CODEL Energy Tech 401 User manual

Operating and Maintenance Manual Monitoring Solutions
Issue: A Revision: 1 Date: 05/07/19 Ref: 100606
EnergyTech 401 CODEL
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 : [phone] f : [phone] e : [e-mail] web : www.codel.co.uk

Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions

Operating and Maintenance Manual Monitoring Solutions
Issue: A Revision: 1 Date: 05/07/19 Ref: 100606
EnergyTech 401 CODEL
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 : [e-mail]
web : www.codel.co.uk

Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions

Operating and Maintenance Manual Monitoring Solutions
Issue: A Revision: 1 Date: 05/07/19 Ref: 100606
EnergyTech 401 CODEL
Contents
1SPECIFICATION ................................................................................................................................................... 11
2GENERAL DESCRIPTION ....................................................................................................................................12
SYSTEM DESCRIPTION ................................................................................................................................................13
2.1
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........................................................................................................................................16
2.1.5 Air Purges ......................................................................................................................................................16
2.1.6 Isolating Valves.............................................................................................................................................16
PRINCIPLES /MODES OF OPERATION ...................................................................................................................17
2.2
2.2.1 Calculation of Gas Concentration.............................................................................................................17
2.2.2 Error Compensation.....................................................................................................................................18
2.2.3 Calculation Sequence ..................................................................................................................................19
2.2.4 Normalisation Equations.............................................................................................................................19
2.2.5 Principles of Cross-Duct Gas Analysers....................................................................................................22
3INSTALLATION INSTRUCTIONS....................................................................................................................... 27
SAFETY CONSIDERATIONS......................................................................................................................................... 27
3.1
ELECTRICAL SUPPLY DATA.................................................................................................................................... 27
3.2
3.2.1 AC Supplies....................................................................................................................................................27
3.2.2 Outputs ..........................................................................................................................................................27
3.2.3 Normalising Inputs.......................................................................................................................................28
3.2.4 Plant Status Input.........................................................................................................................................28
3.2.5 Cable Requirements.....................................................................................................................................29
UNPACKING THE EQUIPMENT............................................................................................................................... 29
3.3
SITING THE EQUIPMENT........................................................................................................................................ 30
3.4
3.4.1 Points to Consider........................................................................................................................................31
DUCT WORK........................................................................................................................................................ 32
3.5
ISOLATING VALVES............................................................................................................................................... 33
3.6
AIR PURGE ........................................................................................................................................................... 33
3.7
TRANSMITTER &RECEIVER UNITS......................................................................................................................... 34
3.8
AIR SUPPLY .......................................................................................................................................................... 35
3.9
SIGNAL PROCESSOR UNIT .................................................................................................................................... 37
3.10
POWER SUPPLY UNIT ........................................................................................................................................... 39
3.11
ELECTRICAL CONNECTIONS.................................................................................................................................. 40
3.12
3.12.1 Installation and Connection of Cables................................................................................................ 40
3.12.2 Connection Schedule ..............................................................................................................................41
4COMMISSIONING.............................................................................................................................................. 42
INTRODUCTION .................................................................................................................................................... 42
4.1
SAFETY CONSIDERATIONS.................................................................................................................................... 43
4.2
POWER SUPPLY VOLTAGE SELECTION.................................................................................................................. 43
4.3
TURNING THE POWER ON................................................................................................................................... 43
4.4
ALIGNMENT.......................................................................................................................................................... 44
4.5

Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions
DETECTOR LEVELS................................................................................................................................................ 47
4.6
4.6.1 Receiver Gain Adjustment...........................................................................................................................47
4.6.2 Signal Processor Gain Adjustment ........................................................................................................... 49
TRANSMITTER ADJUSTMENTS ................................................................................................................................51
4.7
OPERATING PARAMETERS .................................................................................................................................... 52
4.8
TABLE 1–INSTRUMENT SETTINGS ........................................................................................................................ 66
4.9
CURRENT OUTPUT CALIBRATION ......................................................................................................................... 68
4.10
5NORMAL OPERATION......................................................................................................................................69
INTRODUCTION......................................................................................................................................................... 69
5.1
5.1.1 Measurement............................................................................................................................................... 69
5.1.2 Calibration.................................................................................................................................................... 69
NORMAL START-UP PROCEDURE......................................................................................................................... 70
5.2
MODES OF OPERATION ....................................................................................................................................... 70
5.3
KEY OPERATION................................................................................................................................................... 72
5.4
5.4.1 Mode Key.......................................................................................................................................................72
5.4.2 Arrow Keys.....................................................................................................................................................72
5.4.3 Enter Key........................................................................................................................................................72
PROGRAM TREE.................................................................................................................................................... 73
5.5
OPERATING MODE............................................................................................................................................... 74
5.6
PARAMETER MODE .............................................................................................................................................. 74
5.7
5.7.1 Identification..................................................................................................................................................75
5.7.2 Parameters ....................................................................................................................................................75
5.7.3 Averages ........................................................................................................................................................75
5.7.4 Output............................................................................................................................................................75
5.7.5 Alarm..............................................................................................................................................................76
5.7.6 Plant Status ...................................................................................................................................................76
NORMALISATION.................................................................................................................................................. 77
5.8
5.8.1 Display Format..............................................................................................................................................77
DIAGNOSTIC MODE ............................................................................................................................................. 78
5.9
5.9.1 Detector Levels..............................................................................................................................................79
5.9.2 Chopper Motor Frequency..........................................................................................................................79
5.9.3 YVals & Gas ppm........................................................................................................................................ 80
5.9.4 Calibration Data.......................................................................................................................................... 80
5.9.5 Fault Condition .............................................................................................................................................81
SET-UP MODE..................................................................................................................................................... 82
5.10
5.10.1 Security Code Entry................................................................................................................................ 83
5.10.2 Set Averages............................................................................................................................................ 84
5.10.3 Configure O/P..........................................................................................................................................85
5.10.4 Base of Output.........................................................................................................................................85
5.10.5 Averaging Time of the Output..............................................................................................................85
5.10.6 Output Units.............................................................................................................................................85
5.10.7 Output Span.............................................................................................................................................85
5.10.8 Fault Indication ....................................................................................................................................... 86
5.10.9 Set mA Output........................................................................................................................................ 86
5.10.10 Parameters ...............................................................................................................................................87
5.10.11 Security Number......................................................................................................................................87
5.10.12 Identity Number.......................................................................................................................................87

Operating and Maintenance Manual Monitoring Solutions
Issue: A Revision: 1 Date: 05/07/19 Ref: 100606
EnergyTech 401 CODEL
5.10.13 Measurement Path Length ................................................................................................................... 88
5.10.14 Alarm ........................................................................................................................................................ 88
5.10.15 Cal Factor................................................................................................................................................. 89
5.10.16 Plant Status Input................................................................................................................................... 89
5.10.17 Normalisation...........................................................................................................................................92
5.10.18 Setting the Normalising Parameters................................................................................................... 93
5.10.19 Temperature............................................................................................................................................ 94
5.10.20 Oxygen ..................................................................................................................................................... 94
5.10.21 Pressure.....................................................................................................................................................95
5.10.22 Water Vapour ..........................................................................................................................................95
5.10.23 Reset Averages.........................................................................................................................................95
5.10.24 Calibrate................................................................................................................................................... 96
5.10.25 Set Detectors ........................................................................................................................................... 96
5.10.26 Span Adjust ............................................................................................................................................. 96
5.10.27 Calibrate................................................................................................................................................... 98
CHECK CELL MODE.............................................................................................................................................100
5.11
NORMAL SHUTDOWN PROCEDURE.....................................................................................................................100
5.12
ROUTINE CHECKS................................................................................................................................................ 101
5.13
5.13.1 Notes for Using a CODEL Check Cell ................................................................................................101
ALARMS /EMERGENCY CONDITIONS..................................................................................................................104
5.14
EMERGENCY SHUTDOWN PROCEDURE................................................................................................................104
5.15
ISOLATION PROCEDURE ......................................................................................................................................104
5.16
INTERFACE WITH INTEGRATED EMISSIONS MONITORING SYSTEM .......................................................................104
5.17
61. MAINTENANCE................................................................................................................................................106
ROUTINE MAINTENANCE (PREVENTATIVE) ...............................................................................................................106
6.1
6.1.1 Cleaning Windows .....................................................................................................................................106
6.1.2 Replacement of the Heater Element .......................................................................................................106
6.1.3 Replacement of Chopper Motor Assembly ............................................................................................107
6.1.4 Replacement of Gas Cells .........................................................................................................................107
RECOMMENDED SPARE PARTS............................................................................................................................109
6.2
FAULT-FINDING...................................................................................................................................................109
6.3
6.3.1 Checks via the Keypad...............................................................................................................................109
6.3.2 Data Valid LED Out ...................................................................................................................................110
CORRECTIVE MAINTENANCE ............................................................................................................................... 112
6.4
6.4.1 Use of Fault-Finding Tables...................................................................................................................... 112
6.4.2 Commissioning Problems.........................................................................................................................113
6.4.3 Operational Problems ...............................................................................................................................118
SYMPTOM ........................................................................................................................................................... 118
6.5
6.5.1 Individual Tests ...........................................................................................................................................119
6.5.2 LED Indications ...........................................................................................................................................119
6.5.3 Test Points ...................................................................................................................................................120
6.5.4 Span Factor Adjustment............................................................................................................................123
SPECIAL TOOLS AND HANDLING DEVICES...........................................................................................................124
6.6
EQUIPMENT AND SPARE PARTS STORAGE AND PRESERVATION ..........................................................................124
6.7
7PARTS LIST.........................................................................................................................................................125
8TABLE OF FIGURES ...........................................................................................................................................126

Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions

Operating and Maintenance Manual Monitoring Solutions
Issue: A Revision: 1 Date: 05/07/19 Ref: 100606
EnergyTech 401 CODEL
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

Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions