperature threshold. If the normalising water vapour level falls below the threshold, plant status is OFF. For plant status ON the water vapour level must be above the threshold set. 5.10.16.7 Logic Input Select YES or NO and press ENTER.
  • Page 94 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 5.10.17 Normalisation All of the normalisation inputs and parameters are set up from this mode. Press ENTER to access the mode and the ARROW keys will select which of the normalising inputs are to be changed, they are: Temperature ...
  • Page 95 Section 5 Normal Operation 5.10.18 Setting the Normalising After selecting the parameter to be set up, the ARROW keys will select between Parameters entering the standard levels and how the normalisation data is to be brought into the instrument. 5.10.18.1 Set Standard Levels Each normalising parameter normalises the measured gas concentration to standard conditions of temperature, oxygen, pressure and water vapour.
  • Page 96 Connect the analogue output of the temperature transducer into the CODEL analyser and select the analogue input option. This value is used to normalise the gas concentration measurement and to correct for the effects of temperature on the IR absorption spectrum.

  • Page 97: Reset Averages

    Section 5 Normal Operation 5.10.21 Pressure 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 within the processor.

  • Page 98: Calibrate

    If a problem arises with this consult CODEL. WARNING!!! The SPAN FACTOR will be adjusted at the factory by CODEL; do not adjust it unless the instrument sensitivity is suspected. In any case it is recommended that before adjustments are made the original value is recorded.
  • Page 99 Section 5 Normal Operation Page: 99 Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 100: Calibrate

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 5.10.27 Calibrate 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 an estimate of the gas concentration –...
  • Page 101 Section 5 Normal Operation Page: 101 Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 102: Check Cell Mode

    Operating and Maintenance Manual Monitoring Solutions 5.11 Check Cell Mode This mode is for use with a CODEL check cell. It verifies the calibration and operation of the analyser. For details of its use see Notes for Using a CODEL Check Cell.
  • Page 103 Routine Checks 5.13.1 Notes for Using The check cell and holder are optional items available from CODEL. The CODEL a CODEL Check Cell check cell has been designed to verify the reading of CODEL cross duct analysers. When placed within the measurement path a known increase in gas concentration can be generated.
  • Page 104 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Check Cell Installation Remove the two screws retaining the cover on the check cell holder – see Figure 5.13.1.4 Check cell / check cell cover Check cell holder Receiver Figure 21 : Check Cell Holder Place a rubber check cell gasket over the check cell body, onto the base.

  • Page 105: Figure 23 : Check Cell

    Section 5 Normal Operation Slot the check cell in to place and replace and tighten the screws; the cell can be  fitted either way round and is illustrated below. Figure 23 : Check Cell installation  Connect the gas inlet tube to the inlet of the checkcell and connect tube to desired gas, along with a flow restrictor.

  • Page 106: Alarms Emergency Conditions

    Operating and Maintenance Manual Monitoring Solutions The calibration of CODEL analysers is fixed at the point of manufacture. If gross errors exist this could suggest an instrument malfunction; if minor errors are observed, please check the procedure and if necessary return the gas cell for re- certification.
  • Page 107 Section 5 Normal Operation 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: Maintenance

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 6 Maintenance Routine Maintenance (Preventative) The equipment is designed to keep levels of maintenance to an absolute minimum. 6.1.1 Cleaning Windows It is important that the optical windows of both transmitter and receiver are kept reasonably clean and any mounting tubes free from build-up of dust and fly ash.
  • Page 109 Section 6 Maintenance 6.1.3 Replacement of Chopper To replace a chopper motor proceed as follows : Motor Assembly turn the power OFF and remove the transmitter from its air purge.  remove the four screws holding the transmitter front flange in position and ...

  • Page 110: Replacement Of Gas Cells

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Transmitter Adjustments.  6.1.4 Replacement of Gas Cells To replace a gas cell proceed as follows : 6.1.4.1 Transmitter: turn the power OFF and remove the transmitter from its air purge.
  • Page 111 Section 6 Maintenance 6.1.4.2 Receiver: turn the power OFF and remove the receiver from its air purge.  remove the receiver cover from the front flange.  slacken off the four screws holding side detector PCB to the main body of the ...

  • Page 112: Recommended Spare Parts

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Recommended Spare Parts Items marked * are not consumable – therefore only one set of these items needs to be held as back-up spares for each analyser type. All other items have a limited life and full quantities will be required for each individual analyser.

  • Page 113: Data Valid Led Out

    Section 6 Maintenance where : Modulation Frequency 30 to 45Hz Mark/Space Ratio 0.9 to 1.1 Saturation Count 50 maximum for all analysers Should the values be outside of the above ranges, the Data valid LED will extinguish, and the fault condition be displayed – see Data Valid LED Out for details.
  • Page 114 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions The following fault conditions are recognised by the instrument. possible causes : 6.3.2.1 Detector signals saturated incorrect detector gain adjustment. (Sat# over 50) instrument conditioned during high opacity conditions which have now cleared.
  • Page 115 Section 6 Maintenance Corrective Maintenance. Page: 115 Issue: A Revision: 1 Date: 24/07/19 Ref: 100606...

  • Page 116: Corrective Maintenance

    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. Page: 116...

  • Page 117: Commissioning Problems

    Connections OK Proceed next possible cable connections cause signal Connections Secure connections processor loose Signal processor failure Contact your CODEL supplier Possible Cause Test Result Action Symptom 2. Display nonsense Micro-processor fault Re-set Fault clears No further action interrupting mains...
  • Page 118 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Page: 118...
  • Page 119 @ terminals 4&5 See above – not Proceed next possible cause Check ref. wave in 37Hz square Contact your CODEL supplier signal processor – wave approx. 12V oscilloscope - OK @ terminals 2&5 See above – not Check & rectify...
  • Page 120 Transmitter cell Check drive LED LED flashing Proceed to next test drive failure signal LED not flashing Contact your CODEL supplier processor Check No movement Contact your CODEL supplier cell/filter drive Movement Contact your CODEL supplier 4.3 Detector saturated...
  • Page 121 Unable to adjust Proceed to next test Monitor ref. – 45Hz – Contact your CODEL supplier waveform across waveform OK 10 &11 in power Contact your CODEL supplier <30 or >45Hz – supply using waveform oscilloscope incorrect 4.5.

  • Page 122: Operational Problems

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 6.4.3 Operational Problems Possible Cause Test Result Action Symptom Output reading Incorrect normalising Enter parameter Parameters Proceed next possible parameter setting mode and ensure permanently zero or correct cause all parameters are...

  • Page 123: Individual Tests

    Section 6 Maintenance 6.5.1 Individual Tests Some instrument components/operation can be verified as follows : 6.5.1.1 Heater Cartridge Conduct the procedure for changing the heater cartridge within the 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.

  • Page 124: Led Indications

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions Transmitter Adjustments), but do not adjust the trim pot. turn the power ON.  observe the chopper motor and blade between the lens and heater cartridge. If  it is seen to be spinning, the chopper motor is OK if it is not spinning, the supply to the chopper motor can be measured at the test ...

  • Page 125: Test Points

    Section 6 Maintenance 6.5.2.2 Receiver LEDs +V and –V These LEDs should be ON indicating that the power supplies within the unit are functioning correctly. 6.5.2.3 Transmitter LEDs +V and –V These LEDs should be ON indicating that the power supplies within the unit are functioning correctly.
  • Page 126 EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 6.5.3.1 Signal processor T1…………………….. signal from receiver head with some conditioning in the processor, smoothed by a factor of divide by 10. Flattened saw-tooth, 32 to 45Hz (modulation frequency) pk-pk (maximum), centred on 0V. 0V for T1 to T6 may be taken from 0V test point, top left of board.
  • Page 127 Section 6 Maintenance +5 and 0V………….. Supply rails for the micro-processor. voltage. 12V………………….. Supply rail for the plant status input. +15V, -15V & 0VA…. Supply rails for the analogue current output. VIN…………………… Output from the D/A converter. 0 to 2.5V represents 0 to 20mA (4mA at 0.5V) -15V1, 0V &...

  • Page 128: Span Factor Adjustment

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions T3……………………. Reference wave. T4……………………. Reference wave. 6.5.4 Span Factor Adjustment The span factor does not normally need adjusting. However, if any of the following changes have taken place it may be necessary to adjust it: Gas cell changed either in the receiver or the transmitter Interference filter changed in the receiver.

  • Page 129: Special Tools And Handling Devices

    Now press Enter to set the span factor.  Special Tools and Handling Devices None are required to use or maintain CODEL EnergyTech 401 analysers. Equipment and Spare Parts Storage and Preservation All equipment and spares should be stored in their packaging in a dry, heated warehouse when not in use.

  • Page 130: Parts List

    EnergyTech 401 CODEL Operating and Maintenance Manual Monitoring Solutions 7 Parts List 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...
  • Page 131 Section 8 Table of Figures 8 Table of Figures 1 : T IGURE YPICAL YSTEM AYOUT 2 : T & R IGURE RANSMITTER ECEIVER CHEMATIC 3 : CO IR A IGURE BSORPTION PECTRUM 4 : C IGURE OMPARISON OF PECTRA 5 : T IGURE RANSMISSIVITY OF...

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