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Section 1
Model D-CEM2100 TUV - Dust Monitor
Instalation and Commissioning Manual
Reference: 100178
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Issue: B
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Revision: 6
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Date: 31/01/22
CODEL International Ltd.
Unit 4, 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
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Summary of Contents for Forbes Marshall CODEL D-CEM2100 TUV
- Page 1 Section 1 Model D-CEM2100 TUV - Dust Monitor Instalation and Commissioning Manual Reference: 100178 Issue: B Revision: 6 Date: 31/01/22 CODEL International Ltd. Unit 4, 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 3 Section 1 CODEL A Forbes Marshall Company Page: 1 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178...
- Page 4 DCEM 2100 – TUV 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. The constant search for new products and existing product improvement keeps CODEL one-step-ahead.
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Page 5: Table Of Contents
Supplementary Connection Schedule for Second DDU ..................30 Supplement 2 - Zero Point Alignment tube ......................31 Supplement 3 - Zero Point Alignment Procedure ....................33 Important!! CODEL A Forbes Marshall Company Page: 3 Issue: B Revision: 6 Date: 31/01/22... - Page 6 DCEM 2100 – TUV 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.
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Page 7: Installation
Figure 1: DCEM Transceiver Head • 2 x Site Mounting Flanges Figure 2: Site Mounting Flange • 2 x Air Purges Figure 3: Air Purge CODEL A Forbes Marshall Company Page: 5 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178... - Page 8 DCEM 2100 – TUV • 2 x Ball Valves Figure 4: Ball Valve Assembly • 1 x Power Supply Unit (PSU) Figure 5: Power Supply Unit • 1 x Signal Processor Unit (SPU) Figure 6: Signal Processor Unit CODEL www.codel.co.uk ©...
- Page 9 A second DDU can also be connected to the SPU if required – see Supplement 1 at the end of this document. Figure 7: Data Display Unit CODEL A Forbes Marshall Company Page: 7 Issue: B Revision: 6 Date: 31/01/22...
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Page 10: Positioning The Equipment
DCEM 2100 – TUV Positioning the Equipment The equipment is designed for mounting on stacks in positions open to the weather. It is fully sealed to IP65 and requires no weather covers. Consider the following: • The sensor mounting points must be accessible at both sides of the duct for servicing the transceivers. - Page 11 Figure 8 for a metal stack and for a concrete stack. In the case of a metal stack it may be necessary to fit stiffening ribs for added rigidity. Figure 8: Stub Pipe Arrangement CODEL A Forbes Marshall Company Page: 9 Issue: B Revision: 6...
- Page 12 DCEM 2100 – TUV • Air Purges The purpose of the air purges is to keep the windows of the transceivers clean. The air purges mount directly onto the site mounting flanges. Separate the front flange from the air-purge by unscrewing the four retaining nuts.
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Page 13: Ball Valves
If the valve closes unexpectedly it will remove a finger end quite easily! Figure 10: Compressed Air Connections at the Ball Valve 1.3.2 Transceivers CODEL A Forbes Marshall Company Page: 11 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178... -
Page 14: Psu & Spu
DCEM 2100 – TUV By means of four hexagon head screws, the transceiver head/ball valve assemblies may be attached to the air purges with the flexible gasket supplied, fitted between them. Take care to locate the dowel. 1.3.3 PSU & SPU To mount the PSU &... - Page 15 12. Note: optional second DDU will be specified on the sales order see supplement 1 for installation details. Figure 12: DDU Mounting Details CODEL A Forbes Marshall Company Page: 13 Issue: B Revision: 6...
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Page 16: Electrical Connections
DCEM 2100 – TUV 2 Electrical Connections WARNING! Wiring should only be undertaken by a qualified technician. Ensure that the power supply is isolated. DO NOT switch power on until all wiring work is complete. Installation and Connection of Cables Decide routing for all non-power cables (both those supplied by CODEL and those sourced locally). -
Page 17: Connection Schedule
Electrical Connections Connection Schedule The connection schedule for the D-CEM2100, PSU, SPU & DDU is shown in the following drawing (figure 13). Figure 13: Connection Schedule CODEL A Forbes Marshall Company Page: 15 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178... -
Page 18: Commissioning
DCEM 2100 – TUV The following diagram illustrates how the DCEM 2100 TUV system should look when electrical connections have been made. Transceiver Transceiver Purge Air IN Purge Air IN Signal Processor Power Supply Data Display Unit Unit (SPU) Unit (PSU) (DDU) Mains Power IN 48V Power... -
Page 19: Pre-Commissioning Checks
Finally check that the air purge is functioning. If not, take corrective action. Now the system can be commissioned, complete the following points in the commissioning section making sure to fill in the DCEM2100 TUV commissioning check list as you proceed. CODEL A Forbes Marshall Company Page: 17 Issue: B Revision: 6... -
Page 20: Mounting Air Purges
DCEM 2100 – TUV Mounting Air Purges Mount the Air Purges onto the duct mounted site flanges and ensure that all of the alignment studs are set to mid-point Front Flange Adjustable Alignment studs Site Mounting Flange Stack Mounting Tube Air purge Adjustable Flange... -
Page 21: Check Wiring
Apply power to the system. Check Solenoid Voltage In the signal Processor check the voltage on each of the solenoid connectors Figure 18: Solenoid Voltage Check CODEL A Forbes Marshall Company Page: 19 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178... -
Page 22: Open Ball Valves
DCEM 2100 – TUV Open Ball Valves Look through one purge across the duct to the other – are both ball valves fully open? If not increase the pressure of the plant air supply. Figure 19: Open Ball Valve CODEL www.codel.co.uk ©... -
Page 23: Alignment
After fitting the air purge and ball valve bolt the alignment telescope to the ball valve flange as shown below. Ball Valve Alignment Telescope Figure 20: Fitting Alignment Telescope CODEL A Forbes Marshall Company Page: 21 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178... - Page 24 DCEM 2100 – TUV Referring to the illustration below, at the adjustable mount, lock the nuts at positions 1 & 3. By means of the adjusting nuts at positions 2 & 4, adjust the alignment of the transceiver (TRx1) until the cross-hairs (viewed through the telescope) coincide with the vertical centreline of the light from the red LED;...
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Page 25: Close Ball Valves
At the signal processor, unplug the solenoid supplies and check that the ball valve closes and that the mirror is central; check that the ball valve opens again when the plugs are replaced. Figure 22: Ball Valve Closed CODEL A Forbes Marshall Company Page: 23 Issue: B Revision: 6... -
Page 26: Mounting Transceivers
DCEM 2100 – TUV 3.12 Mounting Transceivers Mount the transceiver heads at either side of the stack. Transceiver Head Air Purge Stack Mounting Tube Ball Valve Stack Mounting Flange Mounted on Stack Figure 23: Mounting Transceivers Measure Resistance 3.13 Measure the resistance between the head bolts and the site flange and record on the commissioning check- list. -
Page 27: Setting Instrument Gains
Error between the two transmissions is expressed as % opacity - any value greater than 1% is too high and the transceivers should be immediately re-aligned in accordance with the instructions given earlier. CODEL A Forbes Marshall Company Page: 25 Issue: B... -
Page 28: Zero And Span Calibration
DCEM 2100 – TUV 3.14.3 Zero and Span Calibration The final commissioning task is to initiate a zero and span calibration cycle, enter Mode 5 on the DDU and scroll down to ‘Calibrate’; the current calibration parameters (stored in the SPU) will appear on the display. The basic calibration on the instrument may be performed from here. -
Page 29: Requirements For En 14181
(see Supplement 3 – Zero Point Alignment tube procedure). CODEL A Forbes Marshall Company Page: 27 Issue: B Revision: 6... -
Page 30: Table Of Figures
DCEM 2100 – TUV 5. Table of Figures Figure 1: DCEM Transceiver Head ......................5 Figure 2: Site Mounting Flange ......................... 5 Figure 3: Air Purge ............................. 5 Figure 4: Ball Valve Assembly ........................6 Figure 5: Power Supply Unit ........................6 Figure 6: Signal Processor Unit ......................... -
Page 31: Supplement 1 - Installation Of A Second Ddu To The D-Cem2100
Unit (PSU) (DDU) Mains Power IN 48V Power Data transfer to remote DDU Outputs Transceiver Cables Solenoid Drive Cables Outputs Data transfer to remote DDU 2 CODEL A Forbes Marshall Company Page: 29 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178... -
Page 32: Supplementary Connection Schedule For Second Ddu
DCEM 2100 – TUV 7 Supplementary Connection Schedule for Second DDU CODEL www.codel.co.uk © 2010 CODEL International Ltd. Page: 30... -
Page 33: Supplement 2 - Zero Point Alignment Tube
Material The tube should be constructed from mild or stainless steel (preferably), 4” Schedule 40, Nominal bore, tube. (114.4 mm diameter, wall thickness 6mm) CODEL A Forbes Marshall Company Page: 31 Issue: B Revision: 6 Date: 31/01/22... - Page 34 DCEM 2100 – TUV Mounting Flange Made from the same material as the tube and is welded to the tube. CODEL www.codel.co.uk © 2010 CODEL International Ltd. Page: 32...
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Page 35: Supplement 3 - Zero Point Alignment Procedure
6mm rod with a Delrin stop placed in the centre of the tube. Optical Stop End Plate 160mm Derlin Optical Stop CODEL A Forbes Marshall Company Page: 33 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178... - Page 36 DCEM 2100 – TUV 9 Supplement 3 - Zero Point Alignment Procedure The procedure for performing a calibration using the zero point alignment tube is as follows: Note: It is crucial that the Zero Point alignment tube measures the same length as the front flange to front flange distance on the stack to perform an accurate zero calibration.
- Page 37 2 & 4 will move the cross-hairs horizontally. With the nuts at positions 2 & 4 locked, adjustment at positions 1 & 3 will move the cross-hairs vertically. CODEL A Forbes Marshall Company Page: 35 Issue: B Revision: 6 Date: 31/01/22 Reference: 100178...
- Page 38 DCEM 2100 – TUV By means of the adjusting nuts at positions 2 & 4, adjust the alignment of the transceiver (TRx1) until the cross-hairs (viewed through the telescope) coincide with the vertical centreline of the light from the red LED; lock the nuts at positions 2 &...
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