CODEL EnergyTech 203 User manual

Technical Manual
Issue: A
Revision:
Date:29/08/18
Ref: 100416
1
EnergyTech 203
Technical 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

Technical Manual
Issue: A
Revision:1
Date:18/12/17
Ref: 100416
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Technical Manual
Issue: A
Revision:1
Date:18/12/17
Ref: 100416
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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

Technical Manual
Issue: A
Revision:1
Date:18/12/17
Ref: 100416
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Technical Manual
Issue: A
Revision:1
Date:18/12/17
Ref: 100416
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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

Technical Manual
Issue: A
Revision:1
Date:18/12/17
Ref: 100416
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Technical Manual
Issue: A
Revision:1
Date:18/12/17
Ref: 100416
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Contents
Contents
1. EnergyTech 203 CO and O2 Gas Analysing System.........................................................................9
1.1. Introducton..........................................................................................................................9
1.2. System Operation ............................................................................................................11
1.3. Measurement Cabinet.....................................................................................................12
2. Measurement Principle...........................................................................................................13
3. Summary Specification ..........................................................................................................15
4. Preparing for Installation .......................................................................................................16
4.1. Unpacking..............................................................................................................................16
4.2. Additional Materials.........................................................................................................17
5. Installation .................................................................................................................................18
5.1. General................................................................................................................................18
5.3. Measurement Cabinet.....................................................................................................19
5.3.1. Remote-Mounted Installation....................................................................................19
5.4. Terminal Connections.....................................................................................................20
5.5. Compressed Air Connections ......................................................................................20
6. Commissioning.........................................................................................................................21
6.1. Pre-Commissioning Checks..........................................................................................21
6.2. Normal Start-Up Sequence............................................................................................21
7. Normal Operation.....................................................................................................................22
7.1. Introduction.......................................................................................................................22
7.2. Normal Start-Up Procedure...........................................................................................22
7.3. Modes of Operation.........................................................................................................23
7.4. Key Operation...................................................................................................................24
7.5. Program Tree.....................................................................................................................25
7.6. Operating Mode................................................................................................................26
7.8. Parameter Mode ...............................................................................................................26
7.9. Chamber.............................................................................................................................28
7.9.1. Display Format............................................................................................................28
7.10. Diagnostic Mode...........................................................................................................29
7.10.1. Detector Outputs (CO sensor)...........................................................................30
7.9.2. Thermistor (CO sensor)..................................................................................................30

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7.9.6. Temperature................................................................................................................31
7.9.8. Fault Condition............................................................................................................32
7.10. Set-Up Mode..................................................................................................................33
7.10.1. Security Code Entry.............................................................................................35
7.10.2. Configure O/P 1 & 2............................................................................................35
7.10.3. Parameters ...........................................................................................................37
7.10.4. Span Factor..........................................................................................................39
7.10.5. Chamber................................................................................................................39
7.10.6. Pressure................................................................................................................40
7.10.7. Calibrate................................................................................................................40
7.10.8. Alarms and Emergency Conditions...................................................................42
7.11. Emergency Shutdown/Isolation Procedure ..........................................................42
8. List of figures........................................................................................................................43
9. Appendix A –Codel EnergyTech 203 DDU Standard ModBus map.......................44
10. Appendix B - Spare parts list........................................................................................47
11. Appendix C - Wiring Connections.............................................................................48

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Date:18/12/17
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1. EnergyTech 203 CO and O2 Gas Analysing System
1.1. Introducton
The EnergyTech 203 carbon monoxide (CO) and oxygen (O2) analyser is the ideal equipment for fine
tuning the air / combustible proportions in a way to improve process efficiency without compromising
safety.
Combustion efficiency is determined by low-level oxygen excess in the flue gas and is limited by the
production of hazardous combustible gas (mainly CO) at low oxygen concentrations. It is thus crucial
to control the O2 excess concentration as well the amount of combustible gas in the flue gas to optimise
combustion. Thanks to the CODEL infrared and zirconia technology, the analyser provides both oxygen
concentration and an accurate measurement of CO in the flue gas. The CODEL system samples the
gas from the critical area through a steel sintered filter mounted in the wall of the chamber.
The filter is back flushed with compressed air at regular intervals to ensure an uninterrupted flow of
sample gas and to minimise maintenance. The sampled gas requires no further pre-conditioning and is
carried via a sample line and pump to the measurement chamber which is equipped with a compact
gas analyser. The measurement chamber is temperature controlled to avoid a build-up of corrosive
condensation. The analyser can re-calibrate automatically to minimise drift and ensure on-going high
performance. The system also includes the facility to be checked manually against bottled audit gases.

Technical Manual
Issue: A
Revision:1
Date:18/12/17
Ref: 100416
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The mounting arrangements of the EnergyTech 203 are shown in figure 1 below.
Figure 1 : Mounting Arrangements
No
Description
Part No.
Qty
1
Water Drain Solenoid N/C
740.341
1
2
Vacuum Filter
740.342
1
3
Coalescing Filter (99% @ 0.01 Micron)
744.131
1
4
Pressure Transducer
744.048
1
5
Sample Gas Solenoid
740.194
1
6
Span Gas Solenoid
744.341
1
7
ET 200 series Diaphragm Pump
744.133
1
8
Source Head
991.138
1
9
Insulated Heated Sample Chamber
991.790
1
10
Detector Head
991.682
1
11
Oxygen Measurement Probe
Probe: 720.154 / Manifold: 903.352
1
12
Oxygen Probe PCB Enclosure
PCB: 720.153 / Enclosure: 700.044
1
13
24V Power Supply Unit
400.126
1
14
I/O Terminal Rail
1
15
EnergyTech Comms Control PCB
803.534
1
16
Backpurge Solenoid
740.341
1
7
6
5
4
3
2
1
11
12
13
14
8 9 10
6
5
4
3
2
1
15
16