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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 : +44 (0) 1629 814 351 f : +44 (0) 8700 566 307 e : [email protected] web : www.codel.co.uk
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
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 t one of the numbers below or alternatively visit our web site.
: +44 (0) 1629 814 351 f e web
:
:
:
+44 (0) 8700 566 307 [email protected] www.codel.co.uk
CODEL offices, Bakewell, Derbyshire
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
Technical Manual
Contents
1. Overview of the CODEL Model V-CEM5100 Flow Monitor
1.4. Signal Processor Unit (SPU
4.3.1. Fitting of Stub-Pipes and Mounting Flanges
5.1. Installation and Connection of Cables
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
Technical Manual
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
OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028
Technical Manual
CODEL
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CODEL
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/Nm
3
), 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.
Rx2
(Ch B)
Rx1
(Ch A)
Figure 1 : General Arrangement of the V-CEM5100
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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.
Rx1
(Ch A)
Rx2
(Ch B)
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:
R
BA
LIM .
T
1
0
T
A t dt
T 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-offlight and ‘t’ are equal. This can best be explained by considering the two signals A(t) and B(t) as shown below.
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Using the correlation function R
BA
(
) to operate on these two signals the following correlogram is obtained.
NOTE : with
= 0 (i.e. no delay on signal A(t)) then R
BA
(
) = 0, and when A(t) has been delayed by six timeintervals R
BA
(
) 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 R
BA
(
) 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 R
BA
(
) 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 max. value x 100% 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
Response
:
:
Accuracy
Serial Port
:
:
Construction :
Ambient Temperature Limits :
Power Requirements PSU :
V-CEM :
Air Purge Consumption :
Analogue Outputs (DDU)
Logic Outputs (DDU)
General
Construction
:
:
:
:
: selectable to 50m/s selectable 10 seconds to 30 days
±2% of measurement data bus I/P & O/P. fully sealed (IP65) epoxy-coated aluminium enclosures
-20 o
C to +70 o
C - transducers
-20 o
C to +50 o
C - PSU, SPU & DDU
90-264V AC max., 50/60Hz
48V DC (from PSU)
1 l/s @ 1 bar (compressed air), dry (to -20
C) & clean (better than 10
m)
2 x 0/4-20mA current outputs, isolated, 500
load max., fully configurable from keypad
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
DDU display - 32-character alpha-numeric back-lit LCD
DDU keypad -
PSU/SPU/DDU -
4-key soft-touch entry 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 transducer s 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 di ameters ‘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 plantspecific 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 offeredup 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.
Adjusting Nuts
Site Mounting Flange
Retaining Nuts
Air Purge
Insulating Bush
Insertion Tube
OPS.109
Stub Pipe (by others) Adjustable Flange
Front Flange
Rigid Gasket
Figure 3 : Adjustable Mount Details
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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.
cable gland entry blanking plug
(PSU mains)
Note : do not use these cable entry points for mains cables.
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
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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
SPU and DDU.
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Figure 6 : Connection Schedule
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To DDU
Figure 7 : Details of SPU Wiring
SW2
Keep links in place
SW1
Figure 8 : SPU Microprocessor Card
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Address switch
Figure 9 : DDU Microprocessor Card
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6. Commissioning
The instrument should now be fully installed and ready to be commissioned. This involves the following basic procedures that should be carried out with the plant ON:
6.1. Pre-Commissioning Checks
Before proceeding the following checks should be carried out :
If wiring has been installed and connected by others (and particularly if no certification of connection accuracy exists), check all wiring and connections for conformity with the information provided.
Although the instrument is equipped with all practical safeguards against the consequences of incorrect wiring, it is not possible to provide total protection against all errors.
Please be aware that damage arising from incorrect wiring will invalidate the warranty.
Finally check that the air purge is functioning. If not, take corrective action.
6.2. Introduction
Commissioning the instrument consists of the following procedures:
Power Supply Voltage . 85V to 264V AC.
Apply Power . Switch the power on and observe the power supply rail indications.
Alignment . Align transducers using the integral adjustable mounts.
Gain Adjustment . Check the automatic system gain.
Operating Parameters . Set the operating parameters within the micro-processor for correct instrument operation.
These commissioning procedures are now examined in further detail.
6.3. Power Supply Voltage
With the mains supply switched OFF unscrew the four captive screws in the cover of the SPU and open the cover carefully. DO NOT unplug the ribbon cable
6.4. Turning the Power ON
Switch on the power supply. Ensure that the three, power indication LED’s illuminate. If not, check the fuse and the supply.
Replace the cover of the processor, but do not fully tighten the signal processor screws until commissioning is complete. The instrument will automatically select the normal display mode.
6.5. Alignment
No special alignment procedure is required. The transducers should, however, be as perpendicular to the wall of the duct as possible by fully tightening the adjustable mount screws and locking bolts.
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Figure 10 : Adjustable Mount Details
Minor adjustment may be necessary if the mounting flange has been welded incorrectly.
6.6. Detector Levels
The system uses automatic gain control (AGC). The microprocessor in the signal processor continuously adjusts the gain of the signals from the two sensing heads to maintain an optimum level for both channels. The gain settings and detector levels can all be viewed in the Mode 4 Diagnostic display.
There should be no need for a manual gain adjustment. However, should a low channel 1 fault condition or channel 1 saturation condition occur, it means that the detector levels are outside the range of the AGC system and the gain of the transducer heads should be increased or reduced respectively.
A gang of four gain switches within each head adjusts the gain of the detector signal. These have a range of x1
the gain settings:
Remove the cover of each transducer by unscrewing the four M4 countersunk screws. Do not loosen the cable gland.
Change the gain switch settings as required. The hardware gains are set by a series of dip-switches in the sensing head.
Re-attach the cover and replace the four screws.
Gain switches
UP (OPEN) = 0
DOWN (CLOSED) = 1
UP
DOWN
Figure 11: Transducer Gain Switch Location.
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The table below gives the gain values represented by the dip switch settings.
Gain Switch 1 2 3
Low gain
High gain
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
4
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
Gain Value
1
2
4
5
7.7
15.4
30.8
38.5
15.7
31.4
62.8
78.5
22.4
44.8
89.6
112.0
If with a software gain setting of 0 the rms value of channel ‘A’ is greater than 80 the hardware gain must be reduced. If the rms value of channel ‘A’ is less than 20 with a gain setting of 4 the hardware gain must be increased.
6.6.1. Detector Levels
Transducer Gain
The instrument operates by correlating the signals received by the two optical transducers. It is important to ensure that the signal levels from the two transducers are correct. There are two levels of gain adjustment; one a hardware gain adjustment in the sensing heads and the other a software gain adjustment in the signal processor.
The software gain comprises two elements:
- an overall gain applied to both transducers with a gain factor in the range 0 to 4 that is applied as 2 n so that 0 is a gain of 1 and 4 is a gain of 16 and
- a channel ‘B’ gain factor applied only to channel ‘B’.
The channel ‘B’ gain is in the range 1 to 255. This is applied as an arithmetic gain with a normalised value of 64.
A gain value of 32 will thus represent a real gain of 0.5 while a gain value of 128 represents a real gain of 2.
These software gains are normally operated in an automatic mode with the channel ‘B’ gain designed to ensure that the rms values from the two transducers are approximately equal.
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7. DDU Operation
7.1. Introduction
After the instrument has been commissioned it will measure the flow velocity between the two transducers and produce an output proportional to gas velocity. An integral 32-character display shows the calculated levels.
The instrument allows the operator to interrogate the microprocessor to observe the system parameters and to change them if required.
A menu-based program is used, accessed being gained by four keys mounted on the cover of the signal processor.
The DDU communicates serially with the SPU; for successful communications to take place the DDU and SPU serial addresses must be the same:
-
serial comms. address – DDU microprocessor card rotary switch – SW1 serial comms. address – SPU microprocessor card rotary switch – SW1 (SW2 = 0)
7.2. Operating Modes
The instrument has four modes of operation that are identified by a number in the top left hand corner of the display.
1. Operating Mode - displays measured parameters.
2. Parameter Mode - displays operating parameters.
3. Normalisation Mode - not applicable.
4. Diagnostic Mode - investigates instrument operation. Self-checks are continually made by the instrument; should a complication exist the fault will be shown on the fault status display.
5. Set-up Mode - sets operating parameters. The operating parameters must be entered for the instrument to function correctly. This mode can only be accessed using the security code.
Enter Key
Mode Key
Data Valid LED
Back-Lit LCD Display
UP/DOWN Arrow keys
Alarm LED
Figure 12 : Illustration of the Processor Display & Keys
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7.3. Key Operation
of the DDU. After a mode has been selected the and keys will select the various options within that mode.
The ENTER key will input the displayed value and may step the cursor to the next option if this is applicable.
7.3.1. Mode Key
Pressing the MODE key will either take the instrument to the next mode of operation or back to the operating mode if pressed from within a mode.
7.3.2. Arrow Keys
Pressing the and keys will do one of two things depending on the position in the program:
It will increase or decrease the displayed value.
If the key is held down it will scroll quickly to the desired value.
It will step through the available options within a mode or sub-mode.
7.3.3. Enter Key
Pressing the ENTER key will do one of two things depending on the position in the program:
it will input the displayed parameter value,
it will select the displayed mode or option from within a mode or sub mode.
Allow time for the instrument to respond to a key instruction, otherwise a double key entry may be recorded.
7.4. Program Tree
tree is given in this section.
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Figure 13: Main Program Tree
7.5. Operating Modes
NB . PLEASE NOTE THAT ANY DATA CONTAINED IN THE FOLLOWING DISPLAY ILLUSTRATIONS IS
INTENDED TO BE REPRESENTATIVE ONLY.
7.5.1. Measurement Mode
From this mode of operation the averaging time of the displayed flow may be altered to one of the other averaging stacks and the flow measurements observed. When in this mode, the display will appear similar to that shown below. If the display is not similar this, press the MODE key until number 1 appears in the top left corner of the display.
1 Flow = 010.0 m/sec Av03h
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To change the data displayed, press the ENTER key and a, flashing cursor will appear at the beginning of the concentration units, i.e. m/sec or m
3
/sec. The and keys will now change the highlighted parameter. Each push of the ENTER key will select another of the parameters, in the following order:
Units - m/sec or m
3
/sec
Averaging Time - seconds, minutes, hours, or days.
Once the display configuration is as required, press the ENTER key when the cursor is flashing on the averaging time, and the cursor will disappear from the display. The ENTER key may be pressed again if required to bring the cursor back onto the display.
7.5.2. Calibration
The calibration of the flow monitor can be verified by an on-board calibration procedure that may be initiated in a
value and a second point defined at a high value, allowing verification to be made at two points in its defined operating range.
The calibration system operates by the signal processor injecting electronic signals into the transducers. The processor, from the low cal and high cal flow points entered, calculates the time delay in milliseconds that would be experienced between the two transducers, if the real flow in the duct were at selected values.
The signal, injected into the downstream transducers, is phase-shifted relative to the upstream transducer, by the computed delay. The monitor then performs its normal correlation process on the value. This computed flow value should be the same as the value entered for the low cal and high cal flow points.
The calibration cycle consists of two distinct phases, the first being the low flow calibration, the second the high flow calibration. The status of each phase is indicated by means of a counter counting down on the processor display.
At the completion of the calibration, (both low flow and high flow), the processor resets automatically to its normal measurement mode (Mode 1). The resulting calibration data can be viewed from Mode 4
DIAGNOSTICS . Alternatively calibration data may be outputted to the 4-20mA output during the calibration
7.6. Parameter Mode
In this mode, the parameters set within the set-up mode may be examined, but not changed. Press the MODE key until the number 2 appears in the top left corner of the display, then press the ENTER key. The and keys will now scroll through the available options, press the ENTER key to display the selected option.
Press the ENTER key again to exit from each option.
See the SET-UP MODE for further details of the display information, and how to change the held parameters.
7.6.1. Identification
The analyser type, EPROM program ID and identity number are displayed from this option.
7.6.2. Parameters
The following parameters are examined from this option, selected using the and keys:
Detector Separation (Distance)
This is the separation of the detectors in mm; the value is held within the instrument to calculate velocity from the time delay and should be within ±5mm of the actual separation.
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Cross Sectional Area
The cross sectional area in m
2
currently being used to calculate the volumetric flow.
Data Rate
Data Acquisition Rate of Measurement
The system operates by reading and storing the data from the channel ‘A’ transducer at accurately timed intervals varying from 0.5 milliseconds to 4 milliseconds. A window of 256 readings provides the basis for the correlation measurement. The data rate thus determines the time frame of the correlation window from 128 milliseconds at a data rate of 0.5m/sec to 1 second at 4 milliseconds data rate. At a transducer separation of 1m a time of 1 second gives a minimum measured velocity of 1m/sec.
The data rate also provides the resolution for the time measurement. The most sensitive resolution of 0.5msec is required for the highest velocities but the correlation window of 128msec only allows for a minimum velocity of
8m/sec to be measured. For this reason the data rate selection is usually operated in auto mode where the analyser itself selects the correct data rate for the flow conditions prevailing at that time. This enables the working range of the instrument to extend from 1m/sec to over 50m/sec.
Lead Channel
‘A’ or ‘B’ determines which of the transducers is configured to be the upstream detector.
Channel ‘A’ is always defined as the upstream or lead transducer. Depending on the wiring channel ‘A’ may be either transducer 1 or transducer 2. It is necessary to select the channel ‘A’ device from transducer 1 or transducer 2.
7.6.3. Averages
Selecting this option will display the times set for each of the four averaging stacks.
7.6.4. Output
The base, span and averaging of the analogue output are displayed from this option for both outputs 1 & 2.
7.6.5. Alarm
A changeover relay contact output is available to indicate a high flow level. The level at which this output is operated, and the averaging stack, from which the flow value is obtained, may be examined from this display.
This alarm may also be configured as a cal-in-progress indicator.
A second changeover relay contact output is available to indicate a low flow level.
7.6.6. Plant Status
When plant status is OFF (terminals 28 & 29 shorted together), the minutes, hours and days averaging stacks do not update - the plant is considered to be not running properly and if this data is stored the averages will give false (diluted) readings.
This function may be used to ensure data is only collected when the plant is fully operational. The logic input can be used to determine plant status ON or OFF. The plant status and its governing factor may be viewed from this display.
7.6.7. Clock
The current time and date are displayed from this option in the form :
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Time
Date
7.6.8.Cal Config hr * mins * secs day/month/year
This option enables all the calibration configuration parameters to be displayed:
Calibration interval in hours
-
-
-
Logic initiation input ON or OFF
Cal alarm actuation ON or OFF
Calibration data to output ON or OFF
Date and time of next calibration -
Selection of each display is by scrolling with the arrow keys.
7.7. Normalisation
This mode is not applicable to this monitor. Flow is displayed as actual measured vales.
7.8. Diagnostic Mode
7.8.1. Detector Levels
Detector levels from the receivers are displayed here. Press ENTER when the LCD shows Detector Outputs and the detector levels for both channels will be displayed.
4 DIAGNOSTICS
Detector Outputs
The two detector levels ch annel ‘A’ & channel ‘B’ are displayed as instantaneous rms values in the left hand display and smoothed rms in the right hand display. Values in the range 30 to 60 can be expected. Values less than 30 will cause the gain control system to switch to a x2 high gain setting; values higher than 60 will cause the gain to be reduced by a factor of 2.
Ch annel ‘B’ values are additionally adjusted by a software gain stage to equalise channel ‘A’ & channel ‘B’ levels.
4 ChA 0040 0041
ChB 0043 0044
7.8.2. System Gain
The auto gain settings of the detector channels are displayed here along with the channel ‘B’ software gain value.
4 DIAGNOSTICS
System Gain
The gain setting varies from 1 to 128 in multiples of 2.
Ch annel ‘B’ gain is a software adjustment where the channel ‘B’ gain, relative to channel ‘A’, is displayed as a number between 1 and 255.
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4 Det gain 008
ChB gain 114
7.8.3. Displacement
Displacement, which is the location on the correlogram of the minimum, is displayed along with the correlation coefficient.
4 DIAGNOSTICS
Displacement
The ‘displacement’ is the position in the correlation window at which the minimum correlation level is found. This value is determined every second by the analyser. The actual ‘time delay’ between channel ‘A’ and channel ‘B’ transducers is obtained by multiplying the smoothed value of displacement by the data rate.
Displacement is a value up to 254. The actual transit time of the gas between the two measurement points is determined by:
Time = displacement (t) x data rate ms
The correlation coefficient is an assessment of the quality of data.
Correlation coefficient = (Ref val – min val) x 100
(Ref val)
Coefficients of less than 10% will imply an invalid measurement.
4 Corr coeff 091% t = 181 a>dr = 1.0ms
7.8.4. Flow Data
Instantaneous flow (flow (0)) and a 60 second smoothed value (flow (60)) are displayed.
4 DIAGNOSTICS
Flow Data
4 Flw (0) 021.3m/s
Flw (60) 022.1m/s
7.8.5. Calibration Data
Data from the previous calibration can be accessed here. The auto calibration performs both a low and high point calibration. Calibration points can be selected and electronic signals are injected into the measuring heads to simulate a flow at that particular velocity. The high and low flow values then measured by the monitor are displayed at this point.
4 DIAGNOSTICS
Calibration Data
4 Hi cal 25.1m/s
Lo cal 05.0m/s
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7.8.6. Fault Condition
To display the current fault condition, press the ENTER key while this is displayed. This display mode is automatically selected by the instrument should a fault condition occur. The following fault conditions are recognised by the instrument.
1. *ALL CLEAR*
2. Ch’A’ > Low
3. Ch’B’ > Low
4. Ch ‘B’ >range<
5. Comms Failure
-
-
-
-
- no fault condition low detector level low detector level software gain <16 or >240 loss of communications between DDU & SPU
4 DIAGNOSTICS
Fault Condition
4 DIAGNOSTICS
*ALL CLEAR*
By pressing the arrow key the previous fault condition can be observed.
4 Previous Fault
ChB >Range<
If a fault condition exists, the minutes, hours & days averages will not be updated .
7.9. Set-up Mode
All operating parameters - averaging times, output settings, normalisation parameters, path length, calibration, etc. - can be changed from this mode. To prevent any unauthorised changes, the user must enter a four number code before the mode can be entered.
After this mode has been selected, the instrument will suspend its operation and the Data Valid
LED will extinguish. If no key is pressed within 5 seconds after selection of this mode, the instrument will revert to the normal operating mode.
Press the MODE key until the number 5 is displayed in the top left-hand corner. After the security code has been correctly entered, there are 5 sub-modes of operation from which the set-up parameters may be changed, these are:
Set Averages . The four averaging stack times (seconds, minutes, hours & days) may be set as required and also allows the four averaging stacks to be reset.
Configure O/P1 . Analogue output set up - origin, units, span, rolling average & fault condition.
Configure O/P2 . Analogue output set up - origin, units, span, rolling average & fault condition.
Alarm Hi .
Rolling average, units, level.
Alarm Lo .
Rolling average, units, level.
Parameters . The following are set from this mode: security #, identity #, separation, cross sectional area and data rate.
Calibrate . The calibration of the instrument can be set.
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After the correct code has been entered, the user may access each of the five sub-modes (listed above) by using the and keys and pressing ENTER when the required option is displayed.
7.9.1. Security Code Entry
Once the display is as shown here, to gain access to the set-up mode, press the ENTER key. The cursor will now flash over the first digit of the presented code number, select the required first digit with the arrow keys and press ENTER . Repeat this procedure for the four numbers. If the code is correct after the ENTER key is pressed on the last digit, then the sequence will be continued, if it is not correct, the instrument will return to the operating mode.
4 SET UP MODE
Security # 0000
The code number will be set to 0000 by CODEL at the factory; this should be changed by the user from within the set-up mode
Figure 14: Program Tree for the Set-Up Mode.
7.9.2. Set Averages
Four separate averages are calculated within the instrument. These are defined in units of seconds, minutes, hours and days. Any of the four averaging stacks can be used to provide the analogue output of the instrument.
Each averaging time can be set within pre-defined limits.
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Press the ENTER key when this display is shown, the display will now show one of the averages. Use the and keys to select the average time that requires changing, and press the ENTER key to change it. The value can now be changed using the and keys and input by pressing the ENTER key.
5 SET AVERAGES
Set the seconds averaging stack to the required value. This is limited to within 10 to 60 seconds in 10-second intervals.
5 SET AVERAGES secs 60
Set the minutes averaging stack to the required value. This is limited to within 1 to 60 minutes in 1-minute intervals.
5 SET AVERAGES mins 60
Set the hours averaging stack to the required value. This is limited to within 1 to 24 hours in 1-hour intervals.
5 SET AVERAGES hours 24
Set the days averaging stack to the required value. This is limited to within 1 to 30 days in 1-day intervals.
5 SET AVERAGES days 30
7.9.3. Configure O/P1
The analogue current loop output (terminals 19 & 20), is set up from this mode. Press the ENTER key while this display is shown to select it, then press the and keys to step through the available options. Press the
ENTER key to enter each option and change the displayed parameter.
5 CONFIGURE O/P1
7.9.3.1. Base of Output
An origin of 0 or 4mA can be set for the current loop output. The and keys will toggle between these two options. Press the ENTER key to enter the new value.
5 CONFIGURE O/P1
Output = 4 to 20mA
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7.9.3.2. Averaging Time of the Output
Any of the four averaging stacks (seconds, minutes, hours or days) may be used for the analogue output. They are selected by the and keys and entered using the ENTER key.
5 CONFIGURE O/P1
Average 01m
7.9.3.3. Output Units
The analogue output can represent the gas concentration in units of either m/sec or m
3
/sec. The and keys will toggle between these two options. Press the ENTER key to enter the new value.
5 CONFIGURE O/P1
Units m/sec
7.9.3.4. Output Span
Select the required span using the and keys for each digit. The ENTER key is pressed to enter the value of each digit. The units will be displayed in either m/sec or m
3
/sec, depending on what has been selected beforehand. The current value will be displayed for 1 second when this option is entered. The display then defaults to zero; thus the span value must be re-entered for the unit to function correctly.
5 CONFIGURE O/P1
Span 020.0m/sec
7.9.3.5. Set mA Output
Should a fault condition occur the current output of the instrument may be set to any of the following options:
Set the output at 0 mA – ZERO .
Adjust the output to the measured concentration even though a fault condition exists – MEAS .
Hold the last measurement – HOLD .
Set the output to full scale (20mA) – F .
S .
5 CONFIGURE O/P1
Fault cond ZERO
One of these options can be selected by pressing the ARROW keys, when the desired option is displayed press the ENTER key.
6.9.3.6. Set mA Output
This is set at the factory and should not be altered without due consideration.
From this option the current levels of the analogue output are set up. Press the ENTER key to select it, and the operator is prompted to set the current levels at 0 and 20mA.
5 CONFIGURE O/P1
Set Zero (0000)
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When this is displayed the current output should be set to 0mA as measured with a calibrated current meter across the analogue current loop terminals. Nothing else should be connected to these terminals when the output is being set up. The value is adjusted using the two arrow keys; the arrow will take the current output up and the arrow will take it down. Press the ENTER key when the correct output current is displayed on the ammeter.
Zero milliamps should be set up; no matter what has been selected as the base of the current output .
In a similar manner as above the current output level should now be set to 20mA.
5 CONFIGURE O/P1
Set Span (4095)
20mA should be set up regardless of existing flow measurement.
7.9.4. Configure O/P2
The analogue current loop output (terminals 25 & 26), is set up from this mode. Press the ENTER key while this display is shown to select it, then press the and keys to step through the available options. Press the
ENTER key to enter each option and change the displayed parameter.
5 CONFIGURE O/P2
7.9.4.1. Base of Output
An origin of 0 or 4mA can be set for the current loop output. The and keys will toggle between these two options. Press the ENTER key to enter the new value.
5 CONFIGURE O/P2
Output = 4 to 20mA
7.9.4.2. Averaging Time of the Output
Any of the four averaging stacks (seconds, minutes, hours or days) may be used for the analogue output. They are selected by the and keys and entered using the ENTER key.
5 CONFIGURE O/P2
Average 01m
7.9.4.3. Output Units
The analogue output can represent the gas concentration in units of either m/sec or m
3
/sec. The and keys will toggle between these two options. Press the ENTER key to enter the new value.
5 CONFIGURE O/P2
Units m/sec
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7.9.4.4. Output Span
Select the required span using the and keys for each digit. The ENTER key is pressed to enter the value of each digit. The units will be displayed in either m/sec or m
3
/sec, depending on what has been selected beforehand. The current value will be displayed for 1 second when this option is entered. The display then defaults to zero; thus the span value must be re-entered for the unit to function correctly.
5 CONFIGURE O/P2
Span 020.0m/sec
7.9.4.5. Set mA Output
Should a fault condition occur, the current output of the instrument may be set to any of the following options.
Set the output at 0 mA – ZERO .
Adjust the output to the measured concentration even though a fault condition exists – MEAS .
Hold the last measurement – HOLD .
Set the output to full scale (20mA) – F .
S .
5 CONFIGURE O/P2
Fault cond ZERO
One of these options can be selected by pressing the ARROW keys, when the desired option is displayed press the ENTER key.
6.9.3.6. Set mA Output
This is set at the factory and should not be altered without due consideration.
From this option the current levels of the analogue output are set up. Press the ENTER key to select it, and the operator is prompted to set the current levels at 0 and 20mA.
5 CONFIGURE O/P2
Set Zero (0000)
When this is displayed the current output should be set to 0mA as measured with a calibrated current meter across the analogue current loop terminals. Nothing else should be connected to these terminals when the output is being set up. The value is adjusted using the two arrow keys; the arrow will take the current output up and the arrow will take it down. Press the ENTER key when the correct output current is displayed on the ammeter.
Zero milliamps should be set up; no matter what has been selected as the base of the current output .
In a similar manner as above the current output level should now be set to 20mA.
5 CONFIGURE O/P2
Set Span (4095)
20mA should be set up regardless of existing flow measurement.
7.9.5. Alarm Hi
The operation of the volt-free contact alarm output (terminals 12, 13 & 14), is configured from this mode.
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7.9.5.1. Source
The alarm can be configured to trigger from any one of the four averaged values (sec, mins, hours or days).
5 ALARM Hi
Source 30s
7.9.5.2. Units
The units in which the alarm is operated can be set to m/sec or m
3
/sec.
5 ALARM Hi
Units m/sec
7.9.5.3. Level
The level (threshold) at which the alarm is triggered is adjustable in the Units previously selected.
5 ALARM Hi
Level 20m/sec
Select the level, 1 digit at a time, using and and set by pressing ENTER .
7.9.6. Alarm Lo
The operation of the volt-free contact alarm output (terminals 15, 16 & 17), is configured from this mode.
7.9.6.1. Source
The alarm can be configured to trigger from any one of the four averaged values (sec, mins, hours or days).
5 ALARM Lo
Source 30s
7.9.6.2. Units
The units in which the alarm is operated can be set to m/sec or m
3
/sec.
5 ALARM Lo
Units m/sec
7.9.6.3. Level
The level (threshold) at which the alarm is triggered is adjustable in the Units previously selected.
5 ALARM Lo
Level 0.5m/sec
Select the level, 1 digit at a time, using and and set by pressing ENTER .
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7.9.7. Parameters
Select this option by pressing the ENTER key. The and keys will now display the available options from within this sub-mode, when the option that requires changing is displayed, press the ENTER key. When all required changes have been made, select the EXIT option and press ENTER .
5 PARAMETERS
7.9.7.1. Security Number
To prevent any unauthorised tampering with the set up information, it is important that the security code is changed from the factory setting. Each digit is selected with the ENTER key and changed with the and keys.
5 PARAMETERS
Security # 0000
It is important to make a note of this number otherwise it will not be possible to change the instrument set-up.
7.9.7.2. Units
The system operates in metric units to provide output data in m/sec.
5 PARAMETERS
Units metric
7.9.7.3. Detector Separation (Distance)
The current value entered for separation will be displayed for 1 second, then the display will default to zero. The separation must be re-entered for the unit to calculate flow correctly.
5 PARAMETERS
Distance 1000mm
7.9.7.4. Cross Sectional Area
The cross sectional area must be entered in m
2
to enable volumetric flow to be correctly displayed.
5 PARAMETERS
CS Area 010.0m2
7.9.7.5. Data Rate
The DATA RATE selected will depend on the range of flow velocities to be measured. Estimate the Time of
Flight (TOF) for the minimum and maximum expected flow velocities as follows:
Maximum TOF (ms) = separation (mm)/minimum flow velocity (m/s)
Minimum TOF (ms) = separation (mm)/maximum flow velocity (m/s)
The DATA RATES available are 0.5, 1.0, 2.0, 4.0 and 8.0ms.
Select the DATA RATES such that:
Max. TOF/DATA RATE
255
Min. TOF/DATA RATE
50
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For example, if the min. and max. expected flow velocities are 5m/s and 20m/s respectively with a transducer separation of 1000mm, then the max. TOF = 200 and then min. TOF = 50. Consequently the ideal DATA RATE is ms. Selecting a DATA RATE of 0.5ms would be unacceptable because the max. TOF/DATA RATE = 400 which is >255. Selecting a DATA RATE of 2ms would not be desirable because the min. TOF/DATA RATE =
25 which is <50.
For the above example a Data Rate of 0.5ms limits the min. flow velocity to 1000/(0.5 x 255) =
7.84m/s. A Data Rate of 2ms and greater permits the full range of expected velocities but limits the available resolution of the measurement.
5 PARAMETERS
Data rate 1.0ms
Auto Ranging
Switching the data to ‘auto’ enables the monitor to select automatically, the appropriate data rate for the flow being measured.
7.9.7.6. Channel Switch
It is normal to install the transducers so that transducer ‘A’ is the upstream (Lead) detector. Should the installation have been made so that transducer ‘B’ is the upstream detector, this can be accommodated by setting the channel switch from ‘A’ to ‘B’ using the and keys.
5 PARAMETERS
Channel switch A
7.9.7.7. Span Factor
This is a factory-set measurement flow scaling factor and should not be altered without due consideration.
5 PARAMETERS
Span factor 1000
7.9.7.8.Set Clock
The signal processor contains a battery-backed real-time clock that enables calibrations to be initiated at set and specific times and intervals.
This section enables the clock to be set.
5 PARAMETERS
Set clock
Enter
5 Set clock
Year 2008
Scroll years using
Enter
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5 Set clock
Month 03
Scroll month using
Enter
5 Set clock
Days 26
Scroll days using
Enter
5 Set clock
Hours 14
Scroll hours using
Enter
5 Set clock
Minutes 47
Scroll minutes using
Enter
5 Set clock
Seconds 17
Scroll seconds using
7.9.8. Calibrate
The way in which the calibration is initiated and in which calibration data is outputted is configured here. A manually initiated calibration can also be triggered from this mode.
7.9.8.1. Calibrate
CALIBRATE Enter
Set Cal. Data
Calibrate
Config. Cal
Set Cal. Data – sets up parameters for the calibration
5 CALIBRATE
Set Cal Data
Enter
5 CALIBRATE
Lo cal 05.0m/sec
Set the low span calibration target value, 1 digit at a time, using the and keys and Enter .
Enter
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5 CALIBRATE
Hi cal 20.0m/sec
Enter
Set the high span calibration target value, 1 digit at a time, using the and keys and Enter .
5 CALIBRATE
Set # cycles = 50
Set the number of cycles used for calibration, 1 digit at a time, using the and keys and Enter .
Enter
Calibrate – manually activates a calibration
5 CALIBRATE
Calibrate
Enter
5 Lo flow 025
Cal in progress
End when count = 0
5 Hi flow 023
Cal in progress
End when count = 0
Config. Cal – sets parameters for a remote/timed activated calibration
Config Cal Enter Initiate
Enter cal timer
Enter interval
next cal cal alarm output data logic
Initiate
This enables selection of the time of calibration. Calibration can be triggered by configuring the plant status logic input to a calibration trigger. Additionally calibration can be triggered at period intervals and pre-set times, controlled from the on-board clock.
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Cal. Timer
This enables calibration to be triggered at period intervals, from the real-time clock. Firstly the ‘interval’ should be set from 0 to 168 (1week) using the and keys. Note that a setting of 000 inhibits calibration initiation from the timer.
The start time of the first calibration can be set in realtime hours under ‘next cal’. Using the and keys, scroll the time of day from 0000 to 2400 hours, at which time the first calibration will occur. All subsequent calibrations will be referred to this time.
Logic
The plant status input can be reconfigured to act on a remote calibration command. The command is initiated by shorting the plant status input terminals (28 & 29) in the signal processor. Configure this option by selecting YES or NO , to ‘Initiate via Plant Status’ .
Cal. Alarm
The alarm Hi relay can be reconfigured to act as a ‘cal in progress’ alarm. Select this option, by selecting YES or NO at this point. If YES is selected, the normal alarm operation will be disabled.
Output Data
The results of the calibration check can be outputted via the 0 or 4-20mA output, by selecting YES at this point.
When this option is selected on beginning a calibration, the output will switch to its zero (0 or 4mA) point, while the Lo flow section of the calibration is made (for approximately 20 seconds). Then, the Hi flow section of the calibration is made, while the result of the Lo flow section is outputted, and held until the Hi flow is completed
(20 seconds). The Hi flow section of the calibration is then repeated to enable the results of the completed Hi flow section to be outputted.
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8. Routine Maintenance
The equipment is designed to keep the levels of maintenance to an absolute minimum.
8.1. Cleaning Windows
It is important that the windows at the transducers remain reasonably clean. They may be cleaned, by removing the transducer from the air purge, (by removing the three M6 socket head screws) and cleaning each window with a clean soft dry cloth.
Clean the internal surfaces of the mounting tubes to remove any build-up of dust or ash.
It is estimated that window cleaning should be required every 6 months. However, this interval will depend entirely on the operating conditions and the dirtier these are the more frequently cleaning may be required.
On positive-pressure ducts ensure that precautions are taken prior to removal of the transducers for lens cleaning – failure to do so could result in maintenance personnel being exposed to dangerous, hot, toxic gases.
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9. Basic Fault Finding
The electronics require no routine maintenance. They are all solid state and undergo a rigorous factory burn-in procedure. If there is any doubt about the equipment performance, the signal processor may be interrogated from the keypad to determine whether or not the equipment is functioning normally.
to determine correct performance. This can be done at any time without interrupting or disturbing the analogue output of the equipment.
The analysers that make up the SmartCem system are sophisticated devices and any problems necessitating internal repair should only be undertaken by fully trained technicians.
In the absence of CODEL trained technicians on site it is strongly recommended that in the event of a fault
CODEL or its local service agent be contacted immediately with the current information contained in the analyser records.
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10. List of Figures
Figure 1 : General Arrangement of the V-CEM5100
Figure 2 : Stub Pipe Arrangement
Figure 3 : Adjustable Mount Details
Figure 4 : PSU & SPU Mounting Details
Figure 5 : DDU Mounting Details
Figure 6 : Connection Schedule
Figure 7 : Details of SPU Wiring
Figure 8 : SPU Microprocessor Card
Figure 9 : DDU Microprocessor Card
Figure 10 : Adjustable Mount Details
Figure 11: Transducer Gain Switch Location.
Figure 12 : Illustration of the Processor Display & Keys
Figure 14: Program Tree for the Set-Up Mode.
OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028
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