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CODEL EnergyTech 100 Series Installation, Commissioning, Operation And Maintenance Manual

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EnergyTech 100 Series
101/102
Installation, Commissioning, Operation
and Maintenance Manual
OPS. 141
CODEL
Issue : A
Revision : 1
Date : 14/06/18
Doc i/d : 0141/6
050028

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Summary of Contents for CODEL EnergyTech 100 Series

  • Page 1 EnergyTech 100 Series 101/102 Installation, Commissioning, Operation and Maintenance Manual OPS. 141 CODEL Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028...
  • Page 2 CODEL Total Solutions – Total Confidence OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028...
  • Page 3 CODEL CODEL International Ltd is a UK company based in the heart of the Peak District National Park in Bakewell, Derbyshire. The company specialises in the design and manufacture of high-technology instrumentation for monitoring combustion processes and atmospheric pollutant emissions.
  • Page 4 CODEL OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028...

  • Page 5: Table Of Contents

    CODEL Contents 1. System Description 1.1. Opacity Measurement 1.2. About this Manual 2. Installation 2.1. Unpacking the Equipment 2.2. Siting the Equipment 2.3. Duct Work 2.4. Air Purge 2.5. Transmitter & Receiver Units 2.6. Air Supply 2.7. Signal Processor and Power Supply Units 2.8.

  • Page 6: Figure 9 : Program Tree

    CODEL 3.6. Basic Calibration 3.6.1. Initial Calibration 3.7. Operating Parameters 3.7.1. Setting Parameters after Initial Calibration 3.7.2. Example 1 : Smoke Monitor 3.7.3. Example 2 : Dust Monitor 3.8. Calibration Data 4. Operation 4.1. Introduction 4.1.1. Measurement 4.1.2. Calibration 4.2. Operating Modes 4.3.
  • Page 7 CODEL 4.8.3. Configure O/P1 4.8.3.1. Output 4.8.3.2. Average 4.8.3.3. Units 4.8.3.4. Span 4.8.3.5. Fault Condition 4.8.3.6. Set mA Output 4.8.4. Configure O/P2 4.8.5. Alarm 1 4.8.5.1. Source 4.8.5.2. Units 4.8.5.3. Level 4.8.5.4. Exit 4.8.6. Alarm 2 4.8.7. Parameters 4.8.7.1. Security Number 4.8.7.2.
  • Page 8 CODEL 6. Routine Maintenance 6.1. Cleaning Windows 6.2. Clean Flue Condition Available 7. Basic Fault Finding 7.1. Initial Checks 7.2. Data Valid LED Out 8. Specifications Appendix A - Optical Transmissivity Measurement & Solid Content Extinction Coefficient and Beer Lambert Relationship Optical Density &...

  • Page 9: System Description

    100 Series 101/102 seeks to overcome these problems by providing a reliable, simple to use instrument with low maintenance requirements. 1.2. About this Manual This manual details the installation, commissioning, operation, routine maintenance and basic fault finding for the EnergyTech 100 Series Analyser. OPS. 141 Issue : A Revision : 1...

  • Page 10: Installation

    CODEL 2. Installation 2.1. Unpacking the Equipment After the equipment has been unpacked, unless specifically requested by the customer, the following equipment items should be found : • transmitter with 10m of cable (standard length) • receiver with 10m of cable (standard length) •...

  • Page 11: Figure 1 : General Arrangement

    CODEL Figure 1 : General Arrangement OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0118/6 050028...

  • Page 12: Duct Work

    CODEL 2.3. Duct Work The transmitter and receiver units are mounted on opposite sides of the duct, and interface with the site mounting flange. To protect operators, it is recommended that an isolating valve is used for ducts that operate higher than atmospheric pressure.

  • Page 13: Air Purge

    CODEL 2.4. Air Purge The purges mount directly onto the site mounting flanges. Separate the front flange from the air-purge by unscrewing the four retaining nuts. This should now be bolted to the site mounting flange with a rigid gasket fitted between them, using the four countersunk screws provided.

  • Page 14: Transmitter & Receiver Units

    • 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 1.5l/s against the working pressure of the duct. CODEL can specify a blower if required.

  • Page 15: Signal Processor And Power Supply Units

    CODEL 2.7. Signal Processor and Power Supply Units To mount the signal processor first remove the cover by loosening the four captive screws, unplug the ribbon cable at the connector on the lid PCB. 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.

  • Page 16: Outputs

    CODEL 2.9. Outputs Three forms of output are provided : • two selectable current outputs (normally 4 to 20mA). Maximum load is 500. • single pole changeover relays for :  two alarm relays triggering at a threshold set in the signal processor.

  • Page 17: Plant Status Input

    CODEL • Contact Outputs : Any 2-core cable capable of supplying the power to the warning device/relay etc. (1A @ 30V DC, 0.3A @ 120V AC, max. power resistive load 30W). • AC Power : Any suitable 3-core power cable capable of carrying 50VA.
  • Page 18 CODEL Figure 6 : Connection Schedule OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028...

  • Page 19: Commissioning

    CODEL 3. Commissioning 3.1. Introduction Commissioning the instrument can takes up to a couple of hours and is conducted as follows : • Power Supply Voltage Selection : No selection is necessary. • Applying Power : Switching the power on and observing the power supply rail indications.

  • Page 20: Key Pad Operation

    CODEL 3.3. Key Pad Operation Each mode is accessed sequentially by each push of the MODE key. Figure 7 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 21: Led Indication

    CODEL Pressing the ENTER key will do one of two things depending on the position in the program : • it will input the displayed parameter value, or • it will select the displayed mode or option from within a mode or sub mode.
  • Page 22 CODEL • Adjust the alignment of the transmitter flange until the bright glow of the transmitter LED can be fully seen when viewed down the receiver orifice. Alignment is achieved by loosening the four locking nuts and adjusting the four adjusting nuts located between the front and the adjustable flanges - see Figure 8.

  • Page 23: Gain Adjustment

    CODEL 3.5. Gain Adjustment The receiver (Rx) gain has two stages. The first, adjustable via the keypad, is in the receiver head and consists of a low (x1) or high (x10) setting. The second stage is a variable gain within the signal processor (SP) and is adjustable using VR1 (VR2 is for Dt level).

  • Page 24: Initial Calibration

    CODEL Ideally the flue/ duct should be operating under clean conditions (zero opacity) for commissioning. If this is not practical, however, a target calibration opacity can be assumed, in which case, should a clean flue become available, the instrument must be re-calibrated.

  • Page 25: Setting Parameters After Initial Calibration

    CODEL To aid commissioning, and to record any subsequent changes to the operating parameters, the table at 3.7.3. Example 2 : Dust Monitor, displays all the options available and can be used as a record. Two example set-ups are also shown in this table.
  • Page 26 CODEL 9. Ranges for the averages are :  minute 01 to 60 in 1 minute intervals  hour 01 to 24 in 1 hour intervals  day 01 to 30 in 1 day intervals 10.When days has been entered the LCD will read RESET, select YES and the display will prompt SURE.
  • Page 27 CODEL ZERO HOLD F.S. MEAS by using the UP and DOWN keys. Press ENTER. 20.Set mA Output is the next option accessed. This option may not need setting as the output calibration will have been set at the factory - skip this and go to point 22 if preferred. Press ENTER and set zero appears on the LCD.

  • Page 28: Example 1 : Smoke Monitor

    CODEL Make a note of this number; this is the security code required every time the SET UP MODE is entered in the future. 31.Press the DOWN arrow key to select Identity, press ENTER. Use the arrow keys to scroll the device identity number between 01 to 255.

  • Page 29: Example 2 : Dust Monitor

    CODEL 10-second, 10-minute, 1-hour and 30-day rolling averages are set- • Output 1 The analogue output (4 - 20mA) represents Ringelmann 0 to 5, with a fast response time 10 seconds. Also, should a system fault occur, the instrument will still attempt to measure the Ringelmann value.
  • Page 30 CODEL • Parameters As the instrument is being used as part of an integrated system, the device identity has been set to 4. This value must be unique from other monitors in the system. The 1-hour rolling average is also being used to provide an alarm at 50 mg/Nm , where the change-over contact relay will operate.
  • Page 31 CODEL Parameter Factory Site Averages seconds minutes hours days Output 1 0 or 4mA base units span average fault condition Output 2 0 or 4mA base units span average fault condition Alarm 1 source units level Alarm 2 source units...

  • Page 32: Calibration Data

    CODEL Oxygen standard level % analogue i/p @ 4mA analogue i/p @ 20mA keypad i/p Pressure standard level kPa analogue i/p @ 4mA analogue i/p @ 20mA keypad i/p kPa Water Vapour standard level % analogue i/p @ 4mA analogue i/p @ 20mA keypad i/p % 3.8.

  • Page 33: Operation

    CODEL 4. Operation 4.1. Introduction After the instrument has been commissioned, it will measure the transmissivity between the transmitter and receiver, and produce an output proportional to either the opacity, dust, Ringelmann or extinction level. An integral 32-character display also shows the calculated levels.

  • Page 34: Program Tree

    CODEL 5. Set-up Mode - set operating parameters. The mode can only be accessed using a security code. The outputs of the instrument are unaffected by key operation in all modes except the set-up mode. 4.3. Program Tree Figure 9 illustrates the main program of the instrument. Where an operating mode is complex, an extra program tree is given in this section.
  • Page 35 CODEL Figure 9 : Program Tree OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0118/6 050028...

  • Page 36: Operating Mode

    CODEL 4.4. Operating Mode From this mode of operation the four averaging times, seconds, minutes, hours and days, may be displayed. The four concentration units, opacity, extinction, dust density Ringelmann levels, altered measured/normalised measurements for dust density observed. When in this mode, the display will appear similar to that shown below. If the display is not similar to this, press the MODE key until number 1 appears in the top left corner of the display.

  • Page 37: Identification

    4.5.1. Identification From this option, the analyser type, its program number, and the device identity of the instrument may be displayed. • Instrument type - EnergyTech 100 Series 101/102 • EPROM number - will display the communications EPROM ID • Identity for factory set-up only 4.5.2.

  • Page 38: Averages

    CODEL 4.5.3. Averages Selecting this option will display the times set for each of the four averaging stacks. 4.5.4. Outputs • Output 1 The base, span and averaging of analogue output 1 are displayed from this option. • Output 2 As above for analogue output 2.

  • Page 39: Plant Status

    CODEL • Alarm 2 As above for alarm 2, analogue output 2. 4.5.6. Plant Status On entering this option the plant status condition is displayed, i.e. ON or OFF. Minutes, hours and days rolling averages are held and current outputs set to zero, with alarms deactivated.

  • Page 40: Display Format

    CODEL 4.6.1. Display Format For each of normalising parameters the display will appear similar to that shown below. 4.7. Diagnostic Mode The detector levels, Analogue to Digital (A-D) levels, receiver gain, calibration and opacity data may be examined from this mode. Press the MODE key until number 4 appears in the top left corner of the display, and push the ENTER key to enter the mode.
  • Page 41 CODEL OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0118/6 050028...

  • Page 42: Detector Outputs

    CODEL 4.7.1. Detector Outputs The output levels from the detector within the receiver and within the transmitter are displayed here. Dt is the detector level at the transmitter and Dr is the detector level at the receiver. The level of Dr is typically between 15,000 and 25,000, and will vary according to duct width, the gain setting and the opacity in the duct, Dt (set by the transmitter pot) is typically similar to Dr.

  • Page 43: Opacity Data

    CODEL 4.7.4. Opacity Data This display indicates the raw (Op0) and the 60 second average (Op60) opacity values. The 60 second smoothed value is used to generate the minutes, hours and days rolling averages. 4.7.5. Fault Condition To display the current fault condition, press the ENTER key while this is displayed.

  • Page 44: Set-Up Mode

    CODEL 4.8. Set-up Mode All system parameters can be changed and a basic calibration initiated from this mode. To prevent any unauthorised changes, the user must enter a four number security code before the mode can be accessed. After this mode has been selected, the instrument will suspend its operation.

  • Page 45: Security Code Entry

    ENTER key is pressed on the last digit, then the sequence will be continued, if it is not correct, the instrument will return to the operating mode. The code number will be set to 0000 by CODEL at the factory, this should be changed by the user from within the set-up mode.

  • Page 46: Figure 11: Program Tree For The Set-Up Mode

    CODEL Figure 11: Program Tree for the Set-up Mode OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028...

  • Page 47: Averages

    CODEL 4.8.2. Averages Four separate averages are calculated within the instrument. These are defined in units of seconds, minutes, hours and days. Any of these four averaging stacks can be used to provide the analogue output of the instrument. Each averaging time is set within pre-defined limits.

  • Page 48: Configure O/P1

    CODEL Set the days averaging stack to the required value. This is limited from 1 to 30 days in 1-day intervals. The average values currently held in the four averaging stacks can be reset using this option. This will erase the current averages that are held in all of the stacks.

  • Page 49: Output

    CODEL 4.8.3.1. Output 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. 4.8.3.2. Average Any of the four averaging stacks (seconds, minutes, hours or days) may be used for the analogue output.

  • Page 50: Fault Condition

    CODEL Press the ENTER key and the Zero value will need to be entered. Select using the ARROW keys for each digit. The ENTER key is pressed to enter the value of each digit. The units displayed will depend on what has been selected above.

  • Page 51: Set Ma Output

    CODEL One of these options can be selected by pressing the ARROW keys, when the desired option is displayed press the ENTER key. 4.8.3.6. Set mA Output This will already have been configured at the factory - do not alter unless the calibration is suspected to be wrong.

  • Page 52: Alarm

    CODEL In a similar manner as above, the current output level should now be set to 20mA using terminals 47(+mA) or 48(0V). The limits for the display are 0 to 4095. A typical value will be 3700. 4.8.4. Configure O/P2 This menu sets analogue output 2.

  • Page 53: Units

    CODEL 4.8.5.2. Units This option is entered after Source has been completed. Select the units required for the alarm as in section 4.8.3.3. Units. When these have been selected press ENTER and the Level option is accessed. 4.8.5.3. Level Select the required level for ALARM 1. Note that the current value is displayed for 1 second, but then it defaults to zero and so must be re-entered for the alarm level to be properly configured.

  • Page 54: Security Number

    CODEL 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. When all required changes have been made, select the EXIT option and press ENTER.

  • Page 55: Measurement Path Length

    CODEL 4.8.7.3. Measurement Path Length When this option is accessed the value defaults to zero after 1 second. The path length entered is used for reference purposes only and should represent the length of the actual dust measurement, not the flange-to-flange dimension between the source and receiver.

  • Page 56: Normalisation

    CODEL 4.8.8. 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 : •...

  • Page 57: Figure 12 : Normalising Set-Up Program Tree

    CODEL Figure 12 : Normalising Set-Up Program Tree OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0118/6 050028...

  • Page 58: Setting The Normalising Parameters

    CODEL 4.8.8.1. Setting the Normalising Parameters 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. • Set Standard Levels Each normalising parameter normalises the measured dust concentration to standard conditions of temperature, oxygen, pressure and water vapour.

  • Page 59: Oxygen

    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. A keypad input is assumed to be a DRY oxygen level. An analogue input level can be selected for a WET or DRY oxygen measurement instrument.

  • Page 60: Calibrate

    CODEL 4.9. Calibrate From this option the levels of the detector within the receiver and within the transmitter may be displayed. The basic calibration of the instrument is set by a ‘Gain Factor’ which can be calculated during a calibration routine.

  • Page 61: Set Rx Gain

    CODEL 4.9.2. Set Rx Gain Set the receiver gain initially to low. Changing to high will give an approximate tenfold (10x) increase in Dr. 4.9.3. 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 opacity within the duct.

  • Page 62: Calibration For Dust Measurement

    CODEL The calibration routine must be run during commissioning, otherwise the instrument will not be able to calculate the true level within the duct. DO NOT run the calibration routine unless reasonable conditions exist in the duct. If it is not the initial calibration, it is recommended that the Gain Factor is recorded from the parameters option, before the calibration is run.

  • Page 63: Estimate Of A Dust Factor

    4.10.1. Estimate of a Dust Factor For the EnergyTech 100 Series 101/102 to calculate the dust density from the opacity data, the Dust Factor needs to be determined by iso-kinetic sampling. However, if there is a delay before sampling can be conducted, an estimate of the dust factor may be used.

  • Page 64: System Description

    CODEL 5. System Description 5.1. Transmitter The transmitter uses a high intensity light emitting diode (LED) as the light source. An internal detector monitors the transmitted light intensity. A lens in the front of the enclosure focuses the light from the LED across the duct.

  • Page 65: Power Supply Unit

    CODEL The processor is housed in a fully-sealed (designed to IP65) epoxy-coated aluminium enclosure. 5.4. Power Supply Unit The power supply unit receives mains power, 88V to 264V AC, and provides 48V DC to the signal processor unit. The power supply is housed in a fully-sealed (designed to IP65) epoxy-coated aluminium enclosure.

  • Page 66: Routine Maintenance

    CODEL 6. Routine Maintenance The equipment is designed to keep the levels of maintenance to an absolute minimum. 6.1. Cleaning Windows It is important that the optical windows of both the transmitter and the receiver be kept reasonably clean and any mounting tubes free from build-up of dust and fly ash.

  • Page 67: Basic Fault Finding

    CODEL 7. Basic Fault Finding 7.1. Initial Checks The electronics require no routine maintenance. They are all solid state and undergo a rigorous factory burn-in procedure. If there is any doubt about the equipment performance, the signal processor may be interrogated from the keypad to determine whether or not the equipment is functioning normally.

  • Page 68: Data Valid Led Out

    CODEL 7.2. Data Valid LED Out 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. The following fault conditions are recognised by the instrument : ...

  • Page 69: Specifications

    CODEL 8. Specifications Span Fully selectable in terms of dust, opacity, Ringelmann or extinction Response Time Selectable from 10 seconds to 30 day rolling average Maximum Path Length 6 metres Construction Fully sealed to IP65 Ambient temperature limits Transmitter and Receiver...
  • Page 70 CODEL Power consumption 30VA, 88/264V, 50/60Hz Air purge consumption 0.25l/s @ 1.5bar In the absence of actual data, assume (250/x) mg/m of duct generates 10% opacity in an x metre wide duct. This is not a fixed relationship and must be verified by iso-kinetic analysis.

  • Page 71: Appendix A - Optical Transmissivity Measurement & Solid Content

    CODEL Appendix A - Optical Transmissivity Measurement & Solid Content Since the aim of all optical transmissivity measurements is to assess the level of solids emission, it is important to consider the relationship between various optical measurements and the particulate content of the gas. It must first be...

  • Page 72: Extinction Coefficient And Beer Lambert Relationship

    CODEL Extinction Coefficient and Beer Lambert Relationship The attenuation of light of a narrow waveband - such as visible or photopic light by fine particulate matter is very specific and is expressed mathematically by the Beer Lambert Relationship : Transmittance T exp (-k.n.a.l)

  • Page 73: Mass Emission

    CODEL Opacity % Transmittance Opacity (Log 0.05 0.15 0.52 1.00 Mass Emission While it is possible to provide an output for opacity monitors in terms of optical density/extinction, conversion of this parameter into a measurement of mass flow emission, in mg/m for example, requires an empirical calibration to be made for that particular installation and flue condition.
  • Page 74 CODEL Thus, 100 [1 - (1 - O /100) exp l and is directly proportional to the Ringelmann scale range 0 to 5 (equivalent to 0 - 100%O The following illustration shows typical relationships between opacity and Ringelmann for various stack exit diameter/measurement path length ratios Figure 14 OPS.

  • Page 75: Temperature Correction

    CODEL Temperature Correction Usually there is little change in temperature between the measured and exit points, but where it is appreciable the stack exit opacity will be modified. This is due to the gases reducing in volume while the particulate volume remains relatively constant.

  • Page 76: Table Of Figures

    CODEL Table of Figures Figure 1 : General Arrangement Figure 2 : Site Mounting Flange Details Figure 3 : Adjustable Mount and Air Purge Details Figure 4 : Transmitter/Receiver and Air Purge Figure 5 : Signal Processor/Power Supply Mounting Details...

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