CODEL Energy Tech 301 Guide

Technical Manual
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Energy Tech 301
Installation, Commissioning,
Operating & Maintenance Manual
CODEL International Ltd.
Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : [phone] f : [phone] e : [email protected] web : www.codel.co.uk

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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.
The constant search for new products and existing product improvement keeps CODEL one step
ahead. With a simple strategy, to design well-engineered, rugged, reliable equipment, capable of
continuous operation over long periods with minimal maintenance, CODEL has set standards both for
itself and for the rest of the industry.
All development and design work is carried out ‘in-house’ by experienced engineers using proven
state-of-the-art CAD and software development techniques, while stringent assembly and test
procedures ensure that the highest standards of product quality, synonymous with the CODEL name,
are maintained.
High priority is placed upon customer support. CODEL’s dedicated team of field and service
engineers will assist with any application problem to ensure that the best possible use is derived from
investment in CODEL quality products.
If you require any further information about CODEL or its products, please contact us using one of the
numbers below or alternatively visit our web site.
t : [phone]
f : [phone]
e : [email protected]
web : www.codel.co.uk
CODEL offices, Bakewell, Derbyshire

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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.
Caution, hot surface.
Earth (ground) terminal.
Protective conductor terminal
Any important information in this manual is preceded by this sign.
Warning ! We wish to point out that the maximum rating of the Alarm Output Relay is now 60W
@ 250V max. Please bear this in mind when ordering the output cable, if not
supplied with EnergyTech 301 by CODEL.

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Table of Contents
1. General Description 8
2. Specification 9
3. Principles of Operation 11
4. Description 12
5. Installation 13
6. Commissioning 20
7. Maintenance 22

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1.General Description
Continuous Indicative Particulate Monitoring
With the recent increase in world-wide environmental legislation, there has evolved a general
requirement for operators to monitor the performance of their dust collectors and ensure that
emissions to atmosphere are kept below the maximum legal enforcement level.
In the case of small collectors or non-critical processes, it has been accepted by legislators in the UK,
that low cost continuous indicative particulate monitors may be used. These devices give an output
that shows the operator a relative increase or decrease in dust loading and have the facility to initiate
alarms if an unacceptable level is exceeded. Such instruments are described as ‘indicative’ and are
not intended to give quantitative results. They are normally set up using subjective criteria and
without reference to a standard gravimetric stack test.
The better indicative monitors, such as Energy Tech 301, have an analogue and RS485 output that
can be used to constantly record the output from the instrument and enable the operator to review the
results and identify impending filter failure at an early stage. The results may also be used to show
evidence of good practice to environmental authorities.
Whilst it is not recommended to calibrate this class of instrument in mg/m3, the operator may wish to
set an alarm point with reference to a specific mass concentration of particulate required by law. This
manual will show a method that satisfies this requirement using a single iso-kinetic stack test.
If emissions are required to be quantified in mg/m3 on a continuous basis, then please contact Codel
for advice.

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2. Specification
Electronics enclosure
Aluminium casting
Access via lid
2 LED's :
oalarm LED
orelative dust level LED
Epoxy paint finish :
ocolour RAL5010 Traffic Blue
Damping :
omenu driven
Sensitivity :
omenu driven
Alarm level :
omenu driven
Power Requirement:
o85 - 265V A.C.
o25 VA, 0.25 A max
Outputs :
o1 x 4-20mA output
o1 x Contact output -
oRS485 Modbus
Display :
o16 x 2 LED Display
oflashing green LED where the pulse duration increases with dust level
ored alarm LED
Enclosure weatherproofing :
oto IP67 standard
Mains Connection :
oIP67 4-way plug and socket
Output Connections :
oIP67 7-way plug and socket
Intrusive Probe
Stainless steel bar Ø12mm2
Available lengths 250, 500, 750, 1000mm (customer requirement)
Probe protection :
oinsulating sleeve on first 200mm of probe

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Temperature Constraints
Stack gas
o-20oC to +200oC
Operating Range (typical)
0 - 2500mg/m3 mass concentration
Particle size range 0.1 to 100µm
Cabling (if supplied by Codel)
Mains cable : 3-core, PVC insulated, 24/0.2mm
Output cable : 8-core, PVC insulated, screened, 16/0.2mm, Ø9.5mm maximum. Core
colours - green, brown, yellow, violet, white, black, red and blue (not used).
Note; if the cable length is greater than 1km it is recommended to use cable spec 0.75mm2~24/0.2. If
unsure please contact Codel.

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3. Principles of Operation
When a particle moving in a duct collides with (or passes near) a probe that is grounded to earth, a
transfer of charge takes place from the particle to the conductor. This is known as tribo-electricity or
frictional electrification and results in a charge being imparted to the probe.
It can be shown that the following empirical relationship exists:
Where I = frictional current in Amps
Ka= a material constant
M= mass flow rate of particles
V= particle velocity
b= a constant derived from whether the particle
collision was elastic or plastic (a value typically between 1.4 and 1.9)
d= particle diameter.
It can be seen that the resultant current is dependent on a number of factors such as the nature of the
material (Ka), mass flow (M) and velocity (V) and any significant changes in these would result in a
change in current output.
In practice, the material will often be of a ‘monotype’ with a particle size distribution that will vary little
given the characteristics of the dust collection method. Bag filters, cyclones and electrostatic
precipitators constantly produce a small leakage of particles that are all approximately the same size,
and if the velocity of the particles remains fairly constant (say this has a very small effect on
the frictional charge
So it can be seen that although tribo-electric probes are affected by changes in velocity and particle
size distribution, in practice, the amount of drift this induces may be very small and inconsequential
for indicative systems. If your application is subject to massive swings in velocity, consult Codel for
advice.
The main advantages of tribo-electric instruments are as follows:
They are extremely sensitive to fine dusts and are sensitive over a range of <1mg/m3up to
2500mg/m3.
They are able to detect particulates in a size range of 0.1 to m.
They are easy to install and do not require critical alignment.
They have no optical surfaces to keep clean.
Energy Tech 301 is easy to remove and clean and has very low maintenance
requirements.
There are no moving parts and consequently servicing requirements are very low.
dVMK
Ib
a..


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4. Description
The Energy Tech 301 continuous indicative particulate monitor consists of a stainless steel intrusive
probe attached to a robust aluminium enclosure that contains the electronics to amplify and
process the incoming signal. The key feature of the unit is its compactness, as all the electronics and
display are contained within the head. Furthermore, the Energy Tech 301 is designed to be easy to
install and commission.
The static charge caused by the particulate is conducted down the probe to the electronics module
where it is amplified and then conditioned. The Energy Tech 301 incorporates damping circuitry,
manually adjustable by the operator, to ‘smooth’ the output of the instrument to suit application
conditions, for example, to prevent spurious alarms caused by cleaning events within the collector.
The analogue output signal is also provided with adjustable smoothing to accommodate different
application conditions.
The instrument has two visual displays. A flashing green LED pulses proportional to the dust level
(i.e. it pulses more as the dust level increases and less as the dust level decreases). A constant red
LED is activated when the high level dust alarm threshold is exceeded.
A 4-20mA output is available for analogue data-logging and a user selectable volt-free or 24V SPCO
relay for activating an external visible or audible alarm at high dust levels.
One of the main concerns about tribo-electric systems has been an effect called ‘bridging’, where
conductive material builds up on the probe eventually making contact with the duct wall, effectively
‘shorting-out’ the probe and producing an alarm. This has been overcome by other manufacturers by
incorporating a high pressure air purge, that continually blasts air down the length of the probe.
Whilst this may prevent bridging, it also prevents particulate from impinging on the probe with a
consequential loss of signal. The Energy Tech 301 incorporates an insulated sheath attached to the
probe, allowing the bridge to form without shorting-out the probe.
Probe
Insulation Sheath
Mounting Boss
Sensor Head
Figure 1: Energy Tech 301 –Full system

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5. Installation
Selecting a Suitable Sensor Location
There are a number of factors to consider when selecting the position to mount the Energy Tech 301
unit. These are, in order of importance:
Are there any legal constraints that might restrict its location?
For indicative monitors this is unlikely, but it’s worthwhile checking. There are no such
constraints in the UK and USA.
The probe must protrude more than halfway into the duct to ensure good sensitivity.
Choose a location where there is unrestricted flow path and where the probe is within the
main flow of particulate. Ideally, the unit should be placed 5 duct diameters upstream (or
downstream) from any obstruction such as a bend, fan, damper, duct exit or pipe junction,
as illustrated in Figure 2.
In practice of course, it is not always easy to select a location 5 duct diameters from an
obstruction, so some compromise may be necessary. If this is the case, Figure 3 shows
alternative mounting strategies.
Energy Tech 301 should be located where maintenance staff can occasionally gain easy
access.
The unit should not be located where it is vulnerable to knocks. Nor should it be mounted
close to steam traps or other sources of extreme heat.
Energy Tech 301 should not be placed on the bottom of a horizontal duct as dust and
debris will soon accumulate around the base of the probe, leading to bridging.
Energy Tech 301 should be placed well away from any iso-kinetic sampling ports if
possible.
If the dust level display is required to be viewed regularly to confirm acceptable levels, if
possible, install the Energy Tech 301 where the display can be easily seen by plant
operators
Avoid mounting Energy Tech 301 on a vertical duct that vents to atmosphere as it may be affected by
rain ingress.
Figure 2: Energy Tech 301 - Preferred Locations

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Installing the Mounting Stub
WARNING !!!!!!
We strongly advise that the dust collector be turned off, especially when drilling holes or
welding the stub. The duct may be under pressure and debris and air under pressure will be
ejected through any hole and could damage eyes or may be swallowed. If you must work on
the collector when it is on line, suitable eye protection and a breathing mask must be worn.
Steel Stacks
Manufacture the mounting stub shown in Figure 4. Normally this would be in mild steel, but check the
construction material of the stack or duct. If this is stainless steel for example, consider using the
same material, but in any case use an appropriate welding rod, as failure to do so could present
welding problems and cause eventual weld weakness or failure.
Figure 3: Energy Tech 301 -Alternative Mounting
Strategies
Figure 4: Detail of Stack Mounting Stub

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Cut a hole Ø28mm (11/8ins) at the selected location and offer up the stub. DO NOT attempt to weld
the stub to the stack with the probe attached to the stub, as the heat generated (and the
electric arc) will severely damage the probe and electronics. Ensure the stub remains at 900to
the stack, but DO NOT weld when the collector is on line, as the weld pool may super-cool and
cracking may result. Paint the stub with a suitable corrosion resistant paint, prior to mounting the
Energy Tech 301.
If the stack wall is thin gauge and will not weld easily or will not bear the weight of the probe, follow
the method below.
Thin-Walled Stacks
Manufacture a stub as described above. Prepare the mounting plate shown in Figure 5. Cut a hole
Ø28mm (11/8ins) at the centre and drill for large pop rivets or self tapping screws. Bend the plate to
the curvature of the stack and weld the stub to the plate as outlined above. DO NOT attempt to weld
the stub to the plate with the probe attached to the stub as the heat generated (and the electric
arc) will severely damage the probe and electronics.
Drill a hole Ø28mm (11/8ins) in the stack. Offer up the plate and drill the securing holes. It is
important to make the plate as large as possible to improve its load bearing capabilities.
Before securing the plate to the stack, coat its underside with a silicon sealer to ensure that the plate
does not allow any leakage. Paint the stub and mounting plate with a suitable corrosion resistant
paint.
If the probe is to be installed on a non-metallic duct, it will be necessary to install an
electrostatic (Faraday) shield around the area of the duct where the probe resides. The shield
should be of copper and connected to the enclosure by means of the earth plug at the front of
the enclosure and then on to ground. The shield will ensure that the probe does not detect
any stray electrical fields.
Figure 5: Mounting Plate for Thin-Walled Stacks

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Mounting the Sensor
The Energy Tech 301 itself is supplied in two parts, the head and the probe. Cable and cable plugs
are supplied as loose items. First attach the probe to the head by placing the threaded end (it’s an
ordinary RH thread) through the brass fitting and screw in place. Insert a rod or screwdriver through
the hole in the sensor probe and ‘nip it up’.
Remove the front part of the brass fitting from the probe (leaving the lock nut and compression gland
on the probe), and screw onto the mounting stub. Coat the thread in copper grease to ensure easy
removal. DO NOT use insulating tape as this will prevent the instrument grounding to earth via
the boss.
Offer up the probe to the mounting stub and tighten the locknut. DO NOT over-tighten as the unit
will need to be removed occasionally for maintenance purposes. Ensure that the unit is
positioned with the two LED’s horizontal, and with the electrical connection sockets at the bottom.
Figure 6: System Schematic
Wiring the Mains Connector
WARNING !!!!!!
This task should be only be undertaken by qualified personnel, familiar with site safety
regulations. While connecting the cores of the mains cable to the connector, ensure that the
cable is disconnected from the power source.
Separate the two halves of the mains connector (it has 4 sockets), by holding the body and
unscrewing the end containing the pins. Feed the cable through the body via the compression nut.
Carefully remove the cable clamp (it is a tension fit). Strip 6mm (¼ ins) of insulation from the end of
each core and insert in the appropriate socket. The sockets are all numbered (you may need a
magnifying glass) and the earth socket is raised slightly above the rest. Screw the body on to the
front section and then tighten the compression gland at the back of the assembly to ensure it is
weatherproof. See Figure 7.
Mains In
Optional Extra
Junction Box
Customer
monitoring
system

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Output connector
Separate the two halves of the output connector (it has 7 plugs), by holding the body and unscrewing
the end containing the pins. Feed the cable through the body via the compression nut. Carefully
remove the cable clamp (it is a tension fit). Strip 6mm (¼’’) of insulation from the end of each core
and insert in the female end of the pin. The pins are all numbered at their base, you may need the
magnifying glass again. Solder each wire into its pin in turn. Screw the body on to the front section
and then tighten the compression gland at the back of the assembly to ensure it is weatherproof. See
Figure 8.
Figure 8: Volt Free Output
Figure 7: Mains Connector
4-20Ma Out
Analogue 0V
N/O Alarm Contact
RB
RA
N/C Alarm Contact
Alarm Common
RS485

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Figure 9: 24V Output
Optional –RS485 looped with output connection, for maintenance only.
Figure 10: RS485 Connector
4-20Ma Out
Analogue 0V
N/C
RB
RA
0V
+24V
RS485
RA
RB
Alarm Outputs

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Wiring to Power PCB connectors
A wiring diagram is shown at Figure 11 for reference purposes only. These connections are normally
made at the factory.
Figure 11: Wiring Diagram

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6. Commissioning
WARNING !!!!!!
In order to commission the Energy Tech 301, it is necessary to work closely with mains
voltages. Only trained and competent persons should commission this unit using insulated
tools and wearing the appropriate safety equipment. The technician should acquaint himself
with site safety instructions and proceed with due caution.
Ensure that the dust collector is in good working order with no leaking filter bags and the
process is not subject to upset conditions. It is essential to the future accurate operation of
the EnergyTech 301 that the dust collection system is operating at its normal efficiency.
Failure to do so may result in poor results when the system is returned to normal.
Energy Tech 301 Commissioning
1. Power-Up:
a. Turn on the power
b. Wait for power-up sequence to complete and Data validity:
Wait for data valid LED (green) to come on.
In normal working conditions, the data valid LED will come on when the
power-up time has elapsed (by default, set to 0x01 minute–byte at 0x7E48)
and the system has performed the configured calibration (by default, set to
Zero Calibration (0x10) –byte at 0x7E49).
2. Zero Check
a. In Setup Mode scroll to 4.9 passcode, input password 1234 and press enter.
b. Still in set up mode select 4.3 parameters, scroll to find running mode and set the
running mode to maintenance. Press enter to exit.
c. In setup mode, select 4.2 span cal and set the span target to 00.00%.
d. Still in 4.2 span cal, select the span path ‘Elec span sim’ then press enter to exit.
e. In mode 4.3 parameters, scroll to running mode and select ‘Normal’ press enter to
exit.
3. Insitu Span calibration (Hardware Gain setting):
a. In setup mode 4.2 Span cal set the span cal target to current emission level if known
(10% by default)
b. Still in 4.2 Span Cal select ‘Insitu span cal’ and then press enter to initiate an insitu
span cal.
i. Waiting for ISC will be displayed and Data valid LED should go off for around
5 minutes and come back on upon successful completion of the span cal. A
span cal failure is usually due to wrong span target, if this situation occurs,
the analyser will keep pre-span cal data.
ii. In the event of a span cal failure, the Span error cal should be cleared then
make adjustment manually enter setup mode 4.4 signal:
Clear span cal error by sending clear performance error command
0x00002 to 0x000E/0F
Set stage 1 gain to minimum by sending 0x0000 to 0x00FF
Set stage 2 gain to minimum by sending 0x0001 to 0X0004
Adjust stage 1 gain to mid-range by sending 0x007F to 0x7E76/77
If emission levels are below 5%, apply x10 gain to stage 3 gain by
sending 0x0002 to 0x7E7A/7B then reduce stage 1 gain until the
emission levels are around 10%.