CODEL SmartCem V-CEM5100 User manual

OPS.109
Issue : B
Rev. : 1
Date : 23/10/13
Doc. i/d : 0109/6
Ref. : 090028
TECHNICAL MANUAL
SmartCem Emissions Monitoring System
Model V-CEM5100
Flow Monitor
CODEL International Ltd.
Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : [phone] f : [phone] e : [email protected].uk web : www.codel.co.uk

CODEL
OPS.109
Issue : B
Rev. : 1
Date : 23/10/13
Doc. i/d : 0109/6
Ref. : 090028

CODEL
OPS.109
Issue : B
Rev. : 1
Date : 23/10/13
Doc. i/d : 0109/6
Ref. : 090028
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

CODEL
OPS.109
Issue : B
Rev. : 1
Date : 23/10/13
Doc. i/d : 0109/6
Ref. : 090028

Technical Manual CODEL
OPS.109
Issue : B
Rev. : 1
Date : 23/10/13
Doc. i/d : 0109/6
Ref. : 090028
Contents
1. Overview of the CODEL Model V-CEM5100 Flow Monitor 1
1.1. Introduction 1
1.2. Transducer Units 2
1.3. Power Supply Unit (PSU) 2
1.4. Signal Processor Unit (SPU 2
1.5. Data Display Unit (DDU) 2
2. Measurement Principle 3
3. Specification 6
4. Installation 7
4.1. Equipment List 7
4.2. Siting the Equipment 7
4.3. Installation 7
4.3.1. Fitting of Stub-Pipes and Mounting Flanges 8
4.3.2. Air Purges 9
4.3.3. Transducer Heads 10
4.3.4. PSU & SPU 10
4.3.5. DDU 11
5. Electrical Connections 12
5.1. Installation and Connection of Cables 12
5.2. Connection Schedule 12
6. Commissioning 16
6.1. Pre-Commissioning Checks 16
6.2. Introduction 16
6.3. Power Supply Voltage 16
6.4. Turning the Power ON 16
6.5. Alignment 16
6.6. Detector Levels 17
6.6.1. Detector Levels 18
7. DDU Operation 19
7.1. Introduction 19
7.2. Operating Modes 19
7.3. Key Operation 20
7.3.1. Mode Key 20
7.3.2. Arrow Keys 20
7.3.3. Enter Key 20
7.4. Program Tree 20
7.5. Operating Modes 21
7.5.1. Measurement Mode 21
7.5.2. Calibration 22

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7.6. Parameter Mode 22
7.6.1. Identification 22
7.6.2. Parameters 22
7.6.3. Averages 23
7.6.4. Output 23
7.6.5. Alarm 23
7.6.6. Plant Status 23
7.6.7. Clock 23
7.6.8. Cal Config 24
7.7. Normalisation 24
7.8. Diagnostic Mode 24
7.8.1. Detector Levels 24
7.8.2. System Gain 24
7.8.3. Displacement 25
7.8.4. Flow Data 25
7.8.5. Calibration Data 25
7.8.6. Fault Condition 26
7.9. Set-up Mode 26
7.9.1. Security Code Entry 27
7.9.2. Set Averages 27
7.9.3. Configure O/P1 28
7.9.4. Configure O/P2 30
7.9.5. Alarm Hi 31
7.9.6. Alarm Lo 32
7.9.7. Parameters 33
7.9.8. Calibrate 35
8. Routine Maintenance 38
8.1. Cleaning Windows 38
9. Basic Fault Finding 39
10. List of Figures 40

Technical Manual CODEL
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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 CODEL
OPS.109
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Ref. : 090028

Technical Manual Page 1 CODEL
OPS.109
Issue : B
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Date : 23/10/13
Doc. i/d : 0109/6
Ref. : 090028
1.
Overview of the CODEL Model V-CEM5100 Flow Monitor
This instrument is fitted with lenses of Germanium, a naturally occurring semi-metallic element that may
be harmful if the lens is broken and the dust inhaled.
1.1.
Introduction
Correcting measurements to standard temperature, oxygen levels, etc., allows the density of emissions to be
normalised (e.g. mg/Nm3), but in order to obtain a measurement of total emissions for pollution monitoring (e.g.
kg/hr), it is necessary to measure flow.
Many methods require direct contact with the hot dirty gases resulting in high maintenance costs and potential
unreliability. The CODEL Model V-CEM5100 Gas Velocity Monitor utilises an infrared cross-correlation
technique that requires no contact with the flue gases.
The method used resembles flow measurement with chemical dye or radioactive tracers, where the velocity is
derived from the transport time of the tracer between two measuring points a known distance apart. However,
instead of an artificial tracer being added, the naturally occurring fluctuations of the infrared energy in the gas
stream are used as the tracer.
Fully purged transducers with no moving components make the system highly reliable and minimise
maintenance requirements. This stand-alone instrument is ideally suited to monitoring the flow rate of hot, dirty
gases.
The instrument is illustrated in Figure 1.
Figure 1 : General Arrangement of the V-CEM5100
Rx1
(Ch A)
Rx2
(Ch B)

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1.2.
Transducer Units
Each transducer unit consists of a broad band infrared detector, a lens to focus the radiation received on the
detector and a pre-amplification circuit board, all housed within a fully sealed, epoxy-coated aluminium
enclosure. The transducers are supplied with air purge units to maintain the cleanliness of the transducer
windows.
1.3.
Power Supply Unit (PSU)
The PSU accepts mains input voltages and provides the 48V DC supply for the transducers.
1.4.
Signal Processor Unit (SPU
The V-CEM5100 signal processor receives its 48V DC power from the Power Supply Unit (PSU). Signals from
the two transducers are processed and correlated to derive the transmission time of the gas flow from the first
transducer to the second and thus compute the gas velocity. Diagnostic communication is provided via the Data
Display Unit (DDU).
Gain adjustments for the transducer detector signals are provided by trim potentiometers in this processor.
Details for adjustment can be found in Section 6.6. Detector Levels.
1.5.
Data Display Unit (DDU)
A remote DDU is connected to the SPU via a 4-core data bus up to 1km in length. The DDU enables all output
and diagnostic data to be accessed on a 2-line, 32-character, alpha-numeric display and keypad. It also
provides 2 x 4-20mA outputs and 2 x volt-free contact relays for alarms. These outputs are fully configurable
from the keypad and display.

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2.
Measurement Principle
Gas flow is rarely laminar. Turbulence in the flow produces a series of swirling eddies and vortices that are
transported with the bulk flow. Infrared radiation, emitted by a hot gas system, is characterised by a flickering
signal resulting from the swirling effect of these vortices. Two infrared detectors, placed a small distance apart,
will produce very similar flickering signals, but with a displacement in time equivalent to the time taken for the
bulk gas flow to carry the vortices from the first detector to the second.
The V-CEM5100 uses a cross-correlation technique to measure this time displacement and hence the flow. The
two signals from the infrared transducer units are defined as A(t) and B(t) as shown below.
The time-of-flight (and hence the flow velocity) of the naturally occurring turbulent eddies within the flow stream
can be determined by cross-correlating the two signals as shown in the following equation:
RBA    LIM.T  1
T
B t 
0
T
A t 
  dt
where is a variable time delay imposed on the signal A(t). Using this function a correlogram can be computed
which has a maximum when the time-of-flight and ‘t’ are equal. This can best be explained by considering the
two signals A(t) and B(t) as shown below.
Rx1
(Ch A)
Rx2
(Ch B)

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Using the correlation function RBA() to operate on these two signals the following correlogram is obtained.
NOTE: with = 0 (i.e. no delay on signal A(t)) then RBA() = 0, and when A(t) has been delayed by six time-
intervals RBA() is a maximum. The six time-intervals is the delay between the two signals.
Both signals are sampled and digitised at fixed time delay intervals. The correlation function of RBA() is then
computed for a fixed number of time delay intervals to derive the correlogram. For example, if the set of data
above where each signal a(t) and b(t) each comprise a square pulse resulting in a triangular shaped
correlogram, just twelve time delay intervals are shown. The instrument always computes the correlation
function for 256 time delays intervals. The time delay interval used can be selected and is defined as the DATA
RATE. This is, in effect, the resolution of the time delay measurement. It is normally set to 1msec.
Now consider two actual signals from the transducers as shown below :
Using the correlation function RBA() to operate on the above two signals a typical correlogram as shown below
is obtained.

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In the V-CEM5100 the correlogram is inverted as follows:
Consequently in order to determine the max. value the correlogram is scanned to find the minimum.
The first element of the correlogram corresponds to a zero time delay and the 256th element corresponds to
255 time delay increments. Hence, if a DATA RATE of 1ms is selected the 256th element corresponds to a time
delay of 255ms.
Displacement is the point on the ‘x’ axis of the correlogram that coincides with the minimum. The correlation
coefficient is defined as :
Correlation Coefficient = max. value –min. value x 100%
max. value
and is a measure of the confidence at the measurement. Coefficient values of less than 10% would indicate a
non-acceptable measurement.

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3.
Specification
Measurement Range : selectable to 50m/s
Response : selectable 10 seconds to 30 days
Accuracy : ±2% of measurement
Serial Port : data bus I/P & O/P.
Construction : fully sealed (IP65) epoxy-coated aluminium enclosures
Ambient Temperature Limits : -20oC to +70oC - transducers
-20oC to +50oC - PSU, SPU & DDU
Power Requirements PSU : 90-264V AC max., 50/60Hz
V-CEM : 48V DC (from PSU)
Air Purge Consumption : 1 l/s @ 1 bar (compressed air), dry (to -20C) & clean (better
than 10m)
Analogue Outputs (DDU) : 2 x 0/4-20mA current outputs, isolated, 500load max., fully
configurable from keypad
Logic Outputs (DDU) : 2 x volt-free SPCO contacts, 50V, 1A max. configurable as alarm
contacts
: 1 x volt-free SPCO contact, 50V, 1A max. for data valid
General : DDU display - 32-character alpha-numeric back-lit LCD
DDU keypad - 4-key soft-touch entry
Construction : PSU/SPU/DDU - epoxy-coated aluminium

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4.
Installation
4.1.
Equipment List
The CODEL Model V-CEM5100 comprises the following:
- 2 x transducers with 10m of cable (standard length)
- 2 x site mounting flanges
- 2 x insertion tubes
- 2 x air purges
- 1 x Power Supply Unit (PSU)
- 1 x Signal Processor Unit (SPU)
- 1 x Data Display Unit (DDU)
4.2.
Siting the Equipment
The equipment is designed for mounting on boiler ducting or stacks in positions open to the weather. It is fully
sealed to IP65 and requires no weather covers.
Consider the following:
-the transducers must be located such that there are no ‘upstream’ bends, changes in duct diameter
or obstructions within the duct, for a distance of 3-5 duct diameters. In addition, we recommend that
the transducers should be a minimum of 4 duct diameters ‘downstream’ of the fan. If unsure, please
contact CODEL for technical advice.
-the site must be accessible for servicing both transducers and
-transducers should be mounted in the same plane as the flow and we recommend a 1m separation
for most applications. If unsure, please contact CODEL for technical advice.
-the SPU should be mounted local to the transducers and is supplied with 10m of cable as standard.
The transducers need to be mounted so that a maximum pathlength is achieved whilst maintaining an
acceptable confidence level. Ideally, a separation of 1m should be used. However, this will depend on plant-
specific flow patterns. Maximum accuracy of measurement corresponds to maximum time of flight but, if high
turbulence exists the ‘fingerprint’ of the flow may be short, thus the pathlength (transducer separation) should be
reduced; whatever the arrangement ensure that an acceptable level of correlation coefficient is recorded.
4.3.
Installation
The analysers and any other items are normally protected for transportation by an expanded foam packing
material. When unpacking, please ensure that smaller items are not discarded with the packing material.
The analysers are supplied with standard 10m cables already connected.
If any items are missing please inform CODEL or your local CODEL supplier immediately.
The installation site should be free of all encumbrances and safety procedures should be observed at all times.
The recommended order, reflected in this manual, is:
Installation of the stub-pipe and mounting flange
Installation of insertion tubes, air purges and purge air supply
Fitting of transducer heads, PSU, SPU and DDU
Installation and connection of cables

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4.3.1.
Fitting of Stub-Pipes and Mounting Flanges
Before proceeding further note that under no circumstances should holes be cut in the stack
with the plant operational if flue gases are under positive pressure with respect to atmosphere.
Even if pressure is believed to be negative great care should be exercised and all appropriate
protective clothing, including eye protection and protective gas mask, should be worn.
The transducer heads should be mounted vertically above each other and no more than 1m apart.
Construct the mounting assemblies by welding each site mounting flange to a suitable stub-pipe, nominal bore
75mm. The pipe should be long enough to keep the equipment clear of any duct lagging and it also helps to
insulate the equipment from high duct temperatures. Suggested stub-pipe mounting arrangements are shown
below for a metal stack and for a concrete stack. In the case of a metal stack it may be necessary to fit stiffening
ribs for added rigidity.
Figure 2 : Stub Pipe Arrangement

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4.3.2.
Air Purges
Before mounting the air purges ensure that air is supplied to the air purge unit. If this precaution
is not observed then the air purge and the optical surfaces may be severely contaminated.
The purpose of the air purges is to keep the windows of the transducers clean. Air may be supplied by one of
three methods:
Negative Pressure Duct. If the duct across which the instrument is measuring operates at a
negative pressure under all firing conditions, the isolating valve, pressure gauge and flow
restrictor may be removed and the negative draft in the duct allowed to draw-in ambient air
through the open purge inlet.
For positive pressure ducts, they must be supplied with either compressed air, or air from a blower.
Compressed Air. Using a fine flow regulator and filter, compressed air may be used to provide
the low flow required.
Blower Air. A blower may be used to provide air to the air purge. Customers may specify their
own blower; it should be able to deliver 5 litre/second (about 10cfm), against the working
pressure of the duct. CODEL can specify a blower if required.
The flange of the insertion tube is carried between the site mounting flange and the front flange of the air purge.
A rigid gasket is fitted between the site mounting flange and the insertion tube flange. Separate the front flange
from the air-purge by unscrewing the four retaining nuts. With the insertion tube and rigid gasket in place bolt
the front flange to the site-mounting flange using the four countersunk screws provided such that they pass
through the clearance holes in the insertion tube flange.
The rear flange is then offered-up to the front flange onto the protruding studs taking care that the ‘O’-ring seal
on the flange locates smoothly into the central aperture. This is then re-secured by the four nuts that screw
down onto the adjustable flange. The arrangement should now appear as in Figure 3.
Figure 3 : Adjustable Mount Details
Insertion Tube
Site Mounting Flange
Stub Pipe (by others)
Rigid Gasket
Front Flange
Adjusting Nuts
Adjustable Flange
Retaining Nuts
Air Purge
Insulating Bush

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4.3.3.
Transducer Heads
The transducer heads may be attached to the air purges by means of four hexagon head screws, with the
flexible gasket (supplied) fitted between them. The transducers will only fit in one position.
Make sure that the nylon insulating bushes are fitted to the air purge flange –if not fitted, DO
NOT attach the transducers and contact CODEL immediately.
4.3.4.
PSU & SPU
To mount the PSU & SPU first remove the cover by loosening the four captive screws. The case is then secured
to a firm support by use of the four mounting holes, one in each corner of the case. Since the mounting holes
are located outside the seal of the case it is not necessary to seal the mounting holes after installation, nor is it
necessary to remove the circuitry from the case for installation.
If commissioning is not to be carried out immediately reattach the lid to the SPU.
Dimensions and mounting details are shown in Figure 4.
NB. When fitting the mains cable in the PSU secure an M20 banjo earth ring under the gland locknut in
order to provide a good earth bond.
Figure 4 : PSU & SPU Mounting Details
cable gland entry
blanking plug
(PSU mains)
Note: do not use these cable
entry points for mains cables.

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4.3.5.
DDU
To mount the DDU first remove the cover by loosening the four captive screws and unplug the ribbon cable from
at the lid connection. The case is then secured to a firm support by use of the four mounting holes, one in each
corner of the case. Since the mounting holes are located outside the seal of the case it is not necessary to seal
the mounting holes after installation, nor is it necessary to remove the circuitry from the case for installation.
If commissioning is not to be carried out immediately reattach the lid to the processor.
Dimensions and mounting details are shown in Figure 5.
Figure 5 : DDU Mounting Details

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5.
Electrical Connections
Wiring should only be undertaken by a qualified technician.
Ensure that the power supply is isolated.
DO NOT switch power on until all wiring work is complete.
5.1.
Installation and Connection of Cables
Decide routing for all non-power cables (both those supplied by CODEL and those sourced locally). Use
common routing wherever possible and install leaving sufficient free-end length to make final connections.
The maximum recommended length of the connecting cable between the SPU and the DDU (customer supply)
is 100m –if a greater length is required please contact CODEL before installation.
Power cables (customer supply) should be installed separately, using different routes if possible to reduce the
risk of cross interference. Leave sufficient free-end length to make final connections. The maximum
recommended cable length is 5m –if a greater length is required please contact CODEL before installation.
CODEL supplied cables are provided with ferrite beads fitted to all cores to protect against interference and
should not be modified without consulting CODEL.
Mains connection must be via a fused isolating spur and should only be undertaken by a
qualified technician.
See the electrical rating plate on the PSU.
5.2.
Connection Schedule
The connection schedule for the V-CEM5100, PSU, SPU & DDU is shown in the following drawing (Figure 6).
Refer also to Figure 7, Figure 8 and Figure 9 for details of the SPU wiring and address switch locations in the
SPU and DDU.