DCEM 2100 TUV Installalation & Commisioning Manual

SmartCEM
Continuous Emissions Monitoring System
Model D-CEM2100 TUV

Dust Monitor
QAL 1 Certified
Installation and
Commissioning Manual
PLEASE READ THIS DOCUMENT CAREFULLY BEFORE

BEGINNING INSTALLATION AND COMMISSIONING!!
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Installation & Commissioning Manual CODEL
Total Solutions – Total Confidence
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
CODEL International Ltd is a UK company based in the heart of the Peak District National Park in Bakewell,
Derbyshire. The company specialises in the design and manufacture of high-technology instrumentation for
monitoring combustion processes and atmospheric pollutant emissions.
The constant search for new products and existing product improvement keeps CODEL one-step-ahead. With a
simple strategy, to design well-engineered, rugged, reliable equipment, capable of continuous operation over
long periods with minimal maintenance, CODEL has set standards both for itself and for the rest of the industry.
All development and design work is carried out ‘in-house’ by experienced engineers using state-of-the-art CAD
and software development techniques, while stringent assembly and test procedures ensure that the highest
standards of product quality, synonymous with the CODEL name, are maintained.
High priority is placed upon customer support. CODEL’s dedicated team of field and service engineers will
assist with any application problem to ensure that the best possible use is derived from investment in CODEL
quality products.
If you require any further information about CODEL or its products, please contact us using one of the numbers
below.
CODEL International Ltd

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
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Contents
1. Installation
1.1 Equipment List 5
1.2 Positioning the Equipment 8
1.3 Installation 8
1.3.1 Air Purges 10
1.3.2 Ball Valves 11
1.3.3 Transceivers 12
1.3.4 PSU & SPU 12
1.3.5 DDU 13
2. Electrical Connections 14
2.1 Installation and Connection of cables 14
2.2 Connection Schedule 14
3. Commissioning 17
3.1 Pre-Commissioning Checks 17
3.2 Mounting Air Purges 18
3.3 Aligning Air Purges 18
3.4 Fitting Purges and Ball Valves 19
3.5 Check Wiring 19
3.6 Connect Air Supply 19
3.7 Measure Resistance 20
3.8 Power Up 20
3.9 Check Solenoid Voltage 20
3.10 Open Ball Valves 20
3.11 Close Ball Valves 21
3.12 Mounting Transceivers 21
3.13 Measure Resistance 22
3.14 Alignment 22
3.15 Setting Instrument Gains 24
3.15.1 Detector Levels 24
3.15.2 Transmissivities 24
3.15.3 Zero and Span Calibration 24
4. Requirements for EN 14181 26
5. Table of Figures 27
Supplement 1 - Installation of a Second DDU to the D-CEM2100 28
Supplement 2 - Zero Point Alignment tube 30
Supplement 3 - Zero Point Alignment Procedure 33
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Important!!
The warning signs (and meanings) shown below, are used throughout these instructions and are intended to
ensure your safety while carrying out installation, operation and maintenance procedures. Please read these
instructions fully before proceeding.
Caution, risk of electric shock.
Caution, risk of danger.
Caution, hot surface.
Earth (ground) terminal.
Protective conductor terminal.
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Installation & Commissioning Manual Page 5 CODEL
1.Installation
1.1. Equipment List

The CODEL Model D-CEM2100 TUV comprises the following:
 2 x Transceivers with 10m of cable (standard length)
Figure 1: DCEM Transceiver Head
 2 x Site Mounting Flanges
Figure 2: Site Mounting Flange
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 2 x Air Purges
Figure 3: Air Purge
 2 x Ball Valves
Figure 4: Ball Valve Assembly
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 1 x Power Supply Unit (PSU)
Figure 5: Power Supply Unit

 1 x Signal Processor Unit (SPU)
Figure 6: Signal Processor Unit

 1 x Data Display Unit (DDU)
A second DDU can also be connected to the SPU if required – see Supplement 1 at the end of this document.
Figure 7: Data Display Unit

Issue: A
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1.2. Positioning the Equipment

The equipment is designed for mounting on stacks in positions open to the weather. It is fully sealed to IP65
and requires no weather covers.
Consider the following:
1. The sensor mounting points must be accessible at both sides of the duct for servicing the
transceivers.
2. The sensor mounting points should be as free as possible from extremes of temperatures and
vibration.
NB. At low temperatures, condensation might occur on the lens of the instrument causing an incorrect
(high) opacity reading.
3. There must be an uninterrupted sight path between each transceiver.
4. The SPU should be mounted locally to the transceivers, which are supplied with 10m of cable
as standard.
1.3. Installation
The transceivers and any other items are normally protected for transportation by an expanded foam packing
material. When unpacking, please ensure that smaller items are not discarded with the packing material.
The analysers are supplied with standard 10m cables already connected.
If any items are missing please inform CODEL or your local CODEL supplier immediately.
The installation site should be free of all encumbrances and safety procedures should be observed at all times.
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
The recommended order, reflected in this manual, is:
 Installation of the stub-pipe and mounting flange
 Installation of air purges
 Fitting of ball valves and air supply
 Fitting of transceiver heads, PSU, SPU and DDU
 Installation and connection of cables
The transceivers should be mounted on diametrically opposite sides of the stack.
Construct the mounting assemblies by welding each site mounting flange to a suitable stub-pipe, nominal bore
75mm. The pipe should be long enough to keep the equipment clear of any duct lagging and it also helps to
insulate the equipment from high duct temperatures. Suggested stub-pipe mounting arrangements are shown in
Figure 8 for a metal stack and for a concrete stack. In the case of a metal stack it may be necessary to fit
stiffening ribs for added rigidity.
Figure 8: Stub Pipe Arrangement
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
1.3.1. Air Purges
The purpose of the air purges is to keep the windows of the transceivers clean. The air purges mount directly
onto the site mounting flanges. Separate the front flange from the air-purge by unscrewing the four retaining
nuts. This should now be bolted to the site-mounting flange with a rigid gasket fitted between them, using the
four countersunk screws provided.
The rear flange is then offered up to the front flange on to the protruding studs, taking care that the ‘O’ ring seal
on the flange locates smoothly into the central aperture. This is then re-secured by the four nuts that screw
down onto the adjustable flange. The arrangement should now appear as in Figure 9.
Front flange Adjustable flange
Site mounting flange
Stack mounting tube Air purge
Adjusting nuts
Rigid gasket
Figure 9: Adjustable Mount Details
Issue: A
Revision:
Date: 04/02/15
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1.3.2. Ball Valves
The ball valves are mounted to the air purges using four M6 hexagon head screws. Note that these screws
locate through the nylon insulating bushes in the air purge flange and screw into the valve flange. The nylon
insulation bushes are essential to maintain electrical isolation of the transceivers from the duct.
Make sure that the nylon insulating bushes are fitted to the air purge flange – if not fitted, DO
NOT attach the transducers and contact CODEL immediately.
Compressed air connections to the ball valve and air purge are as shown below. Failure of the compressed air
supply will result in the ball valves closing and isolating the transceivers from the flue gas.
Do not insert fingers into the ball valve mechanism at any time while the compressed air is
connected. If the valve closes unexpectedly it will remove a finger end quite easily!
Figure 10: Compressed Air Connections at the Ball Valve
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
1.3.3. Transceivers
By means of four hexagon head screws, the transceiver head/ball valve assemblies may be attached to the air
purges with the flexible gasket supplied, fitted between them. Take care to locate the dowel.
1.3.4. PSU & SPU
To mount the PSU & SPU, first remove the cover by loosening the four captive screws. The case is then
secured to a firm support by use of the four mounting holes, one in each corner of the case, outside the sealing
rim. Since the mounting holes are located outside the seal of the case, it is not necessary to seal the mounting
holes after installation, nor is it necessary to remove the circuitry from the case for installation.
If commissioning is not to be carried out immediately, reattach the lid to the processor. Dimensions and
mounting details are shown in figure 11.
Cable gland entry

blanking plug
(PSU mains)
Note: do not use these cable

entry points for mains cables.
Figure 11: PSU & SPU Mounting Details
NB. When fitting the mains cable in the PSU secure an M20 banjo earth ring under the gland locknut in
order to provide a good earth bond.
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
1.3.5. DDU
To mount the DDU, first remove the cover by loosening the four captive screws and unplug the ribbon cable
from at the lid connection. The case is then secured to a firm support by use of the four mounting holes, one in
each corner of the case, outside the sealing rim. Since the mounting holes are located outside the seal of the
case, it is not necessary to seal the mounting holes after installation, nor is it necessary to remove the circuitry
from the case for installation.
If commissioning is not to be carried out immediately, reattach the lid to the processor. Dimensions and
mounting details are shown in figure 12.
Note: optional second DDU will be specified on the sales order see supplement 1 for installation details.
Figure 12: DDU Mounting Details
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
2. Electrical Connections
WARNING! Wiring should only be undertaken by a qualified technician.
Ensure that the power supply is isolated.
DO NOT switch power on until all wiring work is complete.
2.1. Installation and Connection of Cables

Decide routing for all non-power cables (both those supplied by CODEL and those sourced locally). Use
common routing wherever possible and install leaving sufficient free-end length to make final connections.
The maximum recommended length of the connecting cable between the SPU and the DDU (customer supply)
is 100m – if a greater length is required please contact CODEL before installation.
Power cables (customer supply – minimum rating 240vac, 6A) should be installed separately, using different
routes if possible to reduce the risk of cross interference. Leave sufficient free-end length to make final
connections. The maximum recommended cable length is 5m – if a greater length is required please contact
CODEL before installation.
CODEL supplied cables are provided with ferrite beads fitted to all cores to protect against interference and
should not be modified without consulting CODEL.
WARNING! Mains connection must be via a fused isolating spur and should only be
undertaken by a qualified technician.
See the electrical rating plate on the PSU.
2.2. Connection Schedule

The connection schedule for the D-CEM2100, PSU, SPU & DDU is shown in the following drawing (figure 13).
Issue: A
Revision:
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Figure 13: Connection Schedule
Issue: A
Revision:
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Ref: 100178
The following diagram illustrates how the DCEM 2100 TUV system should look when electrical connections
have been made.
Transceiver Transceiver
Purge Air IN Purge Air IN
Signal Power Data

Processor Supply Unit Display
Unit (SPU) (PSU) Unit (DDU)
48V Power
Mains Power IN
Data transfer to remote DDU Outputs
Transceiver Cable
Solenoid Drive Cable
Normalising Inputs
Figure 14: System Layout
U)
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
3. Commissioning
The instrument should now be fully installed and ready to be commissioned.
3.1. Pre-Commissioning Checks

Before proceeding the following checks should be carried out:
 If wiring has been installed and connected by others (and particularly if no certification of connection
accuracy exists), check all wiring and connections for conformity with the information provided.
 Although the instrument is equipped with all practical safeguards against the consequences of
incorrect wiring, it is not possible to provide total protection against all errors.
Please be aware that damage arising from incorrect wiring will invalidate the warranty.
 Finally check that the air purge is functioning. If not, take corrective action.
Now the system can be commissioned, complete the following points in the commissioning section making sure
to fill in the DCEM2100 TUV commissioning check list as you proceed.
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
3.2. Mounting Air Purges
Mount the Air Purges onto the duct mounted site flanges and ensure that all of the alignment studs are set to
mid-point.
Front Flange
Site Mounting Flange Adjustable Alignment studs
Stack Mounting Tube Air purge
Adjustable
Rigid Gasket Flange
Figure 15: Mounting Air Purges
3.3 Aligning Air Purges
Using an Alignment Telescope firstly align one purge with respect to the opposite purge, then align the
second purge with respect to the first purge. Re-check the alignment of both purges.
Air Purge
Alignment Telescope
Stack Mounting Tube
Figure 16: Aligning Air Purges
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
3.4 Fitting Air Purges and Ball Valves
Ensure there is no obstruction in either sight port and if clear install and secure the Air Purges and Ball
Valves for each transceiver but at this point DO NOT install the transceivers.
Air Purge
Alignment Telescope
Ball Valve Stack Mounting Tube
Figure 17: Fitting Air Purges and Ball Valves
3.5 Check Wiring
Check all interconnecting wiring is correct according to the connection schedule (figure 13), ensuring all
screens connections are made in the cable glands.
3.6 Connect Air Supply
With the Ball Valves mounted connect the air supply and ensure the pressure is >60psi. Ensure that the
solenoid drive cable entry is facing down to stop water ingress.
Air Supply
Ball Valve
Figure 18: Connect Air Supply
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
3.7 Measure Resistance
Measure and record the resistance between the duct work and Ball Valve mounting bolts .
3.8 Power Up
Apply power to the system.
3.9 Check Solenoid Voltage
In the signal Processor check the voltage on each of the solenoid connectors
S2 S1
Figure 19: Solenoid Voltage Check
3.10 Open Ball Valves
Look through one purge across the duct to the other – are both ball valves fully open? If not increase the
pressure of the plant air supply.
Figure 20: Open Ball Valve
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
3.11 Close Ball Valves
At the signal processor, unplug the solenoid supplies and check that the ball valve closes and
that the mirror is central; check that the ball valve opens again when the plugs are replaced.
S2 S1
Figure 21: Ball Valve Closed
3.12 Mounting Transceivers
Mount the transceiver heads at either side of the stack.
Transceiver Head
Air Purge Stack Mounting Tube
Ball Valve
Stack Mounting Flange
Mounted on Stack
Figure 22: Mounting Transceivers
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
3.13 Measure Resistance.

Measure the resistance between the head bolts and the site flange and record on the commissioning check-list.
Measure the resistance between cable gland on the head and the cable gland on the signal processor and
record on the commissioning check-list.
3.14 Alignment
In order for the instrument to function correctly, the transceiver units should be in optical alignment. Some
optical redundancy is present within the instrument and normal duct movements can be accommodated.
Each transceiver has an integral adjustable mount and air purge that are aligned using an optical telescope, as
follows:
- After fitting the air purge and ball valve bolt the alignment telescope to the ball valve flange as
shown below.
Ball Valve
Alignment Telescope
Figure 23: Fitting Alignment Telescope
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
- Referring to the illustration below, at the adjustable mount, lock the nuts at positions 1 & 3.
- By means of the adjusting nuts at positions 2 & 4, adjust the alignment of the transceiver (TRx1)
until the cross-hairs (viewed through the telescope) coincide with the vertical centreline of the light
from the red LED; lock the nuts at positions 2 & 4.
- Now unlock the nuts at positions 1 & 3 and, by means of the adjusting nuts at these positions,
adjust the alignment of the transceiver (TRx1) until the cross-hairs coincide with the horizontal
centreline of the light fr0m red LED; lock the nuts at positions 1 & 3.
2 4
With the nuts at positions 1 & 3

3 locked, adjustment at positions
2 & 4 will move the cross-hairs
horizontally.

2 4 locked, adjustment at positions
vertically.
Figure 24: Transceiver Optical Alignment
- With the four locking nuts tight check that the opposite transceiver (TRx2) is still in the centre of the
cross-hairs – adjust again if necessary.
- Repeat the operation with the alignment telescope attached to the ball valve flange on the opposite
transceiver (TRx2).
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
3.15. Setting Instrument Gains

Having installed the D-CEM2100 in accordance with the installation manual, ensure that purge air is flowing to
the purge units at about 1.5 l/sec. Check that the address in the D-CEM2100 control unit is set to 2.
3.15.1 Detector Levels
These levels should be set if the plant is known to be in total shutdown. If the plant condition is unknown then
set the levels to 5000-6000.
Next check the detector levels; the optimal values are: 10,000 ±1000 (Dr1 & Dr2) and 10,000 ±1000 (Dt1 & Dt2)
open path. The values of Dt1 & Dt2 are factory-set and should not require any adjustment. The Dr1 & Dr2
values will vary as a function of path length - to adjust these values the trim pots in the SPU must be adjusted
with an insulated trim pot screwdriver (see below).
Note: Once the detector

levels are set, it is
normal to see the levels
vary significantly during
normal operation.
Dr1 Dr2
Dt1 Dt2
Figure 25: Detector Level Check
Pressing the ‘up’ and ‘down’ arrows will scroll the display between the current Dr & Dt values.
3.15.2 Transmissivities
At this point, check the transmissivities to ensure proper operation and also check for gross misalignment. Error
between the two transmissions is expressed as % opacity - any value greater than 1% is too high and the
transceivers should be immediately re-aligned in accordance with the instructions given earlier.
3.15.3 Zero and Span Calibration
The final commissioning task is to initiate a zero and span calibration cycle, enter Mode 5 on the DDU and scroll
down to ‘Calibrate’; the current calibration parameters (stored in the SPU) will appear on the display.
The basic calibration on the instrument may be performed from here. It is preferable to conduct this operation
with the plant off with the stack clear of dust. However, if this is not possible, the instrument can calibrate to an
estimate of the opacity.
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Set the calibration target value to 0% opacity (or to an estimated value), and set the desired number of
calibration cycles – recommended 30 minimum.
On completion of the calibration cycle the instrument will automatically commence a window contamination
check to set the % obscuration to zero.
The window compensation routine is also instigated from Mode 5 – refer to Section 4.11. of the operating
manual. Set the number of window cycles – recommended 10 minimum.
NB. Remember - the calibration routine must be run during commissioning, otherwise the instrument
will not be able to calculate the true level within the duct. DO NOT run the calibration routine unless
reasonable conditions exist in the duct. If this is not the initial calibration, it is recommended that the
Gain Factor is recorded from the parameters option, before the calibration is
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
4. Requirements for EN 14181
Plants operating within the European Union that need to meet the requirements of the IPPC, Waste
Incineration Directive or the Large Combustion Plant Directive are required to follow EN 14181 for
the quality assurance of analyser performance.
This means, in essence, purchasing an analyser with a QAL 1 certification, calibrating it to the QAL 2
standard and then performing Annual Surveillance tests and a Linearity test. The QAL 2 calibration
may be undertaken up to six months after the initial installation, in order to allow the analyser to
“settle in”.
Prior to QAL 2 calibration, Annual Surveillance Testing and Linearity checking, the DCEM 2100 has
to have off-line checks performed to establish that it is working correctly. These checks are
undertaken on a Zero point alignment tube (see Supplement 2 – Zero Point Alignment tube).
This tube should be placed near the location of the sensors if possible to minimise disruption when
removing the sensors from the stack; if the tube is placed some distance from the stack, the sensors
and associated enclosure will have to be demounted and set up elsewhere, a very time consuming
procedure (see Supplement 3 – Zero Point Alignment tube procedure).
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
5. Table of Figures
Figure 1: DCEM Transceiver Head 5
Figure 2: Site Mounting Flange 5
Figure 3: Air Purge 6
Figure 4: Ball Valve Assembly 6
Figure 5: Power Supply Unit 7
Figure 6: Signal Processor Unit 7
Figure 7: Data Display Unit 7
Figure 8: Stub Pipe Arrangement 9
Figure 9: Adjustable Mount Details 10
Figure 10: Compressed Air Connections at the Ball Valve 11
Figure 11: PSU & SPU Mounting Details 12
Figure 12: DDU Mounting Details 13
Figure 13: Connection Schedule 15
Figure 14: System Layout 16
Figure 15: Mounting Air Purges 18
Figure 16: Aligning Air Purges 18
Figure 17: Fitting Air Purges and Ball Valves 19
Figure 18: Connect Air Supply 19
Figure 19: Solenoid Voltage Check 20
Figure 20: Open Ball Valve 20
Figure 21: Ball Valve Closed 21
Figure 22: Mounting Transceivers 21
Figure 23: Fitting Alignment Telescope 22
Figure 24: Transceiver Optical Alignment 23
Figure 25: Detector Level Check 24
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Supplement 1 – Installation of a Second DDU to the D-CEM2100

With the addition of a separate PCB in the SPU the D-CEM2100 can operate with a second
DDU, as follows:
- Turn OFF the power to the SPU at the isolator unit.
- Install PCB 802-604 into either slot 5 or slot 6 of the SPU.
- Connect a cable as shown in the supplementary connection schedule (next

page), between the second DDU and PCB 802-604 in the SPU.
- Set SW1 address switch (located on the micro-processor card) in the second
DDU to the same value as that already set in the first DDU.
- At the isolator unit, turn ON the power to the SPU and set parameters in the
second DDU as required.
The arrangement will now look like this:
Transceiver Transceiver
Purge Air IN Purge Air IN
SPU PSU DDU 1
48V Power Mains Power IN
Data transfer to remote DDU 1

Outputs
DDU 2
Data transfer to remote DDU 2

Outputs
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Supplementary Connection Schedule for Second DDU
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Supplement 2 - Zero Point Alignment tube

The Zero point alignment tube is a vital component in the accurate calibration of opacity
monitors. Calibration of these devices cannot be carried out on a stack due to the fact that dust
is ever present in the stack, even if the process is turned off, due to the venturi effect drawing
dust up the stack.
The tube can be obtained from CODEL International but because of their size and weight it is
normally uneconomical to do so. Operators are advised to construct their own and place it near
the dust monitor sampling point.
The arrangement below should be used on ducts less than 10 metres in width. For longer ducts
please contact CODEL International.
Optical stop end plate Optical stop end plate

Optical stop
Half way along tube Tube flange
This distance, from optical stop end plate to optical stop end plate,
must be exactly the same as the front flange to front flange distance
on the stack.
Material
The tube should be constructed from mild or stainless steel (preferably), 4” Schedule 40,
Nominal bore, tube. (114.4 mm diameter, wall thickness 6mm)
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Mounting Flange
Made from the same material as the tube and is welded to the tube.
Optical stops
Due to the slight divergence of the light beams, internal reflections are created which can cause
errors; to prevent this occurring, optical stops should be fitted at both ends of the tube and in the
centre. The assembly consists of two optical stop plates separated by threaded 6mm rod with a
Delrin stop placed in the centre of the tube.
Optical Stop end plate
160mm
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Derlin Optical Stop
Issue: A
Revision:
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Ref: 100178
Supplement 3 - Zero Point Alignment Procedure

The procedure for performing a calibration using the zero point alignment tube is as follows:
Note: It is crucial that the Zero Point alignment tube measures the same length as the front
flange to front flange distance on the stack to perform an accurate zero calibration.
a) Remove the sensors, check cell holder and Ball valve from the site mounting flange.
b) Place the sensors, check cell holder and Ball valve onto the Air purges of the Zero point
alignment tube.
c) Ensure that all the bolts are securely fastened.
Remove Remove
Fitted to stack
Fit Here Fit Here
Fitted to Zero Point Alignment tube
Zero Point Alignment tube
d) The compressed air should be attached to one air purge to allow a slow purge of air
through the tube. The other air purge should be left open
e) Go into the Configuration mode in the DDU and check that the path length is set to the
distance from site mounting flange to site mounting flange (in mm)
f) Now turn on the power and wait until the analyser has completed its start-up routines.
g) With the analyser still turned on, remove the sensor from one side of the tube leaving
the ball valve in place.
h) Bolt the alignment telescope to the ball valve flange as shown below using the two
hexagonal screws plain washers and nuts.
Alignment Telescope fitted
Alignment Telescope
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
Referring to the illustration below, at the adjustable mount, lock the nuts at positions 1 & 3.
1
Telescope Cross hairs
2 4
Red LED

locked, adjustment at positions
horizontally.
2 4
locked, adjustment at positions
vertically.
Issue: A
Revision:
Date: 04/02/15
Ref: 100178
i) By means of the adjusting nuts at positions 2 & 4, adjust the alignment of the transceiver (TRx1)
until the cross-hairs (viewed through the telescope) coincide with the vertical centreline of the
light from the red LED; lock the nuts at positions 2 & 4.
j) Now unlock the nuts at positions 1 & 3 and, by means of the adjusting nuts at these positions,
adjust the alignment of the transceiver (TRx1) until the cross-hairs coincide with the horizontal
centreline of the light from red LED; lock the nuts at positions 1 & 3.
k) Ensure the four locking nuts are tight and check that the opposite LED is still in the centre of the
cross-hairs – adjust again if necessary.
l) Remove the alignment telescope and replace the sensor element.
m) Repeat the operation with the alignment telescope attached to the ball valve flange of the
opposite transceiver.
n) Check the detector levels are as described in section 3.15. and if not adjust the detector levels
as necessary.
o) Finally, go to Calibrate and start a calibration procedure (see section 4.10. of the operating
manual).
IMPORTANT!
Note: the zero point alignment procedure should only be done once, each subsequent zero
calibration will only require the heads to be fitted to the tube, the alignment should still be
correct.
Note: when the zero point alignment tube is not in use, ensure that it is sealed at both ends to
ensure no dust or contamination can enter into the tube.
Issue: A
Revision:
Date: 04/02/15
Ref: 100178

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SmartCEM

Continuous Emissions Monitoring System

Model D-CEM2100 TUV

PLEASE READ THIS DOCUMENT CAREFULLY BEFORE

Total Solutions – Total Confidence

CODEL International Ltd

Tel : +44 (0) 1629 814 351

4. Requirements for EN 14181 26

Supplement 1 - Installation of a Second DDU to the D-CEM2100 28

Supplement 2 - Zero Point Alignment tube 30

Supplement 3 - Zero Point Alignment Procedure 33

Caution, risk of electric shock.

Caution, risk of danger.

Caution, hot surface.

Earth (ground) terminal.

Protective conductor terminal.

1.1. Equipment List

 2 x Transceivers with 10m of cable (standard length)

Figure 1: DCEM Transceiver Head

 2 x Site Mounting Flanges

Figure 2: Site Mounting Flange

Figure 3: Air Purge

Figure 4: Ball Valve Assembly

 1 x Power Supply Unit (PSU)

Figure 5: Power Supply Unit

Figure 6: Signal Processor Unit

Figure 7: Data Display Unit

1.2. Positioning the Equipment

Consider the following:

3. There must be an uninterrupted sight path between each transceiver.

 Installation of the stub-pipe and mounting flange

 Installation of air purges

 Fitting of ball valves and air supply

 Fitting of transceiver heads, PSU, SPU and DDU

 Installation and connection of cables

The transceivers should be mounted on diametrically opposite sides of the stack.

Figure 8: Stub Pipe Arrangement

1.3.1. Air Purges

Front flange Adjustable flange

Site mounting flange

Stack mounting tube Air purge

Figure 9: Adjustable Mount Details

Figure 10: Compressed Air Connections at the Ball Valve

1.3.4. PSU & SPU

Cable gland entry

Note: do not use these cable

Figure 11: PSU & SPU Mounting Details

Figure 12: DDU Mounting Details

Ensure that the power supply is isolated.

DO NOT switch power on until all wiring work is complete.

2.1. Installation and Connection of Cables

See the electrical rating plate on the PSU.

2.2. Connection Schedule

Figure 13: Connection Schedule

Purge Air IN Purge Air IN

Signal Power Data

Figure 14: System Layout

3.1. Pre-Commissioning Checks

3.2. Mounting Air Purges

Site Mounting Flange Adjustable Alignment studs