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. © CODEL International Ltd. September 2002

Station Building, Station Road
Bakewell, Derbyshire DE45 1GE
England

Tel : +44 (0) 1629 814 351

Fax : +44 (0) 8700 566 307
e-mail : [email protected]
web site : www.codel co.uk We reserve the right to modify designs without prior notice.

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Table of Contents
1. CODEL G-CEM4000 Analyser – Introduction 1

1.1. Foreword 1
1.2. Basic Principles 3
1.3. Emission Monitoring and the G-CEM4000 6
1.4. User Interface 7
1.5. Analogue and Logic Inputs and Outputs 7
1.6. CDC Serial Port - for use with the CODEL IEM system 8
1.7. Analyser Protection 9

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 37

5. Commissioning 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 100

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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 in-
situ 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 CO2 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 cross-
duct 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/m3 (which is a
mathematical conversion depending on the molecular weight of the gas being
measured and the flue gas temperature), or in mg/Nm3 (i.e. ’normalised’ to the
required standard conditions).

When the outputs are required to be normalised to a pre-defined O2

concentration as opposed to a CO2 level, then an external O2 4-20mA signal
representing Oxygen levels can be input into the G-CEM4000. All other
normalising parameters i.e. pressure, temperature, and CO2 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/m3, 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 (273Ω Ω

input impedance, ±200V DC common mode voltage range). These inputs
are also able to provide isolated 24V DC supplies to drive either 2 or 3-
wire 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 3000 vpm

• SO2 25000 vpm
• CO2/H2O 25%

Measurement Spans

• CO/NO/NO2/SO2/HCl/UHC selectable up to 9,999vpm

• CO2/H2O 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 ± 0.2%
• H 2O ± 0.2%
• Other gases ± 10vpm or ±2% of measurement (whichever
is the greater).

Measurement Temperature (Flue gas)

• 0-200°C (up to 400°C 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 One for each main measurement channel

(located in SCU) (channels 1 to 7) 0/4-20mA isolated
500Ω max. load
Fully configurable in measurement units (vpm
or %, mg/m3, mg/Nm3), and span

• Logic
(located in SCU)

Inputs

• Analogue Three 4-20mA inputs for normalising

measurements
237Ω 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 For connection to bi-directional 4-wire data bus

(located in Station terminating at the CDC when installed as part
Control unit) of an integrated emission monitoring (IEM) system

Ambient Temperature All units are designed to operate in ambient

temperatures of -20°C to +55°C
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 2450mm

Widest diameter 350mm
Probe length 2150mm
Transceiver Length 300mm
Transceiver diameter 350mm
Probe weight 68kg
Transceiver weight 28kg

• Gas Control Unit

W800mm x H1000mm x D200mm

Weight 100kg

• CDC

W300mm x H250mm x D315mm

Weight 26kg

• Junction Box

W160mm x H160mm x D90mm

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 GCU’s 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 -20°C to +55°C. 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.

• Cables

No. of Core Specification/ O/D Screened

Unit Function
Cores c.s. area min/max YES/NO
Mains Multi-strand 16/0.2mm,
3 5mm/12.8mm No
Supply 0.5mm2 min.
SCU
Serial Multi-strand 16/0.2mm,
4 5mm/12.8mm YES
Comms 0.5mm2 min.

CDC (if Serial Multi-strand 16/0.2mm,

4 5mm/12.8mm YES
required) Comms 0.5mm2 min.

Normalising Multi-strand 16/0.2mm,

2 5mm/12.8mm YES
inputs 0.5mm2 min.
Gas
Analogue Multi-strand 16/0.2mm,
Control 2 5mm/12.8mm YES
outputs 0.5mm2 min.
Unit
Multi-strand 16/0.2mm,
Fault alarm 2 5mm/12.8mm YES
0.5mm2 min.

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 -20°C) 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 -20°C)
- Clean (better than 10µm)
- 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 50 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 stub-
pipe 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 stub-pipes, 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
GRADUALLY, 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.

power
SCU
supply

purge gas
zero/span
filtration &
calibration
drying
gas equipment
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 neutral

solenoid zone
supply
span 1
solenoid
measurement
zone supply

flow rotometer

span 2
solenoid

purge air span gas 1

IN input
automatic drains span gas 2
OUT input
no connection
required

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. Re-
fit 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
red orange
pressure blue pink link 10 (9) core
2-core red orange cable from
blue grey transceiver
oxygen +ve yellow
2-core -ve white
0V green
MISO black
local bus to GCU MOSI blue
4-core +V brown

Figure 18 : Cable Connections in the Junction Box

Figure 19 : Cable Gland

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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 237Ω 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 Hex or decimal Value

Thermistor target value Hex 3800*
Proportional Gain Decimal 50
Integral Gain Decimal 70
Time Constant Decimal 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 Hex or Decimal Value

Temperature target value Decimal 6700
Proportional constant Decimal 50
Integral Constant Decimal 70
Time Constant Decimal 2

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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 Hex or Decimal Value

Temperature target value Decimal 5500*
Proportional constant Decimal 128
Integral Constant Decimal 4
Time Constant Decimal 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 fall-off

peak signal

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 3
6) Sample 2 start start
5)

Sample 3
7)
end

Sample 2 end
Comms. lights Sample 1 start 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:

1
2

Space 1 should equal space 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 photo-
detector 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 WindowsR, 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 is
averaged as described above

Direction : Normal = NO and Reverse (failsafe) in NC

Alarm level : alarm threshold in decimal

Source : 2 byte

* Averaging time values

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Time in Hexadecimal
minutes value
1 0014
2 0028
3 003C
4 0050
5 0064
6 0078
7 008C
8 00A0
9 00B4
10 00C8
11 00DC
12 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.

01 CO
02 CO2
03 NO
04 NO2
05 not used
06 SO2
07 not used
08 UHC/CH4
09 not used
0A H2O
0B HCL

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So using the example shown below:

7EF8; 03 02 01 06 0A 0B FF

Channel 1 NO
Channel 2 CO2
Channel 3 CO
Channel 4 SO2
Channel 5 H20
Channel 6 HCL
Channel 7 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 1 2 3 4 5 6 7
Gas Measured
Identity (for IEM)
Analogue Zero: 0/4mA
output
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 maintain their calibration
stability almost indefinitely, it is often necessary to verify measurement
performance. This may be a routine check after an extended period of
operation, to confirm unusual measurements or as an audit requirement by
some external authority.

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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 (-20°C). 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.

• 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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• all measurements are normalised/corrected to the same

standard conditions of temperature, pressure, water vapour
(dry or wet) and excess oxygen (or CO2).

d) 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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Appendix 2 - Output Memory Map

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0180

Memory Map: vpm data

******************************************************************************

Location Description

0180 } Ch1 ]
0181 } ]
0182 } Ch2 ]
0183 } ]
0184 } Ch3 ] 3min (Analyser response)
0185 } ]
0186 } Ch4 ]
0187 } ]
0188 } Ch5 ]
0189 } ]
018A } Ch6 ]
018B } ]
018C } Ch7 ]
018D } ]
018E } Opacity ]
018F } ]
0190 } Ch1 ]
0191 } ]
0192 } Ch2 ]
0193 } ]
0194 } Ch3 ] x Minute response
0195 } ]
0196 } Ch4 ]
0197 } ]
0198 } Ch5 ]
0199 } ]
019A } Ch6 ]
019B } ]
019C } Ch7 ]
019D } ]
019E } Opacity ]
019F } ]

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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 } ]
01A4 } Ch3 ] 3min (Analyser response)
01A5 } ]
01A6 } Ch4 ]
01A7 } ]
01A8 } Ch5 ]
01A9 } ]
01AA } Ch6 ]
01AB } ]
01AC } Ch7 ]
01AD } ]
01AE } Dust ]
01AF } ]
01B0 } Ch1 ]
01B1 } ]
01B2 } Ch2 ]
01B3 } ]
01B4 } Ch3 ] x Minute response
01B5 } ]
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 } ]
01C4 } Ch3 ] 3min (Analyser response)
01C5 } ]
01C6 } Ch4 ]
01C7 } ]
01C8 } Ch5 ]
01C9 } ]
01CA } Ch6 ]
01CB } ]
01CC } Ch7 ]
01CD } ]
01CE } Dust ]
01CF } ]
01D0 } Ch1 ]
01D1 } ]
01D2 } Ch2 ]
01D3 } ]
01D4 } Ch3 ] x Minute response
01D5 } ]
01D6 } Ch4 ]
01D7 } ]
01D8 } Ch5 ]
01D9 } ]
01DA } Ch6 ]
01DB } ]
01DC } Ch7 ]
01DD } ]
01DE } Dust ]
01DF } ]

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**********************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01E0

Memory Map: Other data

******************************************************************************

Location Description

01E0 } Temperature degC

01E1 }
01E2 } Oxygen/CO2 dry %(*10)
01E3 }
01E4 } Pressure kPa
01E5 }
01E6 } Water Vapour %(*10)
01E7 }
01E8 } Opacity %(*100)
01E9 }
01EA } Extinction (*10000)
01EB }
01EC } Flow m/s(*10)
01ED }
01EE } Flow Nm/s(*10)
01EF }
01F0 } Flow m3/s
01F1 }
01F2
01F3
01F4
01F5
01F6
01F7
01F8
01F9
01FA
01FB
01FC
01FD
01FE
01FF

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**********************************************************************
Model: SCU smartcem Software ID: D07-019A Module: MM0100

Memory Map: Gcem 4000 data

******************************************************************************

Location Description

0100 } Ch1 ppm

0101 }
0102 } Ch2 ppm
0103 }
0104 } Ch3 ppm
0105 }
0106 } Ch4 ppm
0107 }
0108 } Ch5 ppm
0109 }
010A } Ch6 ppm
010B }
010C } Ch7 ppm
010D }
010E } Temperature }
010F } }
0110 } Oxygen }
0111 } } Normalising data
0112 } Pressure }
0113 } }
0114 } Water Vapour }
0115 } }
0116
0117
0118
0119
011A Purging Status (01=power up,02=plant off,0C=precal,08=in cal)
011B Calibration in progress
011C Plant Status
011D Head identifier
011E Reserved for SCU comms validation 00 = o.k., FF = fail
011F Slave13/Master03: SCU Data present command

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******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0120

Memory Map: Dcem 2000 data

******************************************************************************

Location Description

0120 } % Opacity (*100) } seconds

0121 } }
0122 } Extinction (*10000) }
0123 } }
0124 } Dust mg/m3 }
0125 } }
0126 } Dust mg/Nm3 }
0127 } }
0128 } % Opacity (*100) } minutes
0129 } }
012A } Dust mg/m3 }
012B } }
012C } Dust mg/Nm3 }
012D } }
012E } Temperature }
012F } }
0130 } Oxygen }
0131 } } Normalisation Data
0132 } Pressure }
0133 } }
0134 } Water Vapour }
0135 } }
0136
0137
0138
0139
013A Data Valid
013B Calibration in progress
013C Plant Status
013D Head identifier 05= Dcem2000
013E Reserved for SIU comms validation 00 = o.k., FF = fail
013F

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******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0140

Memory Map: Vcem 5000 data

******************************************************************************

Location Description

0140 } x sec }
0141 } }
0142 } y min }
0143 } } Flow m/s(*10)
0144 } z hour }
0145 } }
0146 } d day }
0147 } }
0148 } x sec }
0149 } }
014A } y min }
014B } } Flow m^3/s(*10)
014C } z hour }
014D } }
014E } d day }
014F } }
0150
0151
0152
0153
0154
0155
0156
0157
0158
0159
015A Data Valid
015B Calibration in progress
015C Plant Status
015D Head identifier 06= Vcem0100
015E Reserved for SIU comms validation 00 = o.k., FF = fail
015F

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******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0160

Memory Map: Icem file

******************************************************************************

Location Description

0160 } Ch1 ]
0161 } ]
0162 } Ch2 ]
0163 } ]
0164 } Ch3 ]
0165 } ] Analogue input data
0166 } Ch4 ]
0167 } ]
0168 } Ch5 ]
0169 } ]
016A } Ch6 ]
016B } ]
016C } Ch7 ]
016D } ]
016E } Ch8 ]
016F } ]
0170 Ch1 ]
0171 Ch2 ]
0172 Ch3 ]Logic input data
0173 Ch4 ]
0174 Ch5 ]
0175 Ch6 ]
0176 Ch7 ]
0177 Ch8 ]
0178
0179
017A Data Valid
017B Calibration in progress
017C Plant Status
017D Head identifier 07= Icem0100
017E Reserved for SIU comms validation 00 = o.k., FF = fail
017F

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******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0180

Memory Map: vpm data

******************************************************************************

Location Description

0180 } Ch1 ]
0181 } ]
0182 } Ch2 ]
0183 } ]
0184 } Ch3 ] 3min (Analyser response)
0185 } ]
0186 } Ch4 ]
0187 } ]
0188 } Ch5 ]
0189 } ]
018A } Ch6 ]
018B } ]
018C } Ch7 ]
018D } ]
018E } Opacity ]
018F } ]
0190 } Ch1 ]
0191 } ]
0192 } Ch2 ]
0193 } ]
0194 } Ch3 ] x Minute response
0195 } ]
0196 } Ch4 ]
0197 } ]
0198 } Ch5 ]
0199 } ]
019A } Ch6 ]
019B } ]
019C } Ch7 ]
019D } ]
019E } Opacity ]
019F } ]

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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 } ]
01A4 } Ch3 ] 3min (Analyser response)
01A5 } ]
01A6 } Ch4 ]
01A7 } ]
01A8 } Ch5 ]
01A9 } ]
01AA } Ch6 ]
01AB } ]
01AC } Ch7 ]
01AD } ]
01AE } Dust ]
01AF } ]
01B0 } Ch1 ]
01B1 } ]
01B2 } Ch2 ]
01B3 } ]
01B4 } Ch3 ] x Minute response
01B5 } ]
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 } ]
01C4 } Ch3 ] 3min (Analyser response)
01C5 } ]
01C6 } Ch4 ]
01C7 } ]
01C8 } Ch5 ]
01C9 } ]
01CA } Ch6 ]
01CB } ]
01CC } Ch7 ]
01CD } ]
01CE } Dust ]
01CF } ]
01D0 } Ch1 ]
01D1 } ]
01D2 } Ch2 ]
01D3 } ]
01D4 } Ch3 ] x Minute response
01D5 } ]
01D6 } Ch4 ]
01D7 } ]
01D8 } Ch5 ]
01D9 } ]
01DA } Ch6 ]
01DB } ]
01DC } Ch7 ]
01DD } ]
01DE } Dust ]
01DF } ]

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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 } ]
01C4 } Ch3 ] 3min (Analyser response)
01C5 } ]
01C6 } Ch4 ]
01C7 } ]
01C8 } Ch5 ]
01C9 } ]
01CA } Ch6 ]
01CB } ]
01CC } Ch7 ]
01CD } ]
01CE } Dust ]
01CF } ]
01D0 } Ch1 ]
01D1 } ]
01D2 } Ch2 ]
01D3 } ]
01D4 } Ch3 ] x Minute response
01D5 } ]
01D6 } Ch4 ]
01D7 } ]
01D8 } Ch5 ]
01D9 } ]
01DA } Ch6 ]
01DB } ]
01DC } Ch7 ]
01DD } ]
01DE } Dust ]
01DF } ]

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******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01E0

Memory Map: Other data

******************************************************************************

Location Description

01E0 } Temperature degC

01E1 }
01E2 } Oxygen/CO2 dry %(*10)
01E3 }
01E4 } Pressure kPa
01E5 }
01E6 } Water Vapour %(*10)
01E7 }
01E8 } Opacity %(*100)
01E9 }
01EA } Extinction (*10000)
01EB }
01EC } Flow m/s(*10)
01ED }
01EE } Flow Nm/s(*10)
01EF }
01F0 } Flow m3/s
01F1 }
01F2
01F3
01F4
01F5
01F6
01F7
01F8
01F9
01FA
01FB
01FC
01FD
01FE
01FF

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******************************************************************************
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

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CODEL

******************************************************************************
Model:SCU smartcem Software ID: D07-019A Module: MM7EE0

Memory Map: Internal EEROM

******************************************************************************

Location Description

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 Ch.1 definition
7EF9 Ch.2 definition
7EFA Ch.3 definition
7EFB Ch.4 definition
7EFC Ch.5 definition
7EFD Ch.6 definition
7EFE Ch.7 definition
7EFF

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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F00

Memory Map: Internal EEROM

******************************************************************************

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)
7F07 O2/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 92
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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F20

Memory Map: Internal EEROM

******************************************************************************

Location Description

7F20 } Divisor ]
7F21 } ] Mass flow ch1 = mg/m3 * vol. flow * Multiplier
7F22 } Multiplier ] ---------
7F23 } ] Divisor
7F24 } Divisor ]
7F25 } ]Mass flow ch2
7F26 } Multiplier ]
7F27 } ]
7F28 } Divisor ]
7F29 } ] Mass flow ch3
7F2A } Multiplier ]
7F2B } ]
7F2C } Divisor ]
7F2D } ]Mass flow ch4
7F2E } Multiplier ]
7F2F } ]
7F30 } Divisor ]
7F31 } ] Mass flow ch5
7F32 } Multiplier ]
7F33 } ]
7F34 } Divisor ]
7F35 } ]Mass flow ch6
7F36 } Multiplier ]
7F37 } ]
7F38 } Divisor ]
7F39 } ] Mass flow ch7
7F3A } Multiplier ]
7F3B } ]
7F3C } Divisor ]
7F3D } ]Mass flow ch8
7F3E } Multiplier ]
7F3F } ]

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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F40

Memory Map: Internal EEROM :- O/P parameters

******************************************************************************

Location Description

7F40 Averaging rate #0h

7F41 Averaging rate #1h
7F42 Averaging rate #2h
7F43 Averaging rate #3h
7F44 Averaging rate #4h
7F45 Averaging rate #5h
7F46 Averaging rate #6h
7F47 Averaging rate #7h
7F48 Averaging rate #8h
7F49 Averaging rate #9h
7F4A Averaging rate #Ah
7F4B Averaging rate #Bh
7F4C Averaging rate #Ch
7F4D Averaging rate #Dh
7F4E Averaging rate #Eh
7F4F Averaging rate #Fh
7F50 Averaging rate #10h
7F51 Averaging rate #11h
7F52 Averaging rate #12h
7F53 Averaging rate #13h
7F54 Averaging rate #14h
7F55 Averaging rate #15h
7F56 Averaging rate #16h
7F57 Averaging rate #17h
7F58 } ave update counter (686 * 262.14ms = 179.828s) approx 3mins
7F59 }
7F5A
7F5B
7F5C
7F5D
7F5E
7F5F

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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F60

Memory Map: Internal EEROM :- DAC Calibration Data

******************************************************************************

Location Description

7F60 } DAC span }

7F61 } } Ch.1
7F62 } DAC zero }
7F63 } }
7F64 } DAC span }
7F65 } }Ch.2
7F66 } DAC zero }
7F67 } }
7F68 } DAC span }
7F69 } } Ch.3
7F6A } DAC zero }
7F6B } }
7F6C } DAC span }
7F6D } }Ch.4
7F6E } DAC zero }
7F6F } }
7F70 } DAC span }
7F71 } } Ch.5
7F72 } DAC zero }
7F73 } }
7F74 } DAC span }
7F75 } }Ch.6
7F76 } DAC zero }
7F77 } }
7F78 } DAC span }
7F79 } } Ch.7
7F7A } DAC zero }
7F7B } }
7F7C } DAC span }
7F7D } }Ch.8
7F7E } DAC zero }
7F7F } }

OPS. 080 95
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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F80

Memory Map: Internal EEROM :-

******************************************************************************

Location Description

7F80 } Absolute data loc. } 0100h=NO addr 01

7F81 } } 0120h=NO addr 02
7F82 0/4mA (00=0mA 01=4mA) }
7F83 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7F84 Averaging value }
7F85 } Span } O/P 1
7F86 } }
7F87 } Zero }
7F88 } }
7F89 } Absolute data loc. } 0100h=NO addr 01
7F8A } } 0120h=NO addr 02
7F8B Averaging value }
7F8C Direction } Alarm 1
7F8D } Level }
7F8E } }
7F8F Source (00=1byte) }
7F90 } Absolute data loc. } 0100h=NO addr 01
7F91 } } 0120h=NO addr 02
7F92 0/4mA (00=0mA 01=4mA) }
7F93 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7F94 Averaging value }
7F95 } Span } O/P 2
7F96 } }
7F97 } Zero }
7F98 } }
7F99 } Absolute data loc. } 0100h=NO addr 01
7F9A } } 0120h=NO addr 02
7F9B Averaging value }
7F9C Direction } Alarm 2
7F9D } Level }
7F9E } }
7F9F Source (00=1byte) }

OPS. 080 96
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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7FA0

Memory Map: Internal EEROM :-

******************************************************************************

Location Description

7FA0 } Absolute data loc. } 0100h=NO addr 01

7FA1 } } 0120h=NO addr 02
7FA2 0/4mA (00=0mA 01=4mA) }
7FA3 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7FA4 Averaging value }
7FA5 } Span } O/P 3
7FA6 } }
7FA7 } Zero }
7FA8 } }
7FA9 } Absolute data loc. } 0100h=NO addr 01
7FAA } } 0120h=NO addr 02
7FAB Averaging value }
7FAC Direction } Alarm 3
7FAD } Level }
7FAE } }
7FAF Source (00=1byte) }
7FB0 } Absolute data loc. } 0100h=NO addr 01
7FB1 } } 0120h=NO addr 02
7FB2 0/4mA (00=0mA 01=4mA) }
7FB3 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7FB4 Averaging value }
7FB5 } Span } O/P 4
7FB6 } }
7FB7 } Zero }
7FB8 } }
7FB9 } Absolute data loc. } 0100h=NO addr 01
7FBA } } 0120h=NO addr 02
7FBB Averaging value }
7FBC Direction } Alarm 4
7FBD } Level }
7FBE } }
7FBF Source (00=1byte) }

OPS. 080 97
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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7FC0

Memory Map: Internal EEROM :-

******************************************************************************

Location Description

7FC0 } Absolute data loc. } 0100h=NO addr 01

7FC1 } } 0120h=NO addr 02
7FC2 0/4mA (00=0mA 01=4mA) }
7FC3 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7FC4 Averaging value }
7FC5 } Span } O/P 5
7FC6 } }
7FC7 } Zero }
7FC8 } }
7FC9 } Absolute data loc. } 0100h=NO addr 01
7FCA } } 0120h=NO addr 02
7FCB Averaging value }
7FCC Direction } Alarm 5
7FCD } Level }
7FCE } }
7FCF Source (00=1byte) }
7FD0 } Absolute data loc. } 0100h=NO addr 01
7FD1 } } 0120h=NO addr 02
7FD2 0/4mA (00=0mA 01=4mA) }
7FD3 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7FD4 Averaging value }
7FD5 } Span } O/P 6
7FD6 } }
7FD7 } Zero }
7FD8 } }
7FD9 } Absolute data loc. } 0100h=NO addr 01
7FDA } } 0120h=NO addr 02
7FDB Averaging value }
7FDC Direction } Alarm 6
7FDD } Level }
7FDE } }
7FDF Source (00=1byte) }

OPS. 080 98
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CODEL

******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7FE0

Memory Map: Internal EEROM :-

******************************************************************************

Location Description

7FE0 } Absolute data loc. } 0100h=NO addr 01

7FE1 } } 0120h=NO addr 02
7FE2 0/4mA (00=0mA 01=4mA) }
7FE3 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7FE4 Averaging value }
7FE5 } Span } O/P 7
7FE6 } }
7FE7 } Zero }
7FE8 } }
7FE9 } Absolute data loc. } 0100h=NO addr 01
7FEA } } 0120h=NO addr 02
7FEB Averaging value }
7FEC Direction } Alarm 7
7FED } Level }
7FEE } }
7FEF Source (00=1byte) }
7FF0 } Absolute data loc. } 0100h=NO addr 01
7FF1 } } 0120h=NO addr 02
7FF2 0/4mA (00=0mA 01=4mA) }
7FF3 Data invalid } 00=Zero 01=F.S. 02=Hold 03=Meas
7FF4 Averaging value }
7FF5 } Span } O/P 8
7FF6 } }
7FF7 } Zero }
7FF8 } }
7FF9 } Absolute data loc. } 0100h=NO addr 01
7FFA } } 0120h=NO addr 02
7FFB Averaging value }
7FFC Direction } Alarm 8
7FFD } Level }
7FFE } }
7FFF Source (00=1byte) }

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CODEL

List of Figures

Figure 1 : Typical SmartCEM System Arrangement 2

Figure 2 :G-CEM4000 Analyser with 'in-situ' Probe 4
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. 080 100

Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6