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

Section 1
Specification
Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
Page: 11
1Specification
Span*
selectable from 0-100ppm to 0-10,000ppm, within
the range 200 to 6,000ppm. metres at STP
Display Units
Ppm
mg/m3(measured) mg/Nm3(normalised)
Averaging
four averages selectable from 10 seconds to 30 days
Accuracy
± 2% of measurement or
± 5ppm whichever is greater
Outputs
Analogue
High alarm
Data valid
4-20mA isolated, 500Ω max
Volt-free contact, 10A @ 250V
Volt-free contact, 10A @ 250V
Inputs
Oxygen
Temperature
Pressure
Plant status Contact
4-20mA
4-20mA
4-20mA
Volt free contact
Serial Port
for remote instrument operation,
normalising inputs and outputs
Path Length
0.5 to 8m
Flue Gas Temperature
0 to 650°C
Construction
cast aluminium, fully sealed to IP65
Transmitter
electrically heated silicon nitride cylinder
Detector
lithium tantalite pyro-electric detector
Ambient Temperature Limits
-20oC to 70oC
Power Requirements
85-132/170-264V AC, 50/60 Hz, 50VA
Air Purge Consumption
1 litre/sec @ 1bar (compressed air)
5 litre/sec (blower air)

Page: 12
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions
2General Description
Rapid advances in the design of ‘across the duct’ infrared gas analysers have led
to the general acceptance of this technique for the monitoring of gas levels in
flue gases of power generation boilers and large industrial process steam boilers.
EnergyTech 401 flue gas analyser is designed specifically for large installations:
The EnergyTech 401 is designed to operate on duct widths of less than 8m at flue
gas temperatures up to 300oC. The rugged construction makes installation
extremely simple, and through the use of microprocessor technology they have
many advanced features:
local normalising inputs for compliance with legislation requirements
serial data facility to allow communication between analysers and a central data
logging station
user-definable output in either mg/m3, mg/Nm3or ppm
four rolling averages are held - selectable from 10 seconds to 30 days
integral, back lit 32-character LCD provides diagnostic and measurement
information
plant status input to prevent emissions dilution during plant off periods

Section 2
General Description
Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
Page: 13
System Description
2.1
The EnergyTech 401 monitor consists of four items (see Figure 1):
an infrared transmitter unit to project a beam of infrared radiation across the
duct
a receiver to measure that radiation
a power supply unit to provide the necessary power rails, and
a signal processor to compute the gas concentration from the signals provided
by the receiver unit.
Each of these units is designed to be rugged and durable. They are all fully
sealed to IP 65 standards and are suitable for outside mounting, without the
need for further weatherproof enclosures.
Figure 1 : Typical System Layout
Transmitter
Receiver

Page: 14
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions
At the heart of this unit is a small heater assembly designed by CODEL engineers
to give a high intensity uniform source of infrared energy over a long lifetime, in
excess of two years continuous operation, with a power consumption of only 26
watts. The heater has a stainless-steel cylindrical core, plasma coated with
refractory, and around which is a ‘Kanthal’ heating element. This is then enclosed
within refractory fibres and encapsulated in an aluminium cartridge. In the
infrequent event of failure, the complete heater assembly can be replaced on site
within ten minutes.
The radiation emitted by the heater is then ‘chopped’ by a motor-driven disc,
and focused across the duct by a lens. The chopper disc is driven by a small DC
motor. The phase and frequency of the chopper disc are monitored by a
radiation detector to provide a reference signal that is utilised by the signal
processor unit.
The system calibration is achieved by a small gas cell containing pure reference
gas that can be swung into the sight path by means of a ‘stepper’ motor and
gearbox assembly to enable continuous calibration updates to be maintained.
The chopper motor and stepper motor represent the only moving components
in the entire system.
A printed circuit board mounted at the front of the unit provides control circuitry
for the heater, the motors, and the reference wave detector.
illustrates the transmitter and receiver units.
2.1.1 Infrared Transmitter
Unit

Section 2
General Description
Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
Page: 15
The precision and reliability with which the transmitted can be measured governs
the performance of the complete instrument. For this reason, CODEL have
concentrated their design efforts into producing an extremely simple and robust
receiver unit. It contains no moving parts, is fully sealed and designed to give
many years of trouble-free and maintenance-free operation.
The unit comprises a lens to focus radiation received from across the duct,
followed by a precision interference filter to limit the wave band of energy used.
This filter tolerance is strictly controlled since it alone determines the instrument
scale shape and calibration. The radiation then passes to an optical beam-splitter
where approximately half the radiation is reflected at right angles directly onto a
radiation detector. The other half of the radiation is transmitted, by the beam-
splitter, through a gas cell containing pure reference gas (CO) and onto a second
radiation detector.
The detectors used are lithium tantalite pyro-electric detectors, renowned for
their sensitivity, stability and ability to operate at normal ambient temperatures,
without the need for cooling. They respond only to changing levels of radiation
and thus to the chopped radiation from the infrared source unit and not to
background radiation from the flue or flue gas. The detector signals are
amplified and fed to the signal processor unit.
The signal processor unit is housed in a fully sealed cast-aluminium enclosure. It
houses the microprocessor to monitor the data from the receiver and produces a
4-20mA output signal for gas levels within the flue.
Figure 2 : Transmitter & Receiver
Schematic
2.1.2 Infrared Receiver Unit
2.1.3 Signal Processor Unit

Page: 16
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions
A non-volatile RAM section - requiring no battery back-up - enables all of its
operation data to be retained during a power down condition. The instrument
can resume operation immediately power is restored, without having to be
recalibrated.
All operation data is entered via a surface-mounted keypad, and a 32-character
LCD provides the operator with measurement details and diagnostic information.
Inputs are available to receive the 4-20mA outputs of normalising measurement
transducers - O2, temperature and pressure, if required. This data can also be
entered via the keypad or via the serial data port.
A serial communication facility within the processor, allows the instrument to
communicate with other CODEL analysers and a central data logging unit.
The power supply unit is housed in a fully-sealed cast-aluminium enclosure and
contains the power supplies for the instrument. A switched mode power supply
is utilised to provide an extremely stable power source, able to cope with large
fluctuations in the supply voltage. The contact outputs are also taken from this
unit - data valid and high gas alarm.
The purge unit has its own integral adjustable mount and provides the interface
between the site mounting flange and the transmitter and receiver units. The
purge is designed to provide a steady laminar flow of air away from the
instrument lens, preventing optical contamination.
A supply of air to the purge is essential.
Isolating valves, if required, may be attached between the air purges and the
duct. These will allow protection for personnel servicing instruments on high
pressure ducts.
2.1.4 Power Supply Unit
2.1.5 Air Purges
2.1.6 Isolating Valves

Section 2
General Description
Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
Page: 17
Principles / Modes of
2.2
Operation
Gas levels are determined by measuring the absorption of infrared radiation,
transmitted through the flue gas, in a wave band sensitive to absorption by the
measurement gas. The EnergyTech 401 has two detectors; one measuring the
radiation directly to provide a live output, sensitive to the measurement gas,
while a second detector measuring the radiation after passing through a gas cell
filled with pure reference gas (CO), to provide a reference measurement,
completely unaffected by the measurement gas.
The basic expression from which the gas concentration in the gas is determined
is;
Y = G - K. D2/D1
Where D1 = the reference output from the detector
D2 = the live output from the detector
G = a scaling factor (16000 for CO)
K = a constant, known as the zero-correction
factor, set so that when there is zero
measurement gas in the duct, Y = 0
thus, K = G. D1 (0)
D2 (0)
This parameter Y is then smoothed, linearised and compensated for effects of
path length and flue gas temperature, to produce a measurement of gas
concentration in the flue gas.
2.2.1 Calculation of
Gas Concentration

Page: 18
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions
The accurate determination of gas concentration depends upon the
measurement of the radiation levels received by the detectors. Any error in that
measurement caused by detector drift will produce errors in the determination of
the gas level. In order to maintain accuracy, it is necessary to be able to
compensate for such drifts. A technique of continuous calibration adjustment is
used.
The operating cycle of the instrument is in two parts. First, measurements are
obtained from the two detector outputs D1 and D2. The calibration cell
containing pure CO is then positioned in the sight path and the two detector
outputs are measured again to give readings E1 and E2.
From the basic scale shape equation :
Y = G - K. D2/D1
and from the calibration equation
Yo = G - K. E2/E1 …………(at zero Yo = Set Cal Value)
or K = (G - Yo). E1/E2
thus substituting in the scale shape equation
Y = G - (G - Yo). E1/E2. D2/D1
The two ratios E1/D1 and E2/D2, being derived each from one detector, are
independent of any detector drift, thus making the instrument output
independent of any drift or change in detector gain characteristic.
This operating routine, giving measurements first of D1 and D2 and then, with the
calibration cell in position, of E1 and E2, is repeated continuously and provides an
effective continuous calibration update to enable accuracy to be maintained at all
times.
2.2.2 Error Compensation

Section 2
General Description
Issue: A Revision: 1 Date: 24/07/19 Ref: 100606
Page: 19
The calculations for one complete operating cycle of the instrument are given
below :
measure D1 & D2
measure E1 & E2
compute Y
smooth Y
linearise and correct for path length
normalise measurement
smooth to produce final gas outputs
Normalisation of data collected by the analyser is essential to compare emission
levels of pollutants into the atmosphere. Software in CODEL’s analysers performs
all calculations and provides results in various units, vpm, mg/m3and mg/Nm3;
derivation of these results is described in this section.
CODEL EnergyTech 401 gas analysers are cross-duct type and thus measure the
quantity (or number of molecules) of gas within their sight path. This
measurement is converted into a concentration which is fully compensated for
the expansion effects of temperature, whilst assuming constant atmospheric
pressure. This basic measurement is referred to as ‘ppm’ (parts per million).
However, to obtain a true concentration ‘vpm’ (ppm by volume) the ‘ppm’ value
must be normalised for pressure using the following expression.
vpm = ppm x standard pressure (abs)
measured pressure (abs)
where standard pressure is taken as 101 kPascals.
The next stage in the process is to determine the mass concentration. The
conversion at STP uses conversion factors determined as follows :
N = RMM
V
where N = conversion factor
RMM = relative molecular mass of the gas
2.2.3 Calculation Sequence
2.2.4 Normalisation Equations
Correction to standard
2.2.4.1
pressure
Conversion to mass
2.2.4.2
concentration

Page: 20
EnergyTech 401 CODEL
Operating and Maintenance Manual Monitoring Solutions
V = 22.4 (standard volume of an ideal gas)
The conversion factors for the analysers are given below :
CO Molecular mass (RMM) = 12 + 16 = 28
1 vpm = 28/22.4 = 1.25
mg/m3
SO2Molecular mass (RMM) = 32 + 16 + 16 = 64
1 vpm = 64/22.4 =
2.86 mg/m3
NO Molecular mass (RMM) = 14 + 16 + 16 = 46
(equivalent) 1 vpm = 46/22.4 =
2.05 mg/m3
Legislation demands that all oxides of nitrogen be expressed as NO2equivalent.
It is not necessary to measure both NO and NO2as the relationship is fixed in
particular processes, and typically is 95% NO; 5% NO2.
NOx1vpm = 2.05 x (100%/NO%)
mg/m3
The mass concentration present is calculated as below;
mg/m3(STP) = N. vpm
This value is the mass concentration of the gas at STP.
Finally the effects of water vapour and oxygen need to be considered.
Since the vpm measurement is already normalised for temperature and pressure,
the only further normalisation required is for the dilution effects of water vapour
and oxygen. These are straightforward calculations as shown below;
mg/Nm3= mg/m3(STP) x 20.9 - 0%2standard x 100
20.9 - (0%2measured) DRY 100 - H2O%
Conversion factors (N)
2.2.4.3
Correction for oxygen
2.2.4.4
& water vapour