Coal Mill CO Analyzer Codel Manual

TECHNICAL MANUAL
Coal Mill
CO Gas Analysing System
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 : codel@codel.co.uk web : www.codel.co.uk
OPS.114 Issue : A Rev. : Date : 14/8/08 Doc. i/d : 0114/6 Ref. : 080043
CODEL
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 CODEL offices, Bakewell, Derbyshire
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 : +44 (0) 1629 814 351

f : +44 (0) 8700 566 307
e : codel@codel.co.uk
web : www.codel.co.uk
CODEL
Technical Manual CODEL
Contents
1. Coal Mill CO Gas Analysing System 1

1.1. Introduction 1
1.2. System Operation 2
2. Measurement Principle 4
3. Summary Specification 5
4. Preparing for Installation 6

4.1. Unpacking 6
4.2. Additional Materials 6
5. Installation 7
5.1. General 7
5.2. Site Mounting Flange 7
5.3. Measurement Cabinet 8
5.3.1. Direct-Mounted Installation 8
5.3.2. Remote-Mounted Installation 8
5.4. Data Display Unit 9
5.5. Wiring Connections 9
5.6. Compressed Air Connections 10
6. Commissioning 11
6.1. Pre-Commissioning Checks 11
6.2. Normal Start-Up Sequence 11
7. Normal Operation 12
7.1. Introduction 12
7.1.1. Measurement 12
7.1.2. Calibration 12
7.2. Normal Start-Up Procedure 12
7.3. Modes of Operation 12
7.4. Key Operation 13
7.5. Program Tree 13
7.6. Operating Mode 14
7.7. Parameter Mode 15
7.8. Chamber 16
7.8.1. Display Format 16
7.9. Diagnostic Mode 16
7.9.1. Detector Outputs 17
7.9.2. Thermistor 18
7.9.3. Y & Z Values 18
7.9.4. CO Values 18
7.9.5. Calibration Data 18
7.9.6. Fault Condition 19
7.10. Set-Up Mode 20

7.10.1. Security Code Entry 20
7.10.2. Set Averages 22
7.10.3. Reset Averages 23
7.10.4. Configure O/P 1 & 2 23
7.10.5. Parameters 25
7.10.6. Chamber 26
7.10.7. Pressure 26
7.10.8. Calibrate 27
7.10.9. Alarms and Emergency Conditions 29
7.11. Emergency Shutdown/Isolation Procedure 29
8. List of Figures 30
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 Page 1 CODEL
1. Coal Mill CO Gas Analysing System

1.1. Introduction
Detection and measurement of carbon monoxide levels produced by combustion within a mill is a proven
method of detection of fires. A mill fire detection system must be capable of detecting carbon monoxide (CO) in
the mill whether the mill is idle or in operation. The system must operate with absolute integrity for long periods
and with minimal maintenance.
The CODEL system samples the gas content of the mill outlet through a stainless steel sintered filter mounted in
the wall of the mill outlet duct. The sample gas requires no pre-conditioning and is carried by a sample line and
pump to a measuring chamber equipped with a compact infrared gas analyser; the measurement chamber is
trace-heated to avoid condensation. Integral valves provide automatic calibration and filter cleaning routines.
The system employs an air pump to achieve minimum maintenance.
The system comprises a data display unit (DDU) and a separate measurement cabinet housing the infrared
monitor, measurement chamber and pneumatic valve assembly. The sintered stainless steel filter is housed in
an assembly welded to the mill outlet duct. The measurement cabinet can be mounted directly to the filter
housing or remotely and connected to the filter assembly via a heated sample line.
The two alternative mounting arrangements are shown in Figure 1 below. Figure 2 is a photograph of the inside
of the measurement cabinet.
DDU Measurement chamber Stainless steel Heated sample line

sintered filter (maximum length 20m)
Transmitter (Tx) Receiver (Rx)
Comms to DDU
Air outlet Alternative Mounting

Compressed air IN Arrangement
48V DC input
Outputs
Figure 1 : Mounting Arrangements
Figure 2 : Inside the Measurement Cabinet
1.2. System Operation
A schematic illustration of the CO Gas Analysing System is shown below.
Figure 3 : System Schematic
The gas is drawn from the mill outlet duct via a stainless steel filter and through the measurement chamber
using an air pump. Between the filter and air pump is a ball valve that provides two alternative flow paths, ‘A’ or
‘B’.
In normal operation the flow path is ‘A’ and the typical sample rate is 1 – 1.5 litre/min. This flow rate can be
adjusted by varying the pressure at regulator 1. For a duct-mounted system the pressure will be typically 1bar
(15psi) and is factory-set.
When a heated sample line is employed the flow should only be set after temporarily installing a flow monitor
between the filter housing and the heated sample line. Regulator 1 may then be adjusted to obtain a sample
flow rate of 1 – 1.5 litre/min. Where a flow monitor is not available and provided the stainless steel filter is new
and clean, then regulator 1 should be set to a pressure of 1bar (15psi).
The cleanliness of the stainless steel filter is checked regularly (typically every 4 hours) when back-purging the
system. During back-purging the ball valve is set for flow path ‘B’. The back-purge solenoid is ‘pulsed’ to clean
the filter and the time taken for the pressure to decay is monitored; if the filter is not clean the pressure will take
several seconds to decay.
The time taken for the pressure to decay will also depend upon the length and diameter of the heated sample
line. Hence, when the system is first installed and the stainless steel filter is clean, a ‘BP initialisation’ should be
performed. However, the initialisation routine should not be performed if the system is duct-mounted.
During initialisation the system monitors the time taken for the pressure to decay and sets a decay time
threshold (typically five times longer than the ‘clean’ decay time) for which the stainless steel filter is considered
blocked. If after a back-purge this blocked condition is identified, the data valid relay is actuated and the
diagnostic display will indicate the fault condition ‘filter blocked’ – see 7.9.6. Fault Condition.
The initialisation routine is operated at the factory during testing for both duct-mounted and heated sample line
systems. Where the system is to be used with a heated sample line the factory set-up uses a 10m sample line
with 7mm bore. Remember, the ‘BP initialisation’ routine should not be performed if the system is duct-mounted.
The infrared monitor is zero calibrated by either manually activating a zero calibration in the Set-Up Mode or by
a timed automatic calibration – see 7.10.8. Calibrate.
During calibration the ball valve flow path is B and the changeover solenoid (Figure 3) is set for compressed air.
Under these conditions the flow rate of air through the measurement chamber is limited to 1 – 1.5 litre/min via
the 0.175mm restrictor, provided that regulator 2 is at the factory setting – typically 3.5 – 4bar (50 – 60psi).
The span of the monitor can also be checked by connecting CO span gas to the ‘Span CO IN’ connection on the
cabinet (Figure 3) and selecting ‘Span Gas’ – see 7.10.8. Calibrate.
The output regulator at the CO span gas cylinder should be set to 3.5 – 4bar (50 – 60psi). The span gas reading
is displayed in the ‘Operating Mode’ – see 7.6. Operating Mode.
2. Measurement Principle
The analyser comprises an infrared source assembly mounted on one side of the measurement chamber. On
the opposite side of the measurement chamber is the receiver.
The source consists of a small black-body emitter and gas wheel assembly. The wheel is rotated by a stepper
motor at a constant speed of 1Hz. A unique gas cell arrangement enables the transmitted beam from the source
to be periodically interrupted by a gas sample of pure CO, thus enabling active (D1) and reference (D2)
measuring channels to be created.
At the receiver the infrared beam is filtered by a narrow band interference filter corresponding to the CO
absorption band and detected using a lead solenoid thermoelectrically-cooled infrared detector.
Mounted at the receiver is a microprocessor that monitors the detector signals and derives the carbon monoxide
concentration from a ratio measurement of the active and reference signals.
The gas sampled via the stainless steel sintered filter is drawn through the measurement chamber via an air
pump. Periodically, the chamber is isolated from the filter via a ball valve and the filter is back-flushed to prevent
long-term blockage of the filter.
The system can tolerate a very large build-up of pulverised coal at the filter as this build-up is still very porous to
the gas. However, it is essential that the air used to back-flush the filter is dry (less than -20oC) and oil-free.
Water and/or oil will result in the filter rapidly becoming blocked which no amount of back-flushing will clear.
Every time the system is back-flushed the porosity of the filter is checked. During back-flushing the compressed
air is pulsed to maximise filter cleaning.
At pre-defined intervals the system can be zero calibrated. This calibration is preceded by a back-flushing of the
filter during which time the measurement chamber is back-flushed to remove any traces of CO. The porosity of
the filter is also checked.
At any time span gas can be connected to the system and the accuracy of the CO monitor verified.
3. Summary Specification
Measurement Principle : infrared gas cell correlation.
Span : selectable up to 10000ppm.
Accuracy : 10ppm or +2% span (whichever is the greater).
Resolution : 5ppm.
Compliances : EMC 89/336/EEC directive compliant.
: Low Voltage 73/23/EEC directive compliant.
Analogue Outputs : 2 x 0/4-20mA current outputs, isolated, 500Ω load max. fully
configurable from the keypad.
Logic Outputs : 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.
Display : 32-character alpha-numeric back-lit LCD.
Keypad : 4-key soft-touch entry.
Ambient Temperature : -10 to +45oC.
Analyser Protection : all units are constructed to IP68 standards.
Power Requirement : 48V DC, 125W.
Compressed Air : oil-free, clean and dry to less than -20oC @ 5 to 7 bar, nominal
consumption 20 litre/min (120 litre/min during back-flush).
4. Preparing for Installation

4.1. Unpacking
The equipment is normally protected for transportation by an expanded foam packing material. When unpacking
please ensure that smaller items are not discarded with the packing material.
If any items are missing please inform CODEL or your local CODEL agent immediately.
• standard supplied items:
: 1 x measurement cabinet
: 1 x DDU
: 1 x stainless steel filter assembly
The DDU is supplied with 3m of cable terminated with a plug for connection to the measurement cabinet.
Whilst the DDU, measurement cabinet and filter assembly are essentially interchangeable, the systems are
generally tested as complete units in the factory.
4.2. Additional Materials
: 48V DC power supply
: heated sample line (when required), together with associated controller. The sample
line should have a minimum i/d of 7mm and should be controlled at a minimum
temperature of 60oC.
: compressed air interconnections - The inlet connector to the measuring cabinet is a

∅6mm push fit. However, it is recommended that only the last section (less than 2m) of
the compressed air supply pipe is in ∅6mm piping. NB. During back-purging when
using 120 litre/min the supply pressure at the monitor should not drop by more than
0.5bar.
: compressed air supply regulator, dryer and filter. NB. The compressed air supply must
not exceed 7bar as this may result in damage to internal pressure transducers within
the system. For correct operation of the valve arrangements the pressure must be
greater than 5bar.
5. Installation
5.1. General
The CO gas analysing system may be connected directly to the outlet duct of the coal mill or indirectly via a
heated sample line. If the system is to be installed using a heated sample line then the measurement cabinet
should be sited as near as possible to the location of the stainless steel filter assembly on the duct. The
maximum permissible length for the heated sample line is 20m.
Where the measurement cabinet is to be mounted directly to the duct take care to ensure that duct vibration at
the selected mounting point is minimal as severe vibration may cause malfunctioning of the instrument or at
worst a catastrophic failure of the duct wall due the effects of continuous vibration. For a duct-mounted
application the rear of the measurement cabinet will be equipped with factory-fitted stiffening spars for added
rigidity.
5.2. Site Mounting Flange
Use suitable protective clothing including eye protection. Positive pressure in the duct will
cause hot gases and dust to be vented from the open port.
The site mounting flange that carries the stainless steel filter assembly should be mounted on the top or side of
the mill outlet duct, as shown in Figure 4. Do not mount the flange on the underside of the duct.
9
9 9
8
Figure 4 : Filter Assembly Location
Weld the site mounting flange to the mill outlet duct in the selected position; if necessary stiffening ribs may be
welded under the site mounting flange as shown in Figure 5. Where the measurement cabinet is direct-mounted
to the duct the site mounting flange should be mounted with the bolt holes in the orientation shown in Figure 5.
However, if the measurement cabinet is to be mounted remotely the orientation of the site mounting flange
(Figure 6) is not important.
Ç
Top of Cabinet
Cabinet
Centreline
Figure 5 : Site Mounting Flange (Direct-Mounted System)
Figure 6 : Site Mounting Flange (Remote-Mounted System)
5.3. Measurement Cabinet
5.3.1. Direct-Mounted Installation
Mount the stainless steel filter assembly onto the site mounting flange using the bolts and gasket provided
ensuring that the connection is gas-tight. Mount the measurement cabinet (Figure 7) onto the filter housing via
the flange on the rear of the cabinet and using the bolts and gasket provided; again ensure a gas-tight
connection.
Figure 7 : Measurement Cabinet
5.3.2. Remote-Mounted Installation
The rear of the measurement cabinet is pre-drilled to enable remote mounting; mounting hole details are shown
above in Figure 7. In this case the extracted gases from the coal mill duct are drawn into the measurement
chamber via a heated sample line. Connect the heated sample line at one end to the flange at the rear of the
measurement cabinet and at the other end to the stainless steel filter assembly via the ¼’’ BSP/10mm
compression fittings provided. Remember that the maximum permissible length for the sample line is 20m.
5.4. Data Display Unit
Mount the DDU in a suitable location near the measurement cabinet.

Figure 8 below illustrates the unit and the mounting holes at the rear. The DDU is provided with a 3m cable for
connection to the measurement cabinet.
110mm
Rear of
DDU
4 x mounting holes
∅7mm for M6 bolts
(customer supply).
140mm
Figure 8 : Data Display Unit
5.5. Wiring Connections
Wiring should only be undertaken by a qualified technician.
Ensure that the power supply to the unit is isolated.
DO NOT switch power on to the unit until all installation is complete and the system is ready for
commissioning.
Cables supplied with ferrite beads fitted to cores are intended to protect against interference and
should not be modified without consulting CODEL.
Power to the measurement cabinet should be provided via a 48V power supply unit (customer supply). The
wiring connections are illustrated below in Figure 9.
Figure 9 : Wiring Connection Schedule
5.6. Compressed Air Connections
The compressed air must be clean, oil-free and dry to -20oC. The compressed air supply is connected to the
measurement cabinet via a 6mm push-fit connection. The maximum air flow required is 120 litre/min @ stp.
It is recommended that only the last few metres (i.e. less than 5m) of the air supply line is in 6mm tubing. Using
a greater length of air supply line in 6mm tubing may limit the supply to less than 120 litre/min.
Prior to connecting the air supply line to the measurement cabinet it is advisable to purge the line for
approximately 1 minute to remove any fine dirt particles that could otherwise block the 0.175mm restrictor.
6. Commissioning
The analyser should now be fully installed and ready to be commissioned. This involves the following basic
procedures that can be carried out with the plant ON or OFF:
• analyser configuration
• initialisation
• zero calibration
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 in this Technical Manual.
Although the analyser 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.
It is also recommended that if unfamiliar with this equipment, Sections 1 & 2 should be read before proceeding
further.
Finally:
Check that the compressed air supply is:
• dry and oil-free, and
• at a pressure between 5 & 7bar.
If the measurement chamber is mounted remote from the sample filter assembly it is advisable to adjust the air
supply regulator to the air pump in order to achieve a sample flow of between 1 and 1.5 litre/min. A supply
pressure of typically 1bar will be required for the majority of applications. Additional equipment required to set
this flow is a flow monitor which can monitor a range of 0.5 to 1.5 litre/min. The flow monitor should be
temporarily installed between the air filter assembly and the measurement cabinet.
NB. This can only be carried out after power-up as the system will be in back-purge prior to power-up.
6.2. Normal Start-Up Sequence
a) Switch ON the power supply - if final connection of power supplies has been left until the commissioning
stage note that the requirements are 48V DC, 125W.
b) Wait for the analyser to stabilise (approximately 1 hour) when internal temperatures are in control.
c) Ensure that the plant air supply is connected at 5-7bar – if this pressure is low data will be invalid.
d) Ensure that there are no leaks in the system – check all gaskets, connections and the sample line
(where fitted).
e) Perform an ‘Initiate Back-Purge’ sequence (remote-mounted systems only).
f) Initiate the ‘Zero Calibration Procedure’.
g) The analyser should now be ‘data valid’ and measuring.
7. Normal Operation
7.1. Introduction
After the instrument has been commissioned it will measure the CO levels between the transmitter (Tx) and the
receiver (Rx) and produce an output proportional to the CO levels. The DDU’s integral 32-character display also
shows the calculated levels.
The DDU allows the operator to interrogate the micro-processor to observe the system parameters and to
change them if required.
A menu-based program is used and access is gained by four keys mounted in the cover of the DDU.
7.1.1. Measurement
Once commissioning has been concluded the absorption of IR radiation is measured and a parameter ‘Y’ is
calculated. This value is used to produce a final concentration of CO.
The instrument computes four averages any one of which can be used to drive the analogue output or display it
on the integral LCD of the DDU.
7.1.2. Calibration
During the commissioning procedure a calibration is conducted that sets the calibration constant to produce a
zero level. Once the routine has been conducted the calibration of the instrument is obtained at zero gas level.
7.2. Normal Start-Up Procedure
Power-up the system and wait for 30 minutes. This allows time for the infrared source to heat up. Once the
receiver is detecting a signal a reading will be seen on the SPU display. This should be in normal operating
mode, Mode 1 (shown by a number 1 at the top left corner of the LCD); a reading in ppm will be shown. If this is
so, the system is functioning properly.
7.3. Modes of Operation
The instrument has five modes of operation identified by a number in the top left-hand corner of the display :
• Mode 1 - Operating Mode
- displays average gas concentrations.
• Mode 2 - Parameter Mode
- displays operating parameters.
• Mode 3 - Chamber Mode
- displays measuring chamber data.
• Mode 4 - Diagnostic Mode
- investigates instrument operation. Self-checks are continually made by

the instrument.
• Mode 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 a security code.
The outputs of the instrument are unaffected by key operation in all modes except the set-up
mode.
Figure 10 : Keypad
7.4. Key Operation
Each mode is accessed sequentially by each push of the MODE key. Figure 10 illustrates the display and keys
of the DDU. After a mode has been selected, the ARROW 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.
• 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.
• Arrow Keys
Pressing the ARROW 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.
• 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, or
- 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.
7.5. Program Tree
Figure 11 illustrates the main program of the instrument. When an operating mode is complex, an extra program
tree is given in this section.
Figure 11 : Program Operation Tree
7.6. Operating Mode
From this mode of operation the averaging time of the displayed gas concentration may be altered to one of the
other averaging stacks, and the measured/normalised gas measurements observed. When in this mode, the
display will appear similar to that shown below. If the display is not similar to this, press the MODE key until
number 1 appears in the top left corner of the display.
1 CO 0015ppm
Measured 30s
To change the data displayed press the ENTER key and a flashing cursor will appear at the beginning of the
concentration units, i.e. ppm. The ARROW keys will now change the highlighted parameter. Each push of the
ENTER key will select another of the parameters, in the following order:
- Concentration Units – ppm
- Measured or span gas display (used to indicate current gas flow conditions)
- 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.
7.7. 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 ARROW 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.
• Identification
The analyser type, identity number (set via the rotary switch on the micro-processor card), and EPROM program
ID are displayed from this option. Use the arrow keys to scroll between these options.
• Parameters
The following parameters are examined from this option, selected using the ARROW keys :
- Measurement Path Length - the path length currently used to calculate the gas
concentration.
- Span Factor - from the SET UP MODE – the sensitivity of the instrument can be
adjusted. This will originally be conducted by CODEL at the factory using known gas
concentrations.
- Output Fault - should a fault condition occur, the analogue output can be set from one
of four options.
See 7.10. Set-Up Mode. The selected option may be examined here.
• Averages
Selecting this option will display the times set for each of the four averaging stacks.
• Output
The base, span and averaging of the analogue output are displayed from this option.
• Alarm
A changeover relay contact output is available to indicate a high gas concentration. The level at which this
output is operated, and the averaging stack from which the gas value is obtained, may be examined from this
display.
• Plant Status
This displays Plant ON.
• Clock
The real time clock may be viewed from this display.
• Auto Cal
The parameters for Automatic Zero Calibration are displayed here.
- Interval - the timed interval set between automatic zero calibrations.
- Logic - ON/OF triggering of zero calibration via plant status contact input.
OFF – option not selected.
ON – option selected.
- Cal Alarm - alarm 1 relay option to indicate zero calibration in progress.

OFF – option not selected.
ON – option selected.
- Next Cal. - time/date to next calibration when using timed interval.
7.8. Chamber
Press the MODE key until the number 3 is seen in the top left corner of the display. From this mode the
parameters currently being used to control the measurement chamber can be displayed. Press the ENTER key
to enter the routine and use the ARROW keys to select either temperature or pressure parameters to display.
When the required parameter is displayed press the ENTER key to display the data. Press the ENTER key
again to exit the parameter.
7.8.1. Display Format
The display will appear similar to those shown below for each of the chamber parameters.
3 Temp 060.09oC 3 Pressure

Power 025.1% 101.3kPa
7.9. Diagnostic Mode
The detector levels, thermistor data, ‘Y’ & ‘Z’ values, CO values, cal. data and the fault condition may be
examined from this mode. Press the MODE key until number 4 appears in the top left corner of the display and
press ENTER to enter the mode.
The ARROW keys will now select from the following list; press the ENTER key to select the displayed option.
Figure 12 : Diagnostic Mode Tree
7.9.1. Detector Outputs
Detector output levels are displayed here. D2 is the reference level and should always be less than D1. The
level of D1 should be between 15,000 and 25,000. D2 should be approximately 0.68 x D1 with zero gas levels.
4 D1 = 24765
D2 = 11464
….. and after the smoothing filter has been applied;
4 D1(S) = 24760
D2(S) = 11462
7.9.2. Thermistor
The thermistor measurement value is displayed here; this is an indication of the detector internal temperature.
4 Therm = 04095
CmA = 0375.2
7.9.3. Y & Z Values
A parameter ‘Y’ determines the calculation of the gas concentration. As a check on the program operation, this
parameter and the resulting raw gas calculation, may be interrogated here. Z is the Y value after the application
of any necessary corrections.
4 Y (0) = 10127
Y (S) = 10129
4 Z (0) = 10126
Z (S) = 10126
(S) indicates that the smoothing filter has been applied.
7.9.4. CO Values
Shown here is the gas concentration measured by the analyser. Note that ‘ppm’ is the ‘ppm*m’ value corrected
for path length.
4 CO (0) = 0084ppm*m
CO (S) = 0408ppm
7.9.5. Calibration Data
The calibration factors, determined during the calibration routine (Kcal), and the value currently being used
(Kwkg) can be examined from this display. Should the two values be different, this indicates a change in
instrument temperature between the time of calibration and the current temperature. Press one of the ARROW
keys to examine the temperature information.
4 Kcal 42536
Kwkg 42536
Temperature has a small effect on the filter/gas cell characteristics compensated for by the instrument;
temperature measurement is made within the receiver.
o
4 Rx C = 30.3
o
Cal C = 30.1
Detector levels at calibration -
D1 cal = 24567
D2 cal = 11297
7.9.6. Fault Condition
This display indicates whether the measurement zone purge is ON or OFF.
4 Span Gas 4 Zero Purging

OFF OFF
By pressing the arrow key the current fault condition can be observed.
4 Diagnostic
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 :
• *ALL CLEAR* – no fault condition.
• D1 Æ Low - the detector D1 is too low for correct operation.
• D2 Æ Low - the detector D2 is too low for correct operation.
• D1 Æ High - the detector D1 is too high for correct operation.
• D2 Æ High - the detector D2 is too high for correct operation.
• D1 Æ Saturated - the detector level within the transducer is too high.
• Therm > Range < - the detector temperature is not stable enough for correct operation.
• RxToC Æ High - the temperature of the transducer is too high for correct operation.
• SCwkg < Range > - the calibration constant obtained during the calibration is incorrect.
• Tx IR Failure - the voltage across the IR source is out of range implying that the IR source failed.
• Temp > Range < - the temperature of the measurement chamber is out of range.
• Press > Range < - the pressure measurement is out of range (plant air supply may have failed).
• Filter Æ Blocked – the pressure measurement decay rate of the last back-purge cycle is too long
implying that the sample filter is blocked.
• Comm Failure – the SPU has lost communications with the transceiver via the 4-wire bus.
By pressing the arrow key the previous fault condition can be observed.
4 Previous fault
D1 Æ Saturated
If a fault condition exists, the minutes, hours and days averages will not be updated.
7.10. Set-Up Mode
All operating parameters – averaging times, output settings, chamber 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 6 sub-modes of operation from which the set-up parameters may be changed
(see Figure 13); these are:
- Set Averages - the four averaging stack times (seconds, minutes, hours and days) may be set as
required.
- Configure O/P 1 & 2 - analogue output set up – origin, units, span, rolling average and fault condition.
- Alarm 1 & 2 – source and level set-up.
- Parameters - the following are set from this mode - security code, span factor and clock.
- Chamber - all pressure parameters may be set up from this mode.
- Calibrate - the zero calibration of the instrument can be set.
After the correct code has been entered, the user may access each of the six sub-modes (listed above) by using
the ARROW keys and pressing ENTER when the required option is displayed.
7.10.1. Security Code Entry
Once the display is as shown here, press the ENTER key to gain access to the set-up mode. 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.
5 SET UP MODE
Security # 0000
The code number will be set to 0000 by CODEL at the factory and should be changed by the user from
within the set-up mode.
Figure 13 : Set-Up Mode Tree
7.10.2. 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 predefined limits.
5 SET AVERAGES
Press the ENTER key when this display is shown, the display will now show one of the averages. Use the
ARROW 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 ARROW keys and input by pressing the ENTER key.
5 SET AVERAGES
secs 60
Set the seconds averaging stack to the required value. This is limited to within 10 to 60 seconds in10-second
intervals.
5 SET AVERAGES
mins 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
hours 24
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
days 30
Set the days averaging stack to the required value. This is limited to within 1 to 30 days in 1-day intervals.
7.10.3. Reset Averages
The rolling average data will be cleared from memory – consider carefully before using this option.
5 RESET AVERAGES
Reset YES
The average values that are currently held in the four averaging stacks, can be reset using this option; this will
erase the current average that is held in all of the averaging stacks. Select this option by pressing the ENTER
key and using the ARROW keys. Confirmation is requested before the averages are reset.
If this option is selected, all data in the averaging stacks is reset and the data for as much as the last 30
days will be lost.
7.10.4. Configure O/P 1 & 2
5 CONFIGURE O/P
The analogue current loop output is set up from this mode. Press the ENTER key while this display is shown to
select it, then press the ARROW keys to step through the available options. Press the ENTER key to enter each
option and change the displayed parameter.
• Base of Output
5 CONFIGURE O/P
OUTPUT = 4 TO 20mA
An origin of 0 or 4mA can be set for the current loop output. The ARROW keys will ‘toggle’ between these two
options. Press the ENTER key to enter the new value.
• Averaging Time of the Output
5 CONFIGURE O/P
Average 10s
Any of the four averaging stacks (seconds, minutes, hours and days) may be used for the analogue output.
They are selected by the ARROW keys and entered using the ENTER key.
• Output Units
5 CONFIGURE O/P
Units ppm
The analogue output can represent the gas concentration in units of ppm. – no adjustment (for reference only)
• Output Span
5 CONFIGURE O/P
Span 00000ppm
Select the required span using the ARROW keys for each digit. The ENTER key is pressed to enter the value of
each digit. The units will be displayed in ppm. The current value will be displayed for 1 second when this option
is entered.
The display then defaults to zero; the span value must be re-entered for the unit to function correctly.
• Fault Indication
5 CONFIGURE O/P
Fault cond ZERO
Should a fault condition occur, the current output of the instrument may be set to one of the following options:
- set the output at 0mA – ZERO
- adjust the output to the calculated gas concentration even though a fault condition
exists – MEAS
- hold the last calculated gas concentration – HOLD
- set the output to full scale (20mA) – F.S.
One of these options can be selected by pressing the ARROW keys; when the desired option is displayed press
the ENTER key.
• Set mA Output
This is set at the factory and should not be altered without due consideration.
5 CONFIGURE O/P
Set Zero (0100)
From this option the current levels of the analogue output are set. Press the ENTER key to select it and the
operator is prompted to set the current levels at 0 to 20mA.
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.
The value is adjusted using the two arrow keys; the UP arrow will take the current output up and the DOWN
arrow will take it down. Press the ENTER key when the correct output current is displayed on the ammeter.
Zero mA should be set up no matter what has been selected as the base of the current output. This is
factory set by CODEL.
In a similar manner to above, the current output level should now be set to 20mA.
5 CONFIGURE O/P
Set Span (4000)
Now repeat the above procedure for O/P 2.
• Alarm 1 & 2
5 ALARM
Source 15m
A contact output is available to warn of a high gas concentration. This contact output may be triggered from any
of the four averaging stacks. Select the source with the ARROW key and enter it with the ENTER key.
5 ALARM
Units ppm
Select the units for the alarm – these are not adjustable (for reference only).
5 ALARM
Level ppm
After the source has been selected, the instrument requires a level that the output will be triggered. Set the
desired level with the ARROW keys.
7.10.5. Parameters
5 PARAMETERS
Select this option by pressing the ENTER key. The ARROW 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.
• Security Number
5 PARAMETERS
Security # 0000
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 ARROW
keys.
• Span Factor
Do not enter this mode without first recording the original span factor – this value is displayed in Mode
4. The span factor will be lost when this menu option is entered.
5 PARAMETERS
Span Factor
During the factory test the instrument has a span factor entered that sets the span calibration of the instrument.
This value may be changed from this mode.
As this value controls the calibration of the instrument do not change it without due consideration.
• Set Clock
5 PARAMETERS
Set Clock
The date and time of the real-time clock used for the timed calibrations is set here.
7.10.6. Chamber
5 CHAMBER
All of the measurement chamber inputs and parameters are set up from this mode. Press ENTER to access the
mode and the ARROW keys. The only input range available is for pressure.
7.10.7. Pressure
5 PRESSURE kPa
4mA = 000 20mA = 405
The measurement chamber pressure transducer input range is set here. The 4-20mA inputs within the
processor receive measurement transducer data; the values at 4mA and at 20mA will be requested.
The pressure transducer used in the system is rated at 0-405kPa.
To correct the data to a standard pressure – normally 101kPa, the pressure at the point of measurement needs
to be determined.
7.10.8. Calibrate
5 CALIBRATE
From this option the calibration routine may be set up as follows:
• Set Cal Data
5 CALIBRATE
Set Cal Data
Set the time required for purge air to clear the measurement zone of the probe and also the required number of
C-cycles (typically 30).
The measurement zone is located between the IR source and the receiver. Extracted sample gases are drawn
into the optical path of infrared beams in the measurement zone.
For correct zero calibration it is important that the measurement zone is completely cleared of gases by purging
for a sufficient time before zero calibration takes place. The regulator next to the solenoid valve should be set to
50psi. Purge air is exhausted through the air mover to atmosphere.
If the measurement zone is not adequately purged then the zero calibration will take place with gases still
present, causing the gas concentration to read low. Assume a minimum purge time of 10 minutes.
• Zero Cal
The zero calibration procedure is activated here. The purge time countdown is displayed in seconds and the
calibration measurement cycle countdown (8 x C-cycles).
The calibration routine must be run during commissioning otherwise the analyser will not be able to
calculate the true level of gas in the duct.
• Zero Purge
The solenoid valve controlling the purge air to the measurement zone is activated here.
• Span Gas
The solenoid valve controlling the span gas to the measurement zone is activated here.
• Back-Purge
The sequence of solenoid valve operations to pulse air into the filter is activated here. This is set to give five air
pulses into the sample filter in an attempt to clear any blockage. It is important that this filter is kept clean. The
final pulse of air is meant to determine if the filter is blocked and takes 16 seconds to complete.
• Auto Cal
The auto-calibration routine may be set up and initiated from here as follows:
Auto Cal → Initiate → Cal Timer → Interval

↓ ↓ ↓
Cal Alarm Logic → Logic → Yes Next Cal
Input
↓ ↓ ↓ ↓
Exit Exit No Exit
o Initiate
- allows selection of automatic zero calibration operation.
o Cal Timer
- uses the on-board real-time clock to time zero calibrations.
o Interval
- sets the interval between zero calibrations (i.e. 48hrs = once every two days).
o Next Cal
- this is the start time for the interval (i.e. 2400hrs = start from midnight and repeat frequency
timed by interval).
o Logic
- if (and only if) the plant status contact inputs +PS & 0PS (terminals 22 & 23) are not used for
plant status, then they can be used to remotely initiate the zero calibration routine.
o Logic Input YES
- shorting together terminals 22 & 23 briefly (5 seconds) will activate the zero calibration routine.
DO NOT LEAVE THE TERMINALS SHORTED TOGETHER.
o Logic Input NO
- option inhibited.
o Cal Alarm
- YES - this will switch Alarm 1 relay when the calibration routine is in progress.
- NO - option inhibited.
• Initiate Back-Purge
After the system is set up it is essential to ensure that no leaks are present and that a clean, dry, oil-free
compressed air supply is connected before the back-purge sequence is initiated.
- the Initiate Back-Purge sequence comprises three back-purges, the results of which are later
used for comparison with subsequent back-purge operations in order to determine filter
blockage. The resulting time is only displayed at the end of the sequence.
- The back-purge sequence of solenoid valve operations to pulse air into the filter is activated
here. This is set to give five air pulses into the sample filter in an attempt to clear any blockage.
It is important that this filter is kept clean. The final pulse of air is meant to determine if the filter
is blocked and takes 16 seconds to complete.
7.10.9. Alarms and Emergency Conditions
The alarm thresholds for the system are set as described in the normal operating mode. When an alarm 1
condition is obtained the red LED on the signal processor will light up. This will go out when the alarm condition
has cleared. The 4 to 20mA output from the analyser will also alter according to the pollution levels detected.
7.11. Emergency Shutdown/Isolation Procedure
Shut OFF the power to the PSU and the whole system will close down.
8. List of Figures
Figure 1 : Mounting Arrangements 1
Figure 2 : Inside the Measurement Cabinet 2
Figure 3 : System Schematic 2
Figure 4 : Filter Assembly Location 7
Figure 5 : Site Mounting Flange (Direct-Mounted System) 7
Figure 6 : Site Mounting Flange (Remote-Mounted System) 8
Figure 7 : Measurement Cabinet 8
Figure 8 : Data Display Unit 9
Figure 9 : Wiring Connection Schedule 9
Figure 10 : Keypad 13
Figure 11 : Program Operation Tree 14
Figure 12 : Diagnostic Mode Tree 17
Figure 13 : Set-Up Mode Tree 21

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TECHNICAL MANUAL

CODEL International Ltd.

CODEL International Ltd is a UK company based

The constant search for new products and

All development and design work is carried out

High priority is placed upon customer support.

If you require any further information about

t : +44 (0) 1629 814 351

1. Coal Mill CO Gas Analysing System 1

4. Preparing for Installation 6

7.10. Set-Up Mode 20

Caution, risk of electric shock.

Caution, risk of danger.

Caution, hot surface.

Earth (ground) terminal.

Protective conductor terminal

1. Coal Mill CO Gas Analysing System

DDU Measurement chamber Stainless steel Heated sample line

Air outlet Alternative Mounting

Figure 1 : Mounting Arrangements

Figure 2 : Inside the Measurement Cabinet

1.2. System Operation

A schematic illustration of the CO Gas Analysing System is shown below.

Figure 3 : System Schematic

Span : selectable up to 10000ppm.

Accuracy : 10ppm or +2% span (whichever is the greater).

Compliances : EMC 89/336/EEC directive compliant.

: Low Voltage 73/23/EEC directive compliant.

Logic Outputs : 2 x volt-free SPCO contacts, 50V, 1A max. configurable as

: 1 x volt-free SPCO contact, 50V, 1A max. for data valid.

Display : 32-character alpha-numeric back-lit LCD.

Keypad : 4-key soft-touch entry.

Ambient Temperature : -10 to +45oC.

Analyser Protection : all units are constructed to IP68 standards.

Power Requirement : 48V DC, 125W.

4. Preparing for Installation

• standard supplied items:

: 1 x stainless steel filter assembly

4.2. Additional Materials

: 48V DC power supply

: compressed air interconnections - The inlet connector to the measuring cabinet is a

5.2. Site Mounting Flange

Figure 5 : Site Mounting Flange (Direct-Mounted System)

Figure 6 : Site Mounting Flange (Remote-Mounted System)

5.3. Measurement Cabinet

5.3.1. Direct-Mounted Installation

Figure 7 : Measurement Cabinet

5.3.2. Remote-Mounted Installation

5.4. Data Display Unit

Mount the DDU in a suitable location near the measurement cabinet.

Figure 8 : Data Display Unit

5.5. Wiring Connections

Wiring should only be undertaken by a qualified technician.

Ensure that the power supply to the unit is isolated.

Figure 9 : Wiring Connection Schedule

6.1. Pre-Commissioning Checks

Before proceeding the following checks should be carried out:

Check that the compressed air supply is:

• dry and oil-free, and

• at a pressure between 5 & 7bar.

6.2. Normal Start-Up Sequence

e) Perform an ‘Initiate Back-Purge’ sequence (remote-mounted systems only).

f) Initiate the ‘Zero Calibration Procedure’.

• ALL CLEAR – no fault condition.