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Summary of Contents for CODEL EnergyTech 203
- Page 1 Technical Manual EnergyTech 203 Technical 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...
- Page 2 Technical Manual Issue: A Revision:1 Date:18/12/17 Ref: 100416...
- Page 3 Technical Manual 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 Technical Manual Issue: A Revision:1 Date:18/12/17 Ref: 100416...
- Page 5 Technical Manual 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. Caution, risk of electric shock. Caution, risk of danger.
- Page 6 Technical Manual Issue: A Revision:1 Date:18/12/17 Ref: 100416...
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Page 7: Table Of Contents
Technical Manual Contents Contents EnergyTech 203 CO and O2 Gas Analysing System ................. 9 1.1. Introducton .......................... 9 System Operation ......................11 1.2. Measurement Cabinet ..................... 12 1.3. Measurement Principle ......................13 Summary Specification ......................15 Preparing for Installation ....................... 16 Unpacking .......................... - Page 8 7.11. Emergency Shutdown/Isolation Procedure ............42 List of figures ........................43 Appendix A – Codel EnergyTech 203 DDU Standard ModBus map ....... 44 Appendix B - Spare parts list ..................47 Appendix C - Wiring Connections ................48 Issue: A...
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Page 9: Energytech 203 Co And O2 Gas Analysing System
1. EnergyTech 203 CO and O2 Gas Analysing System 1.1. Introducton The EnergyTech 203 carbon monoxide (CO) and oxygen (O2) analyser is the ideal equipment for fine tuning the air / combustible proportions in a way to improve process efficiency without compromising safety. - Page 10 Technical Manual The mounting arrangements of the EnergyTech 203 are shown in figure 1 below. Figure 1 : Mounting Arrangements Description Part No. Water Drain Solenoid N/C 740.341 Vacuum Filter 740.342 Coalescing Filter (99% @ 0.01 Micron) 744.131 Pressure Transducer 744.048...
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Page 11: System Operation
Technical Manual 1.2. System Operation A schematic illustration of the CO Gas Analysing System is shown below. Figure 2: System Schematic The gas is drawn from the mill outlet duct via a stainless-steel filter through the measurement chamber using a pump. The arrangement of valves allows three paths ‘A’, ‘B’ or ‘C’. ‘A’... -
Page 12: Measurement Cabinet
Technical Manual 1.3. Measurement Cabinet Figure 3 below is a photograph of the inside of the measurement cabinet. Figure 3: Inside the Measurement Cabinet Issue: A Revision:1 Date:18/12/17 Ref: 100416... -
Page 13: Measurement Principle
Technical Manual 2. Measurement Principle 2.1. CO The analyser comprises an infrared source assembly mounted on one side of the measurement chamber. On the opposite side of the measurement chamber is the receiver. The source consists of a small black-body emitter and gas wheel assembly. The wheel is rotated by a stepper motor at a constant speed of 1Hz. - Page 14 Technical Manual 2.2. O2 The O2 sensor consists of a well proven zirconium dioxide-based element. The zirconium dioxide O2 sensor’s working principle measures partial pressure of oxygen in mixture of gases and due to its unique closed loop measurement system design, it does not require a reference gas. While the sensor continuously measures the oxygen level, a heartbeat signal is also generated providing an immediate warning of any failures.
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Page 15: Summary Specification
Technical Manual 3. Summary Specification Operating Principle infrared absorption (CO) / Zirconium dioxide (O2). Span *Fully selectable CO 0-1000ppm. O2 0.1 to 30% Response Time 120 sec to T90 Gas Species Carbon Monoxide (CO) and Oxygen O2 Accuracy ± 10ppm or ± - 2% of span (whichever is the greater). Resolution 5ppm. -
Page 16: Preparing For Installation
The equipment is normally protected for transportation by an expanded foam packing material. When unpacking please ensure that smaller items are not discarded with the packing material. If any items are missing please inform Codel or your local Codel agent immediately. •... -
Page 17: Additional Materials
For correct operation of the valve arrangements the optimum pressure is 5bar. • NB. The cable that runs between the solenoid valve on the probe, and the cabinet is not supplied by CODEL and must be customer supplied. Issue: A Revision:1... -
Page 18: Installation
Figure 6: Filter Assembly Location Weld the mounting flange and stub pipe assembly (Codel supply) to the mill outlet duct in the selected position shown in Figure 7. Do not mount the site flange arrangement directly to the Mill, it must be positioned on the duct from the Mill, failure to do so will result in failure of the sample probe. -
Page 19: Measurement Cabinet
Technical Manual 5.3. Measurement Cabinet 5.3.1. Remote-Mounted Installation The rear of the measurement cabinet is pre-drilled to enable remote mounting; mounting hole details are shown below in Figure 8. Connect the sample line at one end to the measurement cabinet and at the other end to the stainless-steel filter assembly via the ¼’’... -
Page 20: Terminal Connections
Technical Manual 5.4. Terminal Connections Live Mains electrical connections Neutral Earth RS485 RS485 Data valid Data valid Data valid Volt free contact Volt free contact Volt free contact Alarm 1 Alarm 1 Alarm 1 Alarm 1 Volt free contact Volt free contact Volt free contact Volt free contact Alarm 2... -
Page 21: Commissioning
Technical Manual 6. Commissioning The analyser should now be fully installed and ready to be commissioned. This involves the following basic procedures that can be carried out with the plant ON or OFF: • analyser configuration • initialisation • zero calibration 6.1. -
Page 22: Normal Operation
Technical Manual 7. Normal Operation 7.1. Introduction After the instrument has been commissioned it will measure the CO and O2 levels of the sample gas and produce an output proportional to the CO and O2 levels. The integral 32- character display also shows the measured levels, cycling between CO and O2 every 5 seconds. -
Page 23: Modes Of Operation
Technical Manual 7.3. Modes of Operation The instrument has five modes of operation identified by a number in the top left-hand corner of the display: • Mode 1 Operating Mode displays gas concentrations • Mode 2 Parameter Mode displays operating parameters. •... -
Page 24: Key Operation
Technical Manual 7.4. Key Operation Each mode is accessed sequentially by each push of the MODE key. Figure 10 illustrates the display keypad. After a mode has been selected, the ARROW keys will select the various options within that mode. The ENTER key will input the displayed value and may step the cursor to the next option, if this is applicable. -
Page 25: Program Tree
Technical Manual 7.5. Program Tree Figure 11 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 –... -
Page 26: Operating Mode
Technical Manual 7.6. Operating Mode This displays the CO and O2 concentration and operating conditions, when in this mode, the displays 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 27 Technical Manual Interval between back purges. Protocol and baud rate of serial communications. Output Fault - should a fault condition occur; the analogue output can be set from one of four options. Set-Up Mode. The selected options may be modified here. •...
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Page 28: Chamber
Technical Manual 7.9. Chamber Press the MODE key until the number 3 is seen in the top left corner of the display. From this mode the parameters currently being used to control the measurement chamber can be displayed. Press the ENTER key to enter the routine and use the ARROW keys to select either temperature or pressure parameters to display. -
Page 29: Diagnostic Mode
Technical Manual 7.10. Diagnostic Mode The detector levels, thermistor data, ‘Y’ & ‘Z’ values, CO values, cal. Data, temperature, O2 sensor 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 30: Detector Outputs (Co Sensor)
Technical Manual 7.10.1. Detector Outputs (CO sensor) Detector output levels are displayed here. D2 is the reference level and should always be less than D1. The level of D1 should be between 15,000 and 25,000. D2 should be approximately 0.68 x D1 with zero gas levels. -
Page 31: Temperature
Technical Manual 7.9.4. CO Values (CO sensor) Shown here is the gas concentration measured by the analyser. Note that ‘ppm’ is the ‘ppm*m’ value corrected for path length. 7.9.5. Calibration Data (CO sensor) The calibration factors, determined during the calibration routine (Kcal), and the value currently being used (Kwkg) can be examined from this display. -
Page 32: Fault Condition
Technical Manual E.c is the error code from the O2 sensors control circuit . 00 = no faults. H.v is the heater control voltage used for heating the O2 sensor. 7.9.8. Fault Condition This display indicates whether the measurement chamber purge is ON or OFF. By pressing the arrow key the current fault condition can be observed. -
Page 33: Set-Up Mode
Technical Manual • Press > Range < - the pressure measurement is out of range (pressure transducer may have failed). • Filter → Blocked – the pressure measurement is below the threshold implying that the sample filter is blocked. • Warming up –... - Page 34 Technical Manual Enter Press Enter on Exit option Current O/P channel 1 or 2 Species CO or O2 Output Units ppm (CO)or % (O2) Span 0 to 9999 span (ppm) / 0 to 30% Fault Condition Measured, zero mA, FS (20mA)or hold Set mA O/P Set up current output levels Alarm O/P...
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Page 35: 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 and should be changed by the user from within the set-up mode. - Page 36 Technical Manual The analogue output can represent the gas concentration in units of ppm or % depending on the selected species. • 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.
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Page 37: Parameters
Technical Manual Now repeat the above procedure for O/P 2. A contact output is available to warn of a high gas concentration. • Alarm 1 & 2 • Set channel • Set gas species (CO or O2) the units for the alarm are not adjustable (for reference only) and are species specific. After the source has been selected, the instrument requires a level that the output will be triggered. - Page 38 The serial communication identity address value. This value may be changed from this mode. Select here the required serial communication protocol: MODBUS for standard ModBus CODEL for Codel’s own diagnostic software. 7.10.3.1. Baud Rate Select here the speed of the communications, either 4800 or 9600 baud: Back purge interval, set the period between back purging to ensure filter remains clean.
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Page 39: Span Factor
Technical Manual The DDU processor contains a real time clock used for initiating automatic calibrations. The clock time and date are set here: Year - adjust the year by scrolling up or down using the ARROW keys and entering with the ENTER key. Month - adjust the month by scrolling up or down using the ARROW keys and entering with the ENTER key. -
Page 40: Pressure
Technical Manual 7.10.6. Pressure The measurement chamber pressure transducer input range is set here. The 4-20mA inputs within the processor receive measurement transducer data; the values at 4mA and at 20mA will be requested. The pressure transducer used in the system is rated at 0-160kPa. 7.10.7. - Page 41 Technical Manual The calibration routine must be run during commissioning otherwise the analyser will not be able to calculate the true level of gas in the duct. • Zero Purge The solenoid valve controlling the purge air to the measurement zone is activated here. •...
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Page 42: Alarms And Emergency Conditions
Technical Manual The back-purge sequence of solenoid valve operations to pulse air into the filter is activated here. This is set to give five air pulses into the sample filter in an attempt to clear any blockage. It is important that this filter is kept clean. The final pulse of air is meant to determine if the filter is blocked and takes 16 seconds to complete. -
Page 43: List Of Figures
Figure 10: Program Operation Tree ...................... 25 Figure 11: Diagnostic Mode Tree ......................29 Figure 12: Set up mode ......................... 34 Figure 13: Energy Tech 203 Wiring diagram ..................48 Figure 14: EnergyTech 203 Wiring Locations ..................48 Issue: A Revision:1 Date:18/12/17... -
Page 44: Appendix A - Codel Energytech 203 Ddu Standard Modbus Map
The response frame from the CODEL EnergyTech 203 lists the contents of the requested registers, returning 2 bytes per register with the most significant byte first. A maximum of 125 registers can be accessed per request. - Page 45 Each register is defined to be 2 bytes wide. Modbus Register Location 0070h CO Data 0001h =1ppm, 0064h = 100ppm Data Register Locations at CODEL EnergyTech 203 for Interrogation using Standard MODBUS are shown in the following table: Issue: A Revision:1 Date:18/12/17...
- Page 46 Technical Manual Data Register Locations at CODEL EnergyTech203 DDU for interrogation using Standard MODBUS Subject : Prelimary subject to change Doc code : Blank Issue : A Date : 6/2/2017 CODEL Doc ref: QA - 72 B REGISTER FORMAT CUSTOMER SPECIFIC DETAILS...
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Page 47: Appendix B - Spare Parts List
Technical Manual 10. Appendix B - Spare parts list Description Location Part number Single Micro PCB + LCD Backlit Display Cabinet S991.312 Diaphragm Pump (6mm Push) Cabinet 744.133 Filter Element (99% @ 0.01 micron) Cabinet 744.132 SMC ZFC 10μm Vacuum Filter Cabinet 740.342 E/T 200 Series Control/Comms PCB... -
Page 48: Appendix C - Wiring Connections
Figure 13: Energy Tech 203 Wiring diagram Backpurge valve connection Data Valid Relay Alarm 1 Alarm 2 RS485 Modbus (A-2, B-2) 4-20mA Output 2 4-20mA Output 1 110-240V AC 50/60Hz Mains Supply Figure 14: EnergyTech 203 Wiring Locations Issue: A Revision: Date:18/12/17 Ref:100396... - Page 49 Technical Manual Issue: A Revision: Date:18/12/17 Ref:100396...
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