5.1 CEMS - Manual - Forbes Marshal

CODEL
020038
G-CEM 4000
Multi-Gas Analyser
Installation, Commissioning, Operation
and Maintenance Manual
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CODEL International Ltd. is a UK company based in Bakewell, Derbyshire,

specialising in the design and manufacture of high technology instrumentation
for monitoring combustion processes and atmospheric pollution emissions. The
company philosophy is simply, to design well-engineered, rugged and reliable
equipment, capable of continuous operation over long periods with minimal
maintenance.
While every effort has been made to ensure that this manual is free from errors,
CODEL supply all information without warranty.
CODEL International Ltd.

Station Building, Station Road
Bakewell, Derbyshire DE45 1GE
England
Tel
Fax
e-mail
web site
: +44 (0) 1629 814 351

: +44 (0) 8700 566 307
: codel@codel.co.uk
: www.codel co.uk
CODEL International Ltd. September 2002
We reserve the right to modify designs without prior notice.
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Table of Contents
1. CODEL G-CEM4000 Analyser Introduction
1.1. Foreword
1.2. Basic Principles
1.3. Emission Monitoring and the G-CEM4000
1.4. User Interface
1.5. Analogue and Logic Inputs and Outputs
1.6. CDC Serial Port - for use with the CODEL IEM system
1.7. Analyser Protection
2. Summary Specification
10
3. Preparing for Installation
13
3.1. Unpacking.
13
3.2. Additional Materials
15
3.3. Ancillary/Additional Equipment
17
3.4. Services
18
4. Installation
19
4.1. Selection of Measurement Position
19
4.2. Analyser Positioning
21
4.3. Fitting of Stub-Pipes and Mounting Flanges
23
4.4. Installation of Purge Air Supply
26
4.5. Installation of Measurement Tube
26
4.6. Fitting the Transceiver
29
4.7. Installation of the Junction Box
29
4.8. Installation of GCU
29
4.9. Wiring Connections
31
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4.10.Installation of Normalising Measurements (Oxygen, Temperature
37
and Pressure)
4.11.Installation of Calibration Gases
5. Commissioning
37
39
5.1. Pre-Commissioning Checks
39
5.2. Power On
40
5.3. Initial Set-Up Using SmartCOM Software
40
6. Analyser Records
68
6.1. Serial Numbers (Complete on First Inspection)
68
6.2. Installation Records
68
6.3. Commissioning Records
68
7. Calibration and Measurement Verification
70
7.1. Introduction
70
7.2. Factory Calibration
70
7.3. Verification
70
7.4. Re-calibration
73
8. Maintenance
74
9. Fault Finding
75
Appendix 1 Setting Analyser Gains
76
Appendix 2 - Output Memory Map
77
List of Figures
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1. CODEL G-CEM4000 Analyser Introduction

Please take a few minutes to read this section before proceeding with
installation. It is designed to provide an overview of the analyser and its
capabilities so that the information given later will be more easily
understood.
1.1. Foreword
SmartCEM is the ultimate solution for continuous monitoring of flue gas
emissions. It is a fully integrated monitoring concept from the basic analysers
and their calibration verification packages through to digital communications,
data logging and automatic reporting.
At the heart of this concept is the SmartCEM station containing all the analysers
and monitors to provide comprehensive stack emission monitoring. The
SmartCEM Station Control Unit (SCU) provides power to and communicates
with the analysers and monitors within that station.
Data from up to 32 SmartCEM stations is transmitted via a serial digital link
(CODEL SmartBUS) to the Central Datapoint where it is logged on a dedicated
pc or assembled for onward transmission to a plant computer or DCS.
The arrangement of a typical SmartCEM system is illustrated in Figure 1.
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Figure 1 : Typical SmartCEM System Arrangement
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1.2. G-CEM4000 Basic Principles

The G-CEM4000 analyser uses an in-situ probe set into a duct to measure the
concentration of gases of interest. Figure 2 illustrates the arrangement. The insitu tube includes a section that allows the diffusion of flue gases into the
measurement zone or the dispersion of purge or calibration gas out of the tube
and into the duct. This section of the tube is the analysers measurement cell.
The analyser is capable of simultaneous measurement of up to six different
gases (plus water vapour as a seventh measurement if required).
As with conventional cross-duct analysers, this probe configuration does not
require the extraction of a sample from the gas stream and makes its
measurement by analysing the way in which infrared radiation, transmitted
through the measurement section of the probe, is modified by the gases
present.
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Figure 2 :G-CEM4000 Analyser with 'in-situ' Probe
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The transceiver unit containing the infrared source and detector system,
required to measure the received light energy after its passage through the gas,
is totally isolated from the flue gas. There is, therefore, no contact between the
analyser electronics and the flue gas. Correctly installed and commissioned,
this provides the opportunity to achieve very low maintenance factors and
totally eliminates any possibility of altering the composition of the flue gases to
be measured.
The remaining components of a G-CEM4000 analyser are :
The Gas Control Unit (GCU) that controls the input of zero and span
calibration gases into the analyser. It contains the necessary
compressed air filtration and drying equipment to ensure high quality air
supply for the zero calibration and probe purge functions. The analyser
power supply and Station Control Unit (SCU) are also housed within the
GCU. The function of the SCU is as an emissions data processing unit,
communications centre for the monitor and controller of the zero and
span calibration functions. The SCU also acts as a data logging device
in which hours emission and diagnostic data is stored for retrieval in the
case of loss of main data logging in the remote pc or DCS system.
A Junction Box through which is routed the cabling from the transceiver
and the temperature, pressure and oxygen sensors and the cable to the
GCU. The unit should be mounted local to the analyser.
The Central Data Controller (CDC) that accepts data from 1 to 16

SCUs and processes the data for onward transmission to a remote pc or
SCADA system.
All elements of the G-CEM4000 analyser are sealed to IP65 (NEMA 4)

standards. The optional weather shield for the transceiver is recommended for
outdoor installation as it reduces the effects of direct sunlight, wind chill or the
cooling effects of rain.
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1.3. Emission Monitoring and the G-CEM4000

Although G-CEM4000 analysers can be used for process gas analysis, they
have been primarily designed to monitor pollutant emissions from industrial
stacks. Legislation governing such emissions usually requires data to be
reported in very specific formats. G-CEM4000 analysers are therefore designed
to fulfil this requirement without the need for external data manipulation.
Although differing in detail from country to country, the essential demands of
legislation are common world-wide.
1.3.1. Normalisation
Emission limits are always defined under standard conditions of temperature,
pressure and air dilution (air dilution is defined using the waste gas CO 2 or O2
concentration). Most legislation also requires concentrations to be reported on
a dry basis; i.e. water vapour in the flue gas is not permitted to dilute the
measurement. The correction of the measurement from as measured
conditions to standard conditions is known as normalisation. Like all crossduct analysers, G-CEM4000 analysers measure concentrations of pollutant
ppm (parts per million by volume) or %, under the conditions at the
measurement position.
This basic ppm measurement is always corrected for the duct pressure and
presented as vpm by the analyser. G-CEM4000 analysers have the capability
for the outputs and display to be configured in vpm (or %) or mg/m 3 (which is a
mathematical conversion depending on the molecular weight of the gas being
measured and the flue gas temperature), or in mg/Nm 3 (i.e. normalised to the
required standard conditions).
When the outputs are required to be normalised to a pre-defined O 2
concentration as opposed to a CO 2 level, then an external O 2 4-20mA signal
representing Oxygen levels can be input into the G-CEM4000. All other
normalising parameters i.e. pressure, temperature, and CO 2 are measured as
standard by the G-CEM4000
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1.3.2. Verification
It is important that the accuracy of measurement can be verified. Often,
legislation requires the regular testing, reporting and correction of measurement
zero and span. G-CEM4000 analysers are equipped with automatic zero
verification and correction procedures that allows the measurement cell to
be flooded with dry air (or Nitrogen) to provide a zero check or a certified
calibration gas as a span verification.
1.4. User Interface
The analyser is supplied with SmartCOM pc software that enables a pc
connected to the SCU to display of all real-time measurements as well as the
setting up and display of all the analysers configurable operating parameters.
This interface includes a diagnostic mode that allows interrogation of the
condition of the analysers critical functions for service and trouble-shooting
purposes. A full description is provided in Section 5.
1.5. Analogue and Logic Inputs and Outputs
The G-CEM4000 SCU is equipped with an analogue output (0/4-20mA) for
each measurement channel (up to seven). Each output is freely configurable
for any span (within the limits for that measurement, as given in Section 2.
Summary Specification and measurement units (vpm or %, mg/m 3, mg/Nm3).
Volt-free contact outputs (250V/10A) are provided for data valid and
measurement alarm level (common output for all measurement channel
alarms).
Three 4-20mA inputs are provided for normalisation measurements (273
input impedance, 200V DC common mode voltage range). These inputs
are also able to provide isolated 24V DC supplies to drive either 2 or 3wire external normalisation measurement transducers.
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1.6. CDC Serial Port - for use with the CODEL IEM system
The CDC is equipped with a 2-way serial communications port for use with the
CODEL IEM system. On a plant where more than one CODEL analyser is
installed, this is the preferred method and, even for a single analyser
installation, can provide significant benefits. The main ones are:
Up to 32 SCUs can be connected to a CDC via a single data bus.
No corruption of digital data, even over long distances.
Common data (e.g., normalisation measurements and plant status)

can be transmitted to all relevant measurement channels and
analysers from a single input.
Real time display can show all measurements simultaneously.
Multi-level and period alarms can be freely configured for any

measurement data set.
Up to 5 years data can be logged and instantly recalled in graphical

or tabular format.
All processor user interface functions can be carried out from a

central control point, i.e. once physical installation is complete, all
commissioning operations can be carried out from the central control.
Thereafter, real time analyser operating parameters, including
diagnostic data, can be accessed at any time.
All real time and historical data and diagnostics can be accessed
remotely via a MODEM.
Reports can be formatted to suit local legislation and printed

automatically.
Digital data can be transferred directly to the plant DCS or computer.
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1.7. Analyser Protection

G-CEM4000 analysers are designed for outdoor installation and all units are
constructed to IP65 (NEMA 4) standards and are designed for ambient
temperatures from -20o to +55oC. For outdoor installation, an optional weather
shield is recommended for the transceiver.
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2. Summary Specification
Measurements
Main measurement channels (1-7)
any combination of up to seven gases from
CO/CO2/NO/NO2/SO2/HCl/UHC/H2O
Measurement Limits (maximum)
CO/NO/NO2/HCl/UHC
SO2
CO2/H2O
3000 vpm
25000 vpm
25%
Measurement Spans
CO/NO/NO2/SO2/HCl/UHC
CO2/H2O
selectable up to 9,999vpm
selectable up to 99%
Note that although very low spans can be configured, this should not be
done without consideration of the measurement uncertainty.
Measurement Uncertainty
CO2
H 2O
Other gases
is the greater).
0.2%
0.2%
10vpm or 2% of measurement (whichever
Measurement Temperature (Flue gas)

0-200C (up to 400C with high temperature probe)
Measurement Units
vpm (% for CO2 and H2O)
mg/m3
mg/Nm3
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Display
via pc running SmartCOM software
real-time measurements
operating parameters
diagnostic information
set-up menus
Outputs
Analogue
(located in SCU)
Logic
(located in SCU)
Analogue
measurements
One for each main measurement channel

(channels 1 to 7) 0/4-20mA isolated
500 max. load
Fully configurable in measurement units (vpm
or %, mg/m3, mg/Nm3), and span
Inputs
Three 4-20mA inputs for normalising
237 input impedance, 200V DC common
mode voltage range (three of these inputs
incorporate isolated 24V DC supplies to
power loop-powered 2 or 3-wire transducers)
Serial Port
(located in Station
Control unit)
For connection to bi-directional 4-wire data bus

terminating at the CDC when installed as part
of an integrated emission monitoring (IEM) system
Ambient Temperature
All units are designed to operate in ambient

temperatures of -20C to +55C
Extreme climatic conditions may require further
protection
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Enclosures
All units are sealed to IP65 (NEMA 4) standards and

are suitable for outdoor installation
Power Requirements
Power Supply Unit -
85-264V AC
47-62Hz
200VA
Purge Gas Requirements

Compressed air/N2
Clean and dry to -20oC.

Normal operation 5 l/min
Calibration (10 minutes) 10 l/min
Dimensions
Transceiver and probe
Overall length
Widest diameter
Probe length
Transceiver Length
Transceiver diameter
Probe weight
Transceiver weight
2450mm
350mm
2150mm
300mm
350mm
68kg
28kg
Gas Control Unit

W800mm x H1000mm x D200mm
Weight
100kg
CDC
Weight
26kg
Junction Box
Weight
2kg
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3. Preparing for Installation

3.1. Unpacking.
The analyser 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.
If any items are missing please inform CODEL or your local CODEL agent
immediately.
3.1.1. The Basic Analyser
All items supplied as standard are illustrated in Figure 3.
Figure 3 : Standard Supplied Items and Dimensions
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The transceiver, GCU and SCU, are supplied with blanking plugs fitted in the
cable gland entry holes. Cable Glands are packed separately.
Some contracts require the mounting of all power supply,

processing and control units in instrumentation panels. In such
cases please refer to the additional system schematics supplied.
These are always contract-specific.
Although transceivers and GCUs are essentially interchangeable, analysers

are configured and tested as complete systems in the factory. If more than one
analyser is received, ensure that all units are matched.
3.1.2. Transceiver Weather Cover
Model 4000 analysers are suitable for outdoor installation in ambient
temperatures ranging from -20C to +55C. However, it is good practice to
install units in positions where they have maximum protection. Whilst this is
usually possible for the GCU and CDC, options may be limited for the
transceiver. To protect generally against exceptional weather conditions, even
in temperate climates, and particularly to facilitate servicing under these
conditions, a weather cover should be fitted on all outdoor installations. Figure
4 illustrates the optional weather cover.
Figure 4 : Optional Weather Cover
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3.2. Additional Materials

The installation of a 4000 Series analyser will require a number of materials in
addition to those supplied with the analyser. The following are intended to
cover most possibilities, but not all listed materials will be required for all
installations. See also Figure 5.
Unit
Cables
Function
SCU
CDC (if
required)
Gas
Control
Unit
No. of
Cores
Core Specification/
c.s. area
O/D
min/max
Screened
YES/NO
Mains
Supply
Multi-strand 16/0.2mm,
0.5mm2 min.
5mm/12.8mm
No
Serial
Comms
0.5mm2 min.
5mm/12.8mm
YES
Serial
Comms
0.5mm2 min.
5mm/12.8mm
YES
Normalising
inputs
0.5mm2 min.
5mm/12.8mm
YES
Analogue
outputs
0.5mm2 min.
5mm/12.8mm
YES
Fault alarm
0.5mm2 min.
5mm/12.8mm
YES
Note that screened cables should have the screen terminated as described in
Section 4. Installation. If steel wire armoured cable is used, the steel wire
sheath should be earthed at the analyser end only.
Other Materials
Stub pipe. 1 x 8 nominal bore (o/d219mm, i/d206mm), steel tube

(see Section 4.3. Fitting of Stub-Pipes and Mounting Flanges for
details).
1 x BS4504, PN16, DN200 steel flange.
Mounting brackets/panels, screws, bolts, etc. for gas control unit

and SCU/CDC.
Cable trays/conduits/ties and associated fixing materials.
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Compressed air supply (10 l/mincleaned and dry to -20C) for (a)
measurement cell purge (2 l/sec on demand) and (b) purging of
the neutral zone (0.5 l/min/sec continuous). 10mm o/d. PTFE
tube is required.
Consideration should also be given to the possible need for

temporary/permanent access platforms and lifting equipment.
Figure 5 : Additional Materials to Consider
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CODEL Supply -
Interconnecting cable, transceiver to Junction Box

Interconnecting cable, pressure transducer to
Junction Box
Interconnecting cable, temperature sensor to
Junction Box
Customer Supply -
Mains power cable

Alarm output cable
Analogue output cable
Interconnecting cable, SCU to CDC
Nylon tube to GCU (10mm o/d)
2 x Nylon/PTFE tube, GCU to Probe (10mm o/d)
Interconnecting cable, Junction Box to GCU
Note : When calculating cable requirements, remember to take into

account cable routing relative to equipment location, and also the need
for conduit, cable trays, supports etc.
3.3. Ancillary/Additional Equipment
The 4000 analyser is rarely supplied alone. It is usually associated with other
equipment that makes up an emission monitoring system. In planning
installation, consideration should be given to the requirements of other
equipment by consulting the specific manuals so that the whole system may be
installed in the most cost effective and efficient way. If the complete system
has been engineered by CODEL, detailed contract specific information and
schematics will have been provided.
Other equipment commonly provided may be:
-
CODEL IEM system (system management, data display, logging

and reporting)
Other CODEL monitors/analysers
Non-CODEL monitors/analysers
Normalising measurement - oxygen
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3.4. Services
Electrical Power
Power Supply Unit -
85-264V AC
47-62Hz
200VA
Compressed Air
@ 5bar
Dry (to -20C)
Clean (better than 10m)
Consumption :
10 l/min during calibration
5 l/min continuous
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4. Installation
PLEASE BE SURE TO READ SECTION 3. Preparing for Installation
BEFORE PROCEEDING
Installation of the several units that make up a 4000 Series analyser may be
carried out in any order. However, the recommended order, reflected in this
manual, is:
-
Selection of measurement position

Installation of the stub-pipe and mounting flange
Installation of purge air supply
Fitting of transceiver and junction box
Installation of GCU and CDC
Installation and connection of cables
Installation of normalising measurements and input connections to
the G-CEM4000
Installation of span verification gases
4.1. Selection of Measurement Position

This analyser measures the average concentration of gas across a significant
proportion of the width of the stack or duct. Measurement position is therefore
not as critical as with single point measuring systems, where consideration must
be given to ensuring representative results. Nevertheless, positions where
significant stratification might occur are best avoided. On most combustion
plant, flue gas homogeneity can be guaranteed after the ID fan, so from this
point of view, the selected position could be anywhere in the ductwork after the
ID fan or in the stack.
The next factor to consider is that of flue gas pressure. Choosing a position
where the flue gas is at negative pressure, compared with ambient pressure, is
not as important as it is for conventional open path cross-duct analysers.
However, it is advantageous in reducing pressure and flow requirements, to
ensure complete flooding of the measurement cell, of both zero and calibration
gases. Under normal operating conditions negative flue gas pressure exists
from 10-15m after the ID fan outlet to stack exit. If possible, open any existing
port near the selected measurement position to confirm.
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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 vibrating 84kg
continuously.
Take care in doing this. Use suitable protective clothing, including eye
protection. Positive pressure in the duct will cause hot flue gases to be
vented from the open port.
The final factors to be considered in selection of measurement position are
those of convenience and cost of installation. Access from existing platforms or
walkways and proximity of existing services are obvious advantages, both for
installation and subsequent commissioning and servicing. Drilling holes in
metal ductwork or flues is easier than drilling concrete stacks. Also ensure that
there is enough space between the duct or stack and any other obstruction to
allow installation of the transceiver and probe. A minimum clearance of 2.25m
is required from the mounting flange. Take care that there is space to
manoeuvre the tube into position ready for insertion (see Figure 9).
Conditions vary from plant to plant but, in general, the following guidelines
should be followed:
Firstly, look for a suitable location on ductwork between the ID fan

and the stack.
Large power plant with multiple flues having concrete wind-shields

can provide good alternative mounting locations within the stack.
Access stairs, lifts and working platforms at various levels usually
exist.
On smaller plant, mounting on metal stacks is acceptable, provided

suitable access platforms exist.
Only locate analysers on single flue concrete stacks if no other

position is possible.
Do not locate analysers any higher than necessary on stacks. There is

no benefit to measurement quality and significant disadvantages for
service personnel.
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4.2. Analyser Positioning

The preferred analyser position is shown below in Figure 6.
Figure 6 : Preferred Transceiver Position

The transceiver should be angled at 50 downward to encourage condensation to
flow into the measurement tube and then dissipate.
Figure 7 : Angled Probe Installation

The measurement tube should always be on the centre line of circular ducts.
On square or rectangular ducts, the axis may be displaced from the centre line.
Figure 8 shows the recommended displacement limit.
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Figure 8 : Rectangular Ducts - Acceptable Position

In many applications, the G-CEM4000 analyser will be installed in close
proximity to other analysers. Figure 9 shows the minimum separation required.
Figure 9 : Spacing From Other Analysers
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4.3. 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,
SHOULD BE WORN.
Construct a mounting assembly (Figure 10) by welding a stainless steel
mounting-flange (BS 4504 PN16 DN150) to suitable diameter stub-pipe. This
should be 6" nominal bore (168mm o/d, 154mm i/d) stainless steel tube and
long enough to extend about 200mm outside the outer surface (including
lagging) of the duct or stack, where possible.
Cut 'slip-fit' holes in the duct at the chosen position; note that the assembly
should be installed at a 5 0 downward angle to the horizontal to allow condensate
to flow into the stack
4.3.1. Metal Ducts/Stacks
Before proceeding, note that the total weight of the measurement probe and
transceiver assembly is approximately 84kg. The duct or stack should be
appropriately strengthened if necessary (see Figure 10).
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Figure 10 : Standard Site Mounting Flange

Tack-weld the inner end of the stub-pipe to the duct/stack. Ensure that it is
aligned at least 50 downward from the horizontal.
If the analyser is not being fitted immediately it is advisable to close the stubpipe with a blanking plate (not supplied) cut and drilled to suit the fitted flange.
The mounting flange should be mounted 'four-square' on the stub-pipe as
shown in the drawing above.
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4.3.2. Concrete and Brick Stacks

A suggested stub-pipe mounting arrangement is shown below. The great variety
of stack dimensions, wall thickness and material that may be encountered do
not permit the recommendation of exact details. However, the general
guidelines, already given in Sections 4.3. Fitting of Stub-Pipes and Mounting
Flanges and 4.3.1. Metal Ducts/Stacks, may be followed. Such installations
require particular care to be taken in establishing alignment of the two stubpipes, as once fixed, they may be impossible to adjust. If in doubt, consult
CODEL before commencing installation.
Figure 11 : Typical Stub Pipe Arrangement for Concrete/Brick Stacks

4.3.3. Double Skin Stacks
Double skin stacks are often designed to allow movement between the inner
and outer skins, to accommodate thermal expansion or contraction when plant
operation changes. This can cause unacceptable movement of stub-pipes if
mounting arrangements are not designed to maintain alignment. There are too
many structural variations to provide a single solution but, if in doubt, consult
CODEL before commencing installation.
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4.4. Installation of Purge Air Supply

The G-CEM4000 requires air supplies for the pre-measurement zone and to
purge the measurement cell for zero verification. This supply should pass
through a proprietary filter unit prior to entering the GCU for further distribution.
4.5. Installation of Measurement Tube
BEFORE PROCEEDING, NOTE THAT THE PROBE IS HEAVY (UP TO

APPROX. 68KG) AND IS AWKWARD TO HANDLE,
PARTICULARLY IF ACCESS IS LIMITED. ENSURE THAT
NECESSARY LIFTING EQUIPMENT IS AVAILABLE AND THAT
PRECAUTIONS ARE TAKEN TO ENSURE THE SAFETY OF ALL
PERSONNEL, WHETHER INVOLVED WITH THE INSTALLATION
OR WORKING NEARBY.
EASE 0F INSTALLATION WILL DEPEND ON SITE CONDITIONS.
WHILE CODEL OR ITS AGENTS ARE AVAILABLE TO PROVIDE
ADVICE ON INDIVIDUAL SITE SITUATIONS, IN THE INTERESTS
OF SAFETY, THIS MANUAL DOES NOT GIVE SPECIFIC
INSTALLATION INSTRUCTIONS. SO IN THE INTERESTS OF
SAFETY, CONSIDER THE FOLLOWING :
a) Plan how the job is to be done and have all necessary lifting and
safety equipment available.
b) Ensure that all personnel involved know the plan, are adequately
protected and that there is no risk to others working nearby.
c) If the plant is operational during this tube insertion procedure,
remember that hot, dirty flue gases can cause serious injury. All
necessary protective clothing, including eye protection, should be
worn.
d) Remember that as the tube is inserted further into the duct, the
weight and moment exerted by the tube within the duct will increase,
whilst the available length of tube (outside the duct) with which to
control this will decrease.
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e) Remember that, if the plant is operating, the tube will get hot with time.
Take all necessary precautions to deal with this.
f) It may be advisable to erect a lifting beam above the proposed
location of the analyser to enable easy ingress and egress of the
probe using a hoist. The picture below shows an 'I' beam acting as a
lifting point for a hoist to carry the load of the probe and transceiver.
Figure 12 : Beam Lifting Point

The measurement tube is supplied fully assembled but without the transceiver
or air purge units fitted.
The tube is now ready for insertion into the duct or stack, through the previously
fitted stub-pipe and site mounting-flange. Note that when finally positioned the
diffuser section of the tube should be rotated so that the four rows of diffuser
disks are positioned as shown in Figure 2 in relation to the general gas flow. As
these are out of sight when the tube is inserted, mark one end of the tube so
that the correct orientation can be achieved after installation. When installing
the measurement tube, ensure that the pressure sensor is mounted above the
centre line of the probe
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Figure 13 : Position of Pressure Sensor

Use the mark previously made to rotate the tube so that the diffusion disks are
oriented to the general gas flow as shown in Figure 2. This is important!
CAUTION!
THE WINDOWS MAY BE DAMAGED BY THERMAL
SHOCK. IF THE PLANT IS OPERATING, SLIDE THE PROBE IN
GR ADU ALLY, PAUSING
FREQUENTLY TO ALLOW
TEMPERATURES TO STABILISE.
As soon as this phase of the installation is complete, air is required at the

measurement zone purge air as quickly as possible to reduce the possibility of
acid gases forming within the measurement zone. Fit the GCU and the
accompanying air lines and switch on the air (as described in 4.8. Installation of
GCU), within hours not days.
It is important to note that if the assembly is inserted into a stack made of
non-conductive material (cement, fibreglass), there is a chance that static
charge will be build up on the analyser and become injurious to personnel
and equipment. It is critical that the mounting flange be grounded to a
substantial earth conductor prior to inserting the probe.
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4.6. Fitting the Transceiver

The Transceiver may now be attached to the probe assembly using the six off
M6 x 25 setscrews provided. It is advisable to support the weight of the analyser
on the two mounting pins on the mounting flange while fitting the setscrews.
4.7. Installation of the Junction Box
Cabling from the transceiver and the temperature, pressure and oxygen sensors
are routed through the junction box. The junction box should be mounted local
to the analyser using 4 x M6 bolts. Mounting hole details are shown in Figure 3.
4.8. Installation of GCU
The GCU, shown below, is suitable for outdoor installation. The power supply
and SCU within the GCU are sealed to IP67. Permissible ambient temperature
range is 20 to +55oC.
SCU
power
supply
purge gas
filtration &
drying
equipment
zero/span
calibration
gas equipment
Figure 14 : GCU
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Mount the GCU to a suitable load bearing surface wall using 4 x M8 bolts.
Mounting hole details are shown in Figure 3. Connect the compressed air input
line to the input connector and the air lines from the GCU to the neutral zone
and measurement zone of the probe. Connect any span gases to the span
inputs of the GCU.
Connect the nylon/PTFE tube to the GCU input and the outputs to the probe
(see Figure 15). When the tubes have been connected to the probe, turn on
the compressed air. Set the regulator to the neutral zone to 10psi and a flow
rate to the measurement zone of 10 l/min. The regulators are actuated by lifting
the black cap and turning; to lock, press the cap down. The compressed air
must be clean and dry as detailed in the Section 2. Summary Specification.
zero air
solenoid
span 1
solenoid
neutral
zone
supply
measurement
zone supply
flow rotometer
span 2
solenoid
purge air
IN
automatic drains
OUT
no connection
required
span gas 1
input
span gas 2
input
Figure 15 : GCU Valves & Pipework Arrangement
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4.9. Wiring Connections

WARNING! 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.
The GCU is supplied with all internal cables fitted. External cables supplied by
the customer should be connected in accordance with the connection schedule
Figure 16.
4.9.1. 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.
Power cables 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.
All units are supplied with cable gland entries fitted with blanking plugs. Cable
glands are packed separately.
To fit a cable gland, remove the appropriate blanking plug with a spanner,
remove the locking nut from the cable gland, screw the cable gland into the
threaded hole from the outside and tighten by hand to compress the seal. Refit the locking nut from inside the case and tighten.
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4.9.2. Analyser/Junction Box/GCU Connections

Fit the required number of cable glands. Maximum overall cable diameter is
15mm.
Connect the 10-core transceiver cable (only 9 cores used), together with the
temperature and pressure (and if used oxygen) sensor cables, to the terminal
connectors in the junction box as shown in Figure 18. Connect the cable
screen in the cable gland as illustrated in Figure 19. At the same time, if not
already set, set the address switch in the SCU to 01 (Figure 21).
Connect the 4-core local bus cable (customer supply) between the junction box
(Figure 18) and the terminal rail in the GCU (Figure 16 and Figure 20).
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Figure 16 : Connection Schedule
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Figure 17 : Mains Power Isolator Switch Connections
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temperature
2-core
pressure
2-core
oxygen
2-core
local bus to
GCU 4-core
red
blue
orange
pink
red
blue
orange
grey
+ve
-ve
yellow
white
0V
MISO
MOSI
+V
green
black
blue
brown
link
Figure 18 : Cable Connections in the Junction Box
Figure 19 : Cable Gland
10 (9) core
cable from
transceiver
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cable
connection
block
Figure 20 : Gas Control Unit Connection Block
address switch
Figure 21 : Address Switch in Station Control Unit
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4.10. Installation of Normalising Measurements (Oxygen, Temperature and

Pressure)
The G-CEM is supplied with a pressure and temperature inputs fitted as
standard for normalising purposes.
If external normalising measurements are to be used, either for the analyser
itself or as the lead analyser in an IEM measurement group (refer to IEM
manual for details), proceed as follows:
Install all normalising measurements by reference to their individual manuals.
The temperature and pressure sensors are supplied with the analyser.
Connect the 4-20mA outputs from the oxygen sensor to the Junction Box as
shown in Figure 18.
Any of these inputs will accept independently powered current loop inputs. Input
impedance is 237 and the common mode voltage range is 200V DC.
The pressure and temperature inputs are also able to provide power for either
two- or three-wire transducers requiring a 24V DC supply.
All cable screens should either be connected to the cable glands as illustrated
in Figure 19 or terminated at the transducer. Screens must NOT be earthed
at more than one point.
4.11. Installation of Calibration Gases
If required, span verification may be carried out using certified test gases. This
is achieved by flooding the measurement cell with the required gas as shown in
Figure 22.
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Figure 22 : Testing Span Using Audit Gases
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5. 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 (set-up)
zero calibration
5.1. 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 Section
4.9.1. Installation and Connection of Cables and Section 4.10.
Installation of Normalising Measurements (Oxygen, Temperature and
Pressure).
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 the G-CEM 4000 analyser, read Section 1. CODEL

G-CEM4000 Analyser Introduction before proceeding. This
provides an overview of the analyser's capabilities and the uses of
the parameters that will be configured during commissioning.
Finally
Check that the neutral zone air purge is functioning. If not, take corrective
action.
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5.2. Power On
Switch on the power supply. The order in which these units are switched on is
not important.
If final connection of power supplies has been left until the commissioning
stage, note that the requirements are :
Power Supply
80-260V AC, 50-60, 200VA, single phase
Although measurement values will now be displayed they will

probably be meaningless and will remain so until the
commissioning procedure is complete.
The following commissioning instructions are provided in detail and are written
for the first time user.
5.3. Initial Set-Up Using SmartCOM Software
Install SmartCOM software on a pc using the installation procedure.
Connect the special interface cable between the pc serial port and the screw
connector on the GCU.
Start SmartCOM software and you will see the screen below. Set the correct pc
comms port identity in the 'Comms validity indicator'.
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Figure 23 : Initial SmartCOM Screen

Set sensor selector to SCU. Insert address of SCU at Address selector (this
will probably be 1).
Set sensor selector to GCEM 4000, set Function selector to 'Read'. Click on
'read data control' and ensure the 'message received indicator' turns green and
that data is deposited in the 'Data access window' (Figure 24), where a binary
stream should be visible in the data window. If not, try again, but if after several
attempts nothing happens, check for good communications between the pc and
SCU.
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Figure 24 : SCU - Read Screen
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5.3.1. Adjust Alignment

The following procedure will ensure that the sensor head is in optimal alignment
with the measurement probe, but before proceeding, allow 4-hour warm-up time
after power-up.
Switch on the purge air using the following procedure. Select 'Calibration' in the
Function selector and the screen below should appear.
Set 'Working Set Cal data' in the type box, click on 'Read' and ensure that the
green 'message received' LED is activated. The required data will now fill the
appropriate boxes.
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Select 'Activate calibration' in the 'Type' box and the following screen should
appear.
Set Calibrate to 'Off'. Set manual purge air to On; click on the 'Lock tick' to
release it and click on 'Apply'.
At this point check that the flow meter on the air line to the measurement zone
is showing 10 l/min. If not, adjust it so that it is. If the flow meter is unable to
show sufficient flow, open the air control valve to allow more through. A value
of less than 10 l/min is unacceptable and will lead to a poor zero calibration and
consequently poor accuracy from the analyser.
Before alignment can be carried out the following parameters must be checked
to see if the Target and Measured values are within range. If this is not the case
then allow more time for the analyser to warm-up.
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5.3.2. Set Thermistor Control

Select 'Thermistor Control' at the Function selection and the following screen
will appear.
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Click on 'Read' and the following screen should now show :
Some of the data displayed is in hexadecimal (base 16) notation, not decimal
(base 10). Check the values against the table below and change any that are
incorrect.
The 'Thermistor measured value' and 'Cooler current' should now display at
values close to those selected.
Variable
Thermistor target value
Proportional Gain
Integral Gain
Time Constant
Hex or decimal
Hex
Decimal
Decimal
Decimal
Value
3800*
50
70
1
* This value may vary depending upon factory set-up.
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5.3.3. Source Temperature Control

Select Source Temp Control in the Function selector and the following screen
should appear.
Click Read to update the display values. Ensure that the green message
received LED illuminates to confirm that the data is current. Check these values
against those shown in the following table and adjust if necessary.
Function
Temperature target value
Proportional constant
Integral Constant
Time Constant
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Decimal
Decimal
Decimal
Decimal
Value
6700
50
70
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5.3.4. Set Cell Oven Control

Select 'Cell oven control' in Function selector and click on 'Read' to update the
displayed values. Ensure that the green 'message received' LED activates to
confirm that the data is current. Check these values against those shown in the
following table and adjust if necessary. Please note that some are in
hexadecimal and some in decimal notation.
Function
Temperature target value
Proportional constant
Integral Constant
Time Constant
Hex or Decimal
Decimal
Decimal
Decimal
Decimal
Value
5500*
128
4
5
* This value may change depending on the application.
To upload any new values, change the variable in the white box, ensure that
'Auto control' is set to 'On' and click on 'Apply'. Ensure the 'message received'
LED goes to green.
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Now, with purge air on align the transceiver in relation to the probe.
a) Select 'Alignment' in the Function selector.
b) Select detector 6.
c) Set auto update rate to 3 seconds and click on 'Auto read stop/start
control'.
d) Using the alignment and locking nuts on the four alignment studs (Figure
25)adjust the position of the transceiver mount such that the gap between
it and the alignment flange is equal all the way round. Watching the
alignment display in SmartCEM start to adjust the alignment on the
vertical plane by adjusting both the alignment and the locking nuts, until
the maximum signal strength is achieved.
this gap should be

equal all round
transceiver mount
alignment flange
Figure 25 : Alignment Adjusters
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Important Note:
When adjusting the alignment nuts to achieve maximum signal, it
will be seen that when maximum signal is achieved the locking
alignment nuts will continue to turn in the same direction before
the signal starts to fall off, thus there is a maximum signal strength
plateau.
plateau
maximum signal strength
Lock position
first maximum peak signal
fall-of
It is very important that before locking the alignment/locking nuts

the centre of this plateau must be found. When the first maximum
peak signal is achieved continue to turn the alignment/locking nut
in the same direction, making note of adjustment made, before
fall-off is achieved. i.e. one turn of the nuts. In this case the
plateau is therefore one turn of the locking nuts long and should
be turned back a half-turn to meet the centre point of the plateau.
At this point lock the alignment and locking nuts very tight! Once
the locking position is achieved in the vertical plane, the process
must be repeated in the horizontal plane.
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e) Select detector wave forms in the Function box and the following
screen should be displayed.
2)
3)
1)
4)
Sample 2 start
6)
Sample 3
start
5)
Sample 3
end
7)
Sample 2 end
Sample 1 start
Comms. lights
Sample 1 end
1) Select Detector 6 in the detection channel box.

Note: If the analyser is not measuring CO then detector number 10 must be
used for the alignment process.
2) Select the Graph page.
3) Select GCE4000 and Detector waveforms
4) Read a detector wave form by pressing Read waveform data;
wait for the waveform to be displayed opposite.
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5) The displayed signal should look as shown below, with the six
lines protruding form it. These lines denote the three start and
three stop points of the sampling. At this point the sampling
positions made, need to be adjusted; this can be checked as
follows:
Space 1 should equal space 2.
1
2
Looking at the sample detector wave form, it can be seen that

spaces (1) and (2) are equal; this must also be achieved on the
displayed signal.
6) Read the detector sampling positions by pressing Read data
and the sampling positions will be displayed in the table.
Note: When moving the sampling positions the sample 2 start
and end positions will move together; increasing the sample 2
value will move these points to the right and decreasing sample 2
value will move the sample points to the left. Using increments of
20 in the sampling value will give very small changes to sampling
positions.
7) To make adjustments to the sampling positions select the
relevant detector channel, then edit the sample 2 value in the
box; when the desired value is entered click apply making sure
that the two comms. lights turn green.
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8) Now re-check that spaces (1) and (2) are equal and if not, repeat
step 7) until this is the case.
9) Take the valve for sample 2 achieved from step 8) and from this
value subtract 2360 and enter the result as the sample 1 value.
Then take the sample 2 value and add 2760 and enter the result
as the sample 3 value; transmit these values by pressing the
apply button as described in step 7).
10)Repeat steps 4-9 for each of the 10 detector signals.
Note: On some analysers there will be no signals and a straight line will be
displayed for the detector wave form. This is related to gas channels which the
analyser is measuring.
Compare the background colour of the display against the colour check box
beneath to check if the detector level is good, saturated or there is a comms.
error. Detector levels should be 13000 to 16000.
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5.3.5. Detector levels

To view the analyser detector levels select 'Detector Levels' in the Function
selector and click on 'Read' to update the information. Finally, ensure the green
'message received' LED is activated.
The detector values represent the amount of energy received at the photodetector as the gas wheel rotates. There may be zero values dependent on the
number of detection channels the analyser is set-up for. Where there are values
shown >0 they should be at least 15000 (decimal) 2000 (if the purge air is on).
If not, or if any of the saturation LEDs are red, first check the alignment and if
this does not rectify the situation, contact your local CODEL Distributor or
CODEL direct for further advice. To view the smoothed detector output, select
'smoothed' in the 'Type' box.
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5.3.6. Zero Calibration

At this point the analyser requires a zero calibration to establish correct
baselines for its parameters. In order to commence a calibration, first complete
the previous 4 steps to ensure the analyser is working at it's optimum. Having
installed the G-CEM 4000, a zero calibration must be undertaken to ensure
that the analyser gives meaningful data. Select 'Calibration' in the Function
selector to view the screen below.
Set 'Working Set Cal data' in the 'Type' box, click on 'Read' and ensure the
green 'message received' LED is activated. The required data will now fill the
appropriate boxes. To receive a continuous update set the 'Auto Update rate'
and press 'Start'.
The data shown in the final boxes is crucial to the performance of the analyser
during calibration and must be equal to or greater than the data given below. If
it is not, wait until the analyser warms to this temperature. If it fails to do so,
contact the CODEL Distributor or CODEL International direct.
Oven temperature : 55.00
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When the transceiver has achieved the correct temperature, select 'Activate
calibration' in the 'Type' box and the following screen should appear.
Set the 'Purge time' to 180 seconds, set 'Number of Cal cycles' to 240, set
'Calibrate' to 'On', click on the 'Lock' tick to release it and click on 'Apply'.
Clicking on 'Auto update' will show a clock decrementing through the remaining
Cal cycles.
To stop a calibration, which is not advisable, set 'Calibrate' to 'Off' and click on
'Apply'.
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5.3.7. Current Data

To check the instruments' current readings, select 'Output' in the Function
selector. Click on 'Read' to update the screen and ensure the green 'message
received' LED is actuated. To receive a continuous update set the 'Auto Update
rate' and press 'Start'. This data is for information purposes only and represents
the outputs of the various sensor channels and the current normalisation data.
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5.3.8. 'Y' Values

To view the 'Y' values, select this in the Function selector, click on 'Read' to
update them and ensure the green 'message received' LED is activated. The
'Y' values should be in the region of 10000 (if the purge air is on). If they vary
significantly from these values, check the alignment and if does not rectify the
problem, contact your CODEL Distributor or CODEL direct.
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5.3.9. Span Verification

The G-CEM4000 and GCU are equipped to enable the performing of span
verification checks. This is achieved by connecting the required span gas bottle
to the span gas input of the GCU (see Figure 15). Note that some GCUs may
have more that one input.
Set the pressure on the relevant regulator to the same pressure indicated on
the zero purge regulator.
The control of span verification can be carried out either from SmartCOM or via
the IEM for WindowsR software (if using IEM for WindowsR software refer to the
IEM manual).
Note: Before performing a span check it is good practice to carry out a zero
calibration first as described in Section 5.3.6. Zero Calibration.
When using SmartCOM software :
1)
Select SCU in the sensor window.
2)
Select the SCU address usually 1.
3)
Select purge control in the Function window and the following

screen should appear.
Note that not all these functions are applicable to the G-CEM4000
span check and therefore should not be used.
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2)
3)
10)
1)
4)
8)
Comms.
light
5)
6)
9)
7)
4)
Read back the stored parameter data from the SCU by clicking
Read.
5)
Set the pre/post purge period to 5mins.
6)
Set the gas period to 10mins or greater.
7)
Click Apply.
8)
Select span gas 1 unless number 2 input is being used.
9)
Select ON.
10)
Click Apply and make sure that the comms. Light turns green.
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This will now switch on zero air for 5 minutes to check the zero condition of the
analyser. The zero air will then switch off and the span gas will switch on. At
this point the flow must be checked on the flow rotometer; make sure that it is
10 l/min and adjust if required using the span gas regulator.
Switch to the Data File in the Function box and the following screen will be
displayed.
Make sure that G-CEM4000 is selected and adjust the Auto update time to 20
seconds and click Start. The relevant gas channel value should start to
increase to the value indicated on the span gas bottle (within tolerances). If this
is not the case please contact CODEL or your local representative.
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5.3.10.
General Overview
To obtain a general overview of the most important parameters, select SCU in

Sensor Selector. Select 'General Data' in the Function selector, click on 'Read'
to update them and ensure the green 'message received' LED is activated.
To receive a continuous update set the 'Auto Update rate' and press 'Start'.
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5.3.11. Setting the Output Configuration

The analogue outputs and alarm relay set points should be configured if
required. On some systems using IEM for Windows R, this may be handled by
the pc. Select SCU in the 'Sensor' selector and then select Outputs and the
following screen will appear. Click on "Read" to update the displayed data.
The data displayed now relates to the complete output set for a particular
channel and is configured at the factory. At this point you should understand
that this section is factory set and should be left alone under nearly all
circumstances. If you do need to make changes, you will need to refer to the
Memory map in Appendix 2 - Output Memory Map.
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Current output
Abs. data location :
the memory location of the source of the current

output data
0 - 4mA :
selects the starting value (in mA) for zero output
Data invalid :
Zero
Averaging value :
the time period over which the output data is

averaged in 0 - 256 steps. Each step is 3 seconds
and is input in hexadecimal. Some key values are
shown below.*
Span :
the upper point of the output data
Zero :
the lower start point of range
Relay output
Abs. data location :
the memory location of the source of the alarm

output data
Averaging value :
the time period over which the output data

averaged as described above
Direction :
Normal = NO and Reverse (failsafe) in NC
Alarm level :
alarm threshold in decimal
Source :
2 byte
* Averaging time values
is
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CODEL
Time in
minutes
1
2
3
4
5
6
7
8
9
10
11
12
Hexadecimal
value
0014
0028
003C
0050
0064
0078
008C
00A0
00B4
00C8
00DC
00FO
Refer to Appendix 2 - Output Memory Map for output location memory map.
To deduce what the factory settings for the analyser channels are, employ the
following method. Select 'Read' in the 'Function' box to view the following
screen. Select 'Master' in the 'Target destination' box, type 7EF8 in the 'Start
address' box and type 7 in the 'Number of bytes box. Click on 'Read' and data
should appear in the Data Access Window. If not, click on 'Read' until it does.
The data displayed in two number blocks relates to the species at each
channel.
1
2
3
4
5
6
7
8
9
0A
0B
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CO
CO2
NO
NO2
not used
SO2
not used
UHC/CH4
not used
H2O
HCL
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So using the example shown below:

7EF8; 03 02 01 06 0A 0B FF
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 7
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NO
CO2
CO
SO2
H20
HCL
Not used
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Having now clarified which parameter relates to which channel, turn to

Appendix 2 - Output Memory Map. Then select the output parameter being
used vpm, mg/m3, mass flow, or other data (these are clearly shown at the top
of the sheet). Select from the list the location address relating to the channel to
be interrogated. Normally the group marked '3 min' should be selected. This
relates to the standard data integration set into the analyser. Only use the
second set if it is positively known that the analyser has some other (factory set)
integration period.
Return to the output configuration screen, input the required address to both
boxes marked 'Abs. data location' and click on 'Read'. The current configuration
should now display. Change the required parameter and click on 'Apply'.
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6. Analyser Records
This section is provided to allow recording of analyser identity, installation and
commissioning information, to facilitate any later fault diagnosis and
rectification.
6.1. Serial Numbers (Complete on First Inspection)
Transceiver
Gas Control Unit
Station Control Unit
6.2. Installation Records

Plant (name and location) :
Plant Type/Process
Monitoring Position
Installation Date
6.3. Commissioning Records

Completion Date
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6.3.1. Table 1 : Analyser Configuration Record - Parameters

Parameters common to all channels
Cal Interval (hrs)
Parameters configured for Individual Channels
Channel/Output No
Gas Measured
Identity (for IEM)
Analogue
output
Zero: 0/4mA
Average
Units
Span
Fault Cond.
Set Zero
Set Span
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7. Calibration and Measurement Verification

7.1. Introduction
The following sections provide information on the analyser calibration at the
time of supply (Factory Calibration), methods by which measurement/calibration
can be verified and, should it be necessary, facilities for calibration adjustment.
7.2. Factory Calibration
4000 Series analysers use very tightly controlled infrared wavebands that are
specific to each of the gases measured. The scale-shape for each
measurement (i.e. the relationship between concentration and output) is
therefore uniquely defined and the output, at any measurement level, is only
dependent on gas concentration, gas temperature and any system zero error.
Flue gas temperature is a continuous measured input. Any zero error detected
during commissioning is corrected as part of the commissioning procedure
(Section 5. Commissioning) and any subsequent zero drift is automatically
detected, measured and corrected (Section 7.3.1. Automatic Zero Calibration).
Factory test procedures ensure that analyser calibration is traceable to national
standards and, with the inherent stability of scale-shape and automatic zero,
only a significant fault (that would be detected by the analysers' diagnostic
routines) or incorrect installation/commissioning can cause a calibration error.
The analyser is equipped with means by which the factory calibration can be
modified on site (Section 7.4. Re-calibration), but great care should be taken to
ensure that calibration adjustment is necessary before proceeding with this
routine as it will overwrite the factory calibration settings.
7.3. Verification
Even though 4000 Series analysers are designed to
stability almost indefinitely, it is often necessary
performance. This may be a routine check after
operation, to confirm unusual measurements or as
some external authority.
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maintain their calibration

to verify measurement
an extended period of
an audit requirement by
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4000 Series analysers have a range of verification options, designed to provide

varying levels of independence from both the analyser itself and CODEL
standards. Which one is chosen depends on the resources available and
legislative demands. The different methods can be used in combination to
minimise the amount of external work required to maintain performance
confidence.
7.3.1. Automatic Zero Calibration
This automatic procedure is carried out by the analyser itself and provides
regular checking and, if necessary, adjustment of the zero for each
measurement. The automatic zero calibration procedure provides a regular
check on analyser performance without the need for operator intervention. The
operation of this is covered in the IEM for WindowsR manual.
7.3.2. Manual Zero Verification
The zero of all measurement channels can be verified manually at any time
after being powered-up for at least four hours.
Important! The purge air must be dry to the specified level (-20C). Any water
vapour in the measurement path will show an offset not only on the water
vapour measurement itself, but also on any other measurements that the
analyser automatically corrects for cross-sensitivity to water vapour. Any
calibration subsequently initiated to correct these apparent offsets will be
incorrect.
Ensure that the solenoid valve controlling the purge is powered and the control
cable connected as described in Section 4. Installation.
If an analyser error is still suspected, contact CODEL or the local service agent,
but first consult Section 9. Fault Finding to establish what information to provide.
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7.3.3. Comparative Testing

Legislation often require that continuous emissions monitoring systems are
audited at regular intervals (usually once or twice per year) against an
independent approved test system. These approved test systems are always
extractive analysers and measurements must normally be carried out by
organisations independent of the CEMS manufacturer or the plant operator.
If the analyser is working correctly and the comparative testing is carried out to
the prescribed procedure, it is rare for such exercises to be other than a routine
confirmation of performance. However, to ensure that any discrepancies can
be easily resolved, it is recommended that the following precautions be taken :
a)
Check what level of agreement is required by the relevant

legislation. Most legislation is realistic about what can be
expected in comparing a system that provides an average of a
significant percentage of the whole duct or stack and one that
averages a number of discrete measurements from different
positions at different times.
b)
Be aware of the specified procedure for the comparative test and

ensure that appropriately qualified personnel using certified
equipment and test gases carry it out. Do not accept the validity
of quick, single-point checks with uncertified analysers.
c)
Ensure that, when comparing measurements made by the G-CEM

4000 and the audit system, the measurements are on the same
basis, i.e.
OPS. 080
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they have been recorded simultaneously and during a period

when plant operation is stable
the measurement averages are equivalent (e.g. 10-minute

rolling average measurements from the Model 4000 should be
compared with 10-minute averages from the audit system and
not measurements averaged over significantly different time
periods).
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d)
all measurements are normalised/corrected to the same

standard conditions of temperature, pressure, water vapour
(dry or wet) and excess oxygen (or CO2).
If the reasons for any discrepancies are not apparent, it is strongly

recommended that CODEL or its local service agent be consulted
before any attempt is made to recalibrate the Model 4000
analyser. Re-calibrating to a reference measurement that is
subsequently found to be unreliable creates many unnecessary
difficulties. DON'T RECALIBRATE UNLESS ABSOLUTELY
CERTAIN THAT IT IS NECESSARY!
7.4. Re-calibration
Note :
The laws of physics determine that the scale shape (i.e. the
relationship between gas concentration and analyser output)
is absolutely fixed for a defined measurement waveband.
Only serious faults (e.g. a leaking gas cell), that would be
detected and registered as a data invalid condition by the
analyser itself, can modify this relationship.
If re-calibration cannot wait until the next scheduled automatic zero calibration
(Section 7.3.1. Automatic Zero Calibration), a manual zero calibration may be
implemented (Section 7.3.2. Manual Zero Verification).
Any discrepancy that is now outside the combined measurement uncertainties
of the test gas (or comparative measurement) and the analyser, can only be
due to either a significant fault in the analyser itself, inaccuracy in the test gas
or inappropriate comparative testing (see Section 9. Fault Finding)
Consider and check all other possibilities before assuming an analyser fault.
Analyser faults are rare, are usually detected by the analyser itself (initiating an
automatic data invalid state) and likely to produce very large errors.
When convinced that any discrepancy is due to an analyser problem, contact
CODEL or the local service agent, but first consult Section 9. Fault Finding, to
determine what information to provide.
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8. Maintenance
This version of the 4000 series requires no routine maintenance other than care
of the air purge supplies. Ensure that all filters, dryers and automatic drain units
are serviced and maintained according to the manufacturers' instructions.
Ensure that the compressor is properly serviced and does not inject more oil
into the air supply than the filter system can remove.
THE ACCURACY AND TROUBLE-FREE OPERATION OF THE ANALYSER
DEPENDS ON THE PURGE AIR SUPPLIES BEING MAINTAINED TO THE
REQUIRED STANDARDS.
The probe and fittings are designed, by choice of materials and construction, to
be corrosion resistant and to provide many years of trouble-free operation.
However, it is good practice to take the opportunity of plant shutdown periods to
visually examine components that are not accessible during normal operation.
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9. Fault Finding
4000 Series analysers are sophisticated devices and any problems
necessitating internal repair or adjustment should only be undertaken by fully
trained technicians.
In the absence of any 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 equivalent current information contained in Tables 3
and 4.
To obtain current values for data recorded in Tables 3 and 4 follow the
procedure described in Section 5. Commissioning.
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Appendix 1 Setting Analyser Gains

The need to reset gains after manufacture and testing is very rare, but if
necessary, there are a number of methods that depend on the analysers'
configuration and its date of manufacture. Consult CODEL to check that gain
resetting is necessary and to obtain instructions for the appropriate method.
The analysers' serial number should be quoted at this time.
Note that gain setting requires access to the circuit boards within the
receiver and should only be undertaken by a trained instrument
technician.
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L
Appendix 2 - Output Memory Map

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0180
Memory Map: vpm data
******************************************************************************
Location
0180
0181
0182
0183
0184
0185
0186
0187
0188
0189
018A
018B
018C
018D
018E
018F
0190
0191
0192
0193
0194
0195
0196
0197
0198
0199
019A
019B
019C
019D
019E
019F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1
]
]
Ch2
]
]
Ch3
] 3min (Analyser response)

]
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
Ch1
]
]
Ch2
]
]
Ch3
] x Minute response
]
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
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******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01A0
Memory Map: mg/Nm3 data
******************************************************************************
Location
Description
01A0
}
Ch1
]
01A1
}
]
01A2
}
Ch2
]
01A3
}
]
3min
01A4
(Analyser} response)
]
Ch3
01A5
}
]
01A6
}
]
Ch4
01A7
}
]
01A8
}
]
Ch5
01A9
}
]
01AA
}
Ch6
01AB
}
] ]
01AC
}
Ch7
01AD
}
] ]
01AE
}
Dust
01AF
}
] ]
01B0
}
Ch1
01B1
}
]
]
01B2
}
Ch2
01B3
}
]
]
01B4
}
Ch3
01B5
}
]
] x Minute response
01B6
}
Ch4
01B7
}
]
]
01B8
}
Ch5
01B9
}
]
01BA
}
]
Ch6
01BB
}
]
01BC
}
Ch7
]
01BD
}
]
01BE
}
Dust
]
01BF
}
]
]
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**********************************************************************
Model: SCU SmartCem Software ID: D07-019A Module:
MM01C0
Memory Map: mass flow:- kg/hr,g/s,g/h or Tonnes/year data
******************************************************************************
Location
Description
01C0
}
Ch1
01C1
}
01C2
}
Ch2
01C3
}
3min
01C4
(Analyser response)
}
Ch3
01C5
}
01C6
}
Ch4
01C7
}
01C8
}
Ch5
01C9
}
01CA
}
Ch6
01CB
}
01CC
}
Ch7
01CD
}
01CE
}
Dust
01CF
}
01D0
}
Ch1
01D1
}
01D2
}
Ch2
01D3
}
01D4
}
Ch3
01D5
}
01D6
}
Ch4
01D7
}
01D8
}
Ch5
01D9
}
01DA
}
Ch6
01DB
}
01DC
}
Ch7
01DD
}
01DE
}
Dust
01DF
}
]
]
]
]
]
]
]
]
]
]
] ]
] ]
] ]
]
]
]
]
]
]
] x Minute response
]
]
]
]
]
]
]
]
]
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CODEL
**********************************************************************
MM01E0
Memory Map: Other data
******************************************************************************
Location
01E0
01E1
01E2
01E3
01E4
01E5
01E6
01E7
01E8
01E9
01EA
01EB
01EC
01ED
01EE
01EF
01F0
01F1
01F2
01F3
01F4
01F5
01F6
01F7
01F8
01F9
01FA
01FB
01FC
01FD
01FE
01FF
OPS. 080
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Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Temperature degC
Oxygen/CO2 dry %(*10)
Pressure kPa
Water Vapour %(*10)
Opacity %(*100)
Extinction (*10000)
Flow m/s(*10)
Flow Nm/s(*10)
Flow m3/s
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**********************************************************************
Model: SCU smartcem Software ID: D07-019A Module:
MM0100
Memory Map: Gcem 4000 data
******************************************************************************
Location
0100
0101
0102
0103
0104
0105
0106
0107
0108
0109
010A
010B
010C
010D
010E
010F
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
011A
011B
011C
011D
011E
011F
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Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1 ppm
Ch2 ppm
Ch3 ppm
Ch4 ppm
Ch5 ppm
Ch6 ppm
Ch7 ppm
Temperature }
}
Oxygen
}
} Normalising data
Pressure
}
}
Water Vapour }
}
Purging Status (01=power up,02=plant off,0C=precal,08=in

cal)
Calibration
in progress
Plant Status
Head identifier
Reserved for SCU comms validation 00 = o.k., FF = fail
Slave13/Master03: SCU Data present command
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******************************************************************************
Memory Map: Dcem 2000 data
******************************************************************************
Location
0120
0121
0122
0123
0124
0125
0126
0127
0128
0129
012A
012B
012C
012D
012E
012F
0130
0131
0132
0133
0134
0135
0136
0137
0138
0139
013A
013B
013C
013D
013E
013F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
% Opacity (*100) } seconds

}
Extinction (*10000) }
}
Dust mg/m3
}
}
Dust mg/Nm3
}
}
% Opacity (*100) } minutes
}
Dust mg/m3
}
}
Dust mg/Nm3
}
}
Temperature
}
}
Oxygen
}
} Normalisation Data
Pressure
}
}
Water Vapour
}
}
Data Valid
Calibration in progress
Plant Status
Head identifier 05= Dcem2000
Reserved for SIU comms validation 00 = o.k., FF =
fail
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******************************************************************************
Memory Map: Vcem 5000 data
******************************************************************************
Location
0140
0141
0142
0143
0144
0145
0146
0147
0148
0149
014A
014B
014C
014D
014E
014F
0150
0151
0152
0153
0154
0155
0156
0157
0158
0159
015A
015B
015C
015D
015E
015F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
x sec
}
}
y min
z hour
d day
x sec
y min
z hour
d day
}
} Flow m/s(*10)
}
}
}
}
}
}
}
} Flow m^3/s(*10)
}
}
}
}
Data Valid
Plant Status
Head identifier 06= Vcem0100
fail
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******************************************************************************
Memory Map: Icem file
******************************************************************************
Location
0160
0161
0162
0163
0164
0165
data 0166
0167
0168
0169
016A
016B
016C
016D
016E
016F
0170
0171
0172
0173
0174
0175
0176
0177
0178
0179
017A
017B
017C
017D
017E
fail 017F
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Revision :
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1 ]
]
Ch2 ]
]
Ch3 ]
] Analogue input
Ch4 ]
]
Ch5 ]
]
Ch6 ]
]
Ch7 ]
]
Ch8 ]
]
Ch1 ]
Ch2 ]
Ch3 ]Logic input data
Ch4 ]
Ch5 ]
Ch6 ]
Ch7 ]
Ch8 ]
Data Valid
Plant Status
Head identifier 07= Icem0100
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******************************************************************************
Memory Map: vpm data
******************************************************************************
Location
0180
0181
0182
0183
0184
0185
0186
0187
0188
0189
018A
018B
018C
018D
018E
018F
0190
0191
0192
0193
0194
0195
0196
0197
0198
0199
019A
019B
019C
019D
019E
019F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1
]
]
Ch2
]
]
Ch3
] 3min (Analyser response)

]
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
Ch1
]
]
Ch2
]
]
Ch3
] x Minute response
]
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
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CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01A0
Memory Map: mg/Nm3 data
******************************************************************************
Location
Description
01A0
}
Ch1
]
01A1
}
]
01A2
}
Ch2
]
01A3
}
]
3min
01A4
(Analyser} response)
]
Ch3
01A5
}
]
01A6
}
]
Ch4
01A7
}
]
01A8
}
]
Ch5
01A9
}
]
01AA
}
Ch6
01AB
}
] ]
01AC
}
Ch7
01AD
}
] ]
01AE
}
Dust
01AF
}
] ]
01B0
}
Ch1
01B1
}
]
]
01B2
}
Ch2
01B3
}
]
]
01B4
}
Ch3
01B5
}
]
] x Minute response
01B6
}
Ch4
01B7
}
]
]
01B8
}
Ch5
01B9
}
]
01BA
}
]
Ch6
01BB
}
]
01BC
}
Ch7
]
01BD
}
]
01BE
}
Dust
]
01BF
}
]
]
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******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01C0
******************************************************************************
Location
Description
01C0
}
Ch1
01C1
}
01C2
}
Ch2
01C3
}
3min
01C4
(Analyser response)
}
Ch3
01C5
}
01C6
}
Ch4
01C7
}
01C8
}
Ch5
01C9
}
01CA
}
Ch6
01CB
}
01CC
}
Ch7
01CD
}
01CE
}
Dust
01CF
}
01D0
}
Ch1
01D1
}
01D2
}
Ch2
01D3
}
01D4
}
Ch3
01D5
}
01D6
}
Ch4
01D7
}
01D8
}
Ch5
01D9
}
01DA
}
Ch6
01DB
}
01DC
}
Ch7
01DD
}
01DE
}
Dust
01DF
}
]
]
]
]
]
]
]
]
]
]
] ]
] ]
] ]
]
]
]
]
]
]
] x Minute response
]
]
]
]
]
]
]
]
]
OPS. 080
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Revision :
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87
CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01C0
******************************************************************************
Location
Description
01C0
}
Ch1
]
01C1
}
]
01C2
}
Ch2
]
01C3
}
]
3min
01C4
(Analyser}response)
]
Ch3
01C5
}
]
01C6
}
]
Ch4
01C7
}
]
01C8
}
]
Ch5
01C9
}
]
01CA
}
Ch6
01CB
}
] ]
01CC
}
Ch7
01CD
}
] ]
01CE
}
Dust
01CF
}
] ]
01D0
}
Ch1
01D1
}
]
]
01D2
}
Ch2
01D3
}
]
]
01D4
}
Ch3
01D5
}
]
] x Minute response
01D6
}
Ch4
01D7
}
]
]
01D8
}
Ch5
01D9
}
]
01DA
}
]
Ch6
01DB
}
]
01DC
}
Ch7
]
01DD
}
]
01DE
}
Dust
]
01DF
}
]
]
OPS. 080
88
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Revision :
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CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01E0
Memory Map: Other data
******************************************************************************
Location
01E0
01E1
01E2
01E3
01E4
01E5
01E6
01E7
01E8
01E9
01EA
01EB
01EC
01ED
01EE
01EF
01F0
01F1
01F2
01F3
01F4
01F5
01F6
01F7
01F8
01F9
01FA
01FB
01FC
01FD
01FE
01FF
OPS. 080
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Temperature degC
Oxygen/CO2 dry %(*10)
Pressure kPa
Water Vapour %(*10)
Opacity %(*100)
Extinction (*10000)
Flow m/s(*10)
Flow Nm/s(*10)
Flow m3/s
89
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CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7E00
Memory Map: Internal EEROM
******************************************************************************
Location
Description
7E00
No. of heads connected to
SIU 7E01
7E02
}
7E03
}
7E04
}
7E05
}
7E06
}
7E07
}
7E08
}
Head #1 output file
location 7E09
}
7E0A
}
Head #2 output file
location 7E0B
}
7E0C
}
Head #3 output file
location 7E0D
}
7E0E
}
Head #4 output file
location 7E0F
}
7E10
7E11
7E12
7E13
7E14
7E15
7E16
7E17
7E18
7E19
7E1A
7E1B
7E1C
7E1D
7E1E
7E1F
Reference EEROM Location
OPS. 080
Issue : B
Revision :
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CODE
L
******************************************************************************
Model:SCU smartcem Software ID: D07-019A Module: MM7EE0
******************************************************************************
Location
7EE0
7EE1
7EE2
7EE3
7EE4
7EE5
7EE6
7EE7
7EE8
7EE9
7EEA
7EEB
7EEC
7EED
7EEE
7EEF
7EF0
7EF1
7EF2
7EF3
7EF4
7EF5
7EF6
7EF7
7EF8
7EF9
7EFA
7EFB
7EFC
7EFD
7EFE
7EFF
OPS. 080
Description
Ch.1 definition
Ch.2 definition
Ch.3 definition
Ch.4 definition
Ch.5 definition
Ch.6 definition
Ch.7 definition
91
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CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F00
******************************************************************************
Location
Description
7F00
7F01
NO/NOx flag (00=NO, 01=NOx) NOvpm, NOorNOx mg/m3, mg/Nm3 &
mass emissions
7F02
} NO2 % (*10) [used for NOx calculations
when 7F03}
NO2 ch. not present]
7F04
Plant status off (01=zero, 00=live) vpm, mg/m3, mg/Nm3 & mass emission
outputs 7F05
7F06
O2/CO2 Normalisation flag (00=O2,
01=CO2) 7F07O2/CO2 dry/wet flag (00=DRY, 01=WET)
7F08
} Temperature }
7F09
}
}
7F0A
} Oxygen %(*10) }
Normalisation 7F0B
}
}
Standard levels 7F0C }
Pressure }
7F0D
}
}
7F0E
Water Vapour } (Water Vapour wet/dry flag)
7F0F
}
7F10
} Dust factor A }
7F11
}
} Dust calculated as [Aext'n +
B]ext'n 7F12
} Dust factor B }
7F13
}
}
7F14
} Cross Sectional Area m2
(*100) 7F15 }
for volumetric
flow
7F16
7F17
7F18
7F19
7F1A
7F1B
7F1C
7F1D
7F1E
7F1F
Reference EEROM Location (01 = SET DEFAULT VALUES AT POWER UP)
OPS. 080
Issue : B
Revision :
92

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CODE
L
******************************************************************************
******************************************************************************
Location
7F20
7F21
7F22
7F23
7F24
7F25
7F26
7F27
7F28
7F29
7F2A
7F2B
7F2C
7F2D
7F2E
7F2F
7F30
7F31
7F32
7F33
7F34
7F35
7F36
7F37
7F38
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Divisor
]
] Mass flow ch1 = mg/m3 * vol. flow *
Multiplier
Multiplier
]
--------]
Divisor
Divisor
]
]Mass flow ch2
Multiplier ]
]
Divisor ]
] Mass flow ch3
Multiplier ]
]
Divisor
]
]Mass flow ch4
Multiplier ]
]
Divisor ]
] Mass flow ch5
Multiplier ]
]
Divisor
]
]Mass flow ch6
Multiplier ]
]
Divisor ]
7F39
}
] Mass flow
ch7 7F3A } Multiplier ]
7F3B
}
]
7F3C
} Divisor
]
7F3D
}
]Mass flow
ch8 7F3E } Multiplier ]
7F3F
}
]
OPS. 080
Issue : B
Revision :
Doc i/d : 0080/6
93
CODEL
******************************************************************************
Memory Map: Internal EEROM :- O/P parameters
******************************************************************************
Location
7F40
7F41
7F42
7F43
7F44
7F45
7F46
7F47
7F48
7F49
7F4A
7F4B
7F4C
7F4D
7F4E
7F4F
7F50
7F51
7F52
7F53
7F54
7F55
7F56
7F57
7F58
}
3mins 7F59
7F5A
7F5B
7F5C
7F5D
7F5E
7F5F
OPS. 080
Issue : B
Revision :
Description
Averaging rate #0h
Averaging rate #1h
Averaging rate #2h
Averaging rate #3h
Averaging rate #4h
Averaging rate #5h
Averaging rate #6h
Averaging rate #7h
Averaging rate #8h
Averaging rate #9h
Averaging rate #Ah
Averaging rate #Bh
Averaging rate #Ch
Averaging rate #Dh
Averaging rate #Eh
Averaging rate #Fh
Averaging rate #10h
Averaging rate #11h
Averaging rate #12h
Averaging rate #13h
Averaging rate #14h
Averaging rate #15h
Averaging rate #16h
Averaging rate #17h
ave update counter
(686 * 262.14ms = 179.828s) approx
}
94

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CODE
L
******************************************************************************
Memory Map: Internal EEROM :- DAC Calibration Data
******************************************************************************
Location
7F60
7F61
7F62
7F63
7F64
7F65
7F66
7F67
7F68
7F69
7F6A
7F6B
7F6C
7F6D
7F6E
7F6F
7F70
7F71
7F72
7F73
7F74
7F75
7F76
7F77
7F78
7F79
7F7A
7F7B
7F7C
7F7D
7F7E
7F7F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
DAC span }
} Ch.1
DAC zero }
}
DAC span }
}Ch.2
DAC zero }
}
DAC span }
} Ch.3
DAC zero }
}
DAC span }
}Ch.4
DAC zero }
}
DAC span }
} Ch.5
DAC zero }
}
DAC span }
}Ch.6
DAC zero }
}
DAC span }
} Ch.7
DAC zero }
}
DAC span }
}Ch.8
DAC zero }
}
OPS. 080
Issue : B
Revision :
Doc i/d : 0080/6
95
CODEL
******************************************************************************
Memory Map: Internal EEROM :******************************************************************************
Location
7F80
7F81
7F82
7F83
7F84
7F85
7F86
7F87
7F88
7F89
7F8A
7F8B
7F8C
7F8D
7F8E
7F8F
7F90
7F91
7F92
7F93
7F94
7F95
7F96
7F97
7F98
7F99
7F9A
7F9B
7F9C
7F9D
7F9E
7F9F
OPS. 080
Issue : B
Revision :
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Absolute data loc. } 0100h=NO addr 01

} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
} 00=Zero 01=F.S. 02=Hold
03=Meas Averaging value
}
Span
} O/P 1
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 1
Level
}
}
Source (00=1byte) }
} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
}
Span
} O/P 2
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 2
Level
}
}
Source (00=1byte) }
96

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CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7FA0
Location
7FA0
7FA1
7FA2
7FA3
7FA4
7FA5
7FA6
7FA7
7FA8
7FA9
7FAA
7FAB
7FAC
7FAD
7FAE
7FAF
7FB0
7FB1
7FB2
7FB3
7FB4
7FB5
7FB6
7FB7
7FB8
7FB9
7FBA
7FBB
7FBC
7FBD
7FBE
7FBF
OPS. 080
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}

} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
}
Span
} O/P 3
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 3
Level
}
}
Source (00=1byte) }
} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
}
Span
} O/P 4
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 4
Level
}
}
Source (00=1byte) }
97
Issue : B
Revision :
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CODEL
******************************************************************************
MM7FC0
Location
7FC0
7FC1
7FC2
7FC3
7FC4
7FC5
7FC6
7FC7
7FC8
7FC9
7FCA
7FCB
7FCC
7FCD
7FCE
7FCF
7FD0
7FD1
7FD2
7FD3
7FD4
7FD5
7FD6
7FD7
7FD8
7FD9
7FDA
7FDB
7FDC
7FDD
7FDE
7FDF
OPS. 080
Issue : B
Revision :
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}

} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
}
Span
} O/P 5
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 5
Level
}
}
Source (00=1byte) }
} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
}
Span
} O/P 6
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 6
Level
}
}
Source (00=1byte) }
98

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CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7FE0
Location
7FE0
7FE1
7FE2
7FE3
7FE4
7FE5
7FE6
7FE7
7FE8
7FE9
7FEA
7FEB
7FEC
7FED
7FEE
7FEF
7FF0
7FF1
7FF2
7FF3
7FF4
7FF5
7FF6
7FF7
7FF8
7FF9
7FFA
7FFB
7FFC
7FFD
7FFE
7FFF
OPS. 080
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}

} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
}
Span
} O/P 7
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 7
Level
}
}
Source (00=1byte) }
} 0120h=NO addr 02
0/4mA (00=0mA 01=4mA) }
Data invalid
}
Span
} O/P 8
}
Zero
}
}
} 0120h=NO addr 02
Averaging value
}
Direction
} Alarm 8
Level
}
}
Source (00=1byte) }
99
Issue : B
Revision :
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CODEL
List of Figures
Figure 1 : Typical SmartCEM System Arrangement
Figure 2 :G-CEM4000 Analyser with 'in-situ' Probe
Figure 3 : Standard Supplied Items and Dimensions
13
Figure 4 : Optional Weather Cover
14
Figure 5 : Additional Materials to Consider
16
Figure 6 : Preferred Transceiver Position
21
Figure 7 : Angled Probe Installation
21
Figure 8 : Rectangular Ducts - Acceptable Position
22
Figure 9 : Spacing From Other Analysers
22
Figure 10 : Standard Site Mounting Flange
24
Figure 11 : Typical Stub Pipe Arrangement for Concrete/Brick Stacks
25
Figure 12 : Beam Lifting Point
27
Figure 13 : Position of Pressure Sensor
28
Figure 14 : GCU
29
Figure 15 : GCU Valves & Pipework Arrangement
30
Figure 16 : Connection Schedule
33
Figure 17 : Mains Power Isolator Switch Connections
34
Figure 18 : Cable Connections in the Junction Box
35
Figure 19 : Cable Gland
35
Figure 20 : Gas Control Unit Connection Block
36
Figure 21 : Address Switch in Station Control Unit
36
Figure 22 : Testing Span Using Audit Gases
38
Figure 23 : Initial SmartCOM Screen
41
Figure 24 : SCU - Read Screen
42
Figure 25 : Alignment Adjusters
49
OPS. 080
Issue : B
Revision :
Doc i/d : 0080/6
100

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5.1 CEMS - Manual - Forbes Marshal

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CODEL

CODEL International Ltd. is a UK company based in Bakewell, Derbyshire,

CODEL International Ltd.

: +44 (0) 1629 814 351

CODEL International Ltd. September 2002

We reserve the right to modify designs without prior notice.

1.2. Basic Principles

1.3. Emission Monitoring and the G-CEM4000

1.4. User Interface

1.5. Analogue and Logic Inputs and Outputs

1.7. Analyser Protection

3. Preparing for Installation

3.2. Additional Materials

3.3. Ancillary/Additional Equipment

4.1. Selection of Measurement Position

4.2. Analyser Positioning

4.3. Fitting of Stub-Pipes and Mounting Flanges

4.4. Installation of Purge Air Supply

4.5. Installation of Measurement Tube

4.6. Fitting the Transceiver

4.7. Installation of the Junction Box

4.8. Installation of GCU

4.9. Wiring Connections

4.10.Installation of Normalising Measurements (Oxygen, Temperature

5.1. Pre-Commissioning Checks

5.3. Initial Set-Up Using SmartCOM Software

6.1. Serial Numbers (Complete on First Inspection)

6.2. Installation Records

6.3. Commissioning Records

7. Calibration and Measurement Verification

7.2. Factory Calibration

Appendix 1 Setting Analyser Gains

Appendix 2 - Output Memory Map

Date : September 2002

1. CODEL G-CEM4000 Analyser Introduction

Figure 1 : Typical SmartCEM System Arrangement

Date : September 2002

1.2. G-CEM4000 Basic Principles

Figure 2 :G-CEM4000 Analyser with 'in-situ' Probe

The Central Data Controller (CDC) that accepts data from 1 to 16

All elements of the G-CEM4000 analyser are sealed to IP65 (NEMA 4)

1.3. Emission Monitoring and the G-CEM4000

Date : September 2002

Up to 32 SCUs can be connected to a CDC via a single data bus.

No corruption of digital data, even over long distances.

Common data (e.g., normalisation measurements and plant status)

Real time display can show all measurements simultaneously.

Multi-level and period alarms can be freely configured for any

Up to 5 years data can be logged and instantly recalled in graphical

All processor user interface functions can be carried out from a

Reports can be formatted to suit local legislation and printed

Digital data can be transferred directly to the plant DCS or computer.

1.7. Analyser Protection

Measurement Temperature (Flue gas)

via pc running SmartCOM software

One for each main measurement channel

For connection to bi-directional 4-wire data bus

All units are designed to operate in ambient

All units are sealed to IP65 (NEMA 4) standards and

Power Supply Unit -

Purge Gas Requirements

Clean and dry to -20oC.

Gas Control Unit

3. Preparing for Installation