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020038
G-CEM 4000
Multi-Gas Analyser
Installation, Commissioning, Operation
and Maintenance Manual
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While every effort has been made to ensure that this manual is free from errors,
CODEL supply all information without warranty.
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Table of Contents
1. CODEL G-CEM4000 Analyser Introduction
1.1. Foreword
1.6. CDC Serial Port - for use with the CODEL IEM system
2. Summary Specification
10
13
3.1. Unpacking.
13
15
17
3.4. Services
18
4. Installation
19
19
21
23
26
26
29
29
29
31
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37
and Pressure)
4.11.Installation of Calibration Gases
5. Commissioning
37
39
39
5.2. Power On
40
40
6. Analyser Records
68
68
68
68
70
7.1. Introduction
70
70
7.3. Verification
70
7.4. Re-calibration
73
8. Maintenance
74
9. Fault Finding
75
76
77
List of Figures
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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.
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1.3.2. Verification
It is important that the accuracy of measurement can be verified. Often,
legislation requires the regular testing, reporting and correction of measurement
zero and span. G-CEM4000 analysers are equipped with automatic zero
verification and correction procedures that allows the measurement cell to
be flooded with dry air (or Nitrogen) to provide a zero check or a certified
calibration gas as a span verification.
1.4. User Interface
The analyser is supplied with SmartCOM pc software that enables a pc
connected to the SCU to display of all real-time measurements as well as the
setting up and display of all the analysers configurable operating parameters.
This interface includes a diagnostic mode that allows interrogation of the
condition of the analysers critical functions for service and trouble-shooting
purposes. A full description is provided in Section 5.
1.5. Analogue and Logic Inputs and Outputs
The G-CEM4000 SCU is equipped with an analogue output (0/4-20mA) for
each measurement channel (up to seven). Each output is freely configurable
for any span (within the limits for that measurement, as given in Section 2.
Summary Specification and measurement units (vpm or %, mg/m 3, mg/Nm3).
Volt-free contact outputs (250V/10A) are provided for data valid and
measurement alarm level (common output for all measurement channel
alarms).
Three 4-20mA inputs are provided for normalisation measurements (273
input impedance, 200V DC common mode voltage range). These inputs
are also able to provide isolated 24V DC supplies to drive either 2 or 3wire external normalisation measurement transducers.
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1.6. CDC Serial Port - for use with the CODEL IEM system
The CDC is equipped with a 2-way serial communications port for use with the
CODEL IEM system. On a plant where more than one CODEL analyser is
installed, this is the preferred method and, even for a single analyser
installation, can provide significant benefits. The main ones are:
All real time and historical data and diagnostics can be accessed
remotely via a MODEM.
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2. Summary Specification
Measurements
Main measurement channels (1-7)
any combination of up to seven gases from
CO/CO2/NO/NO2/SO2/HCl/UHC/H2O
Measurement Limits (maximum)
CO/NO/NO2/HCl/UHC
SO2
CO2/H2O
3000 vpm
25000 vpm
25%
Measurement Spans
CO/NO/NO2/SO2/HCl/UHC
CO2/H2O
selectable up to 9,999vpm
selectable up to 99%
Note that although very low spans can be configured, this should not be
done without consideration of the measurement uncertainty.
Measurement Uncertainty
CO2
H 2O
Other gases
is the greater).
0.2%
0.2%
10vpm or 2% of measurement (whichever
mg/m3
mg/Nm3
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Display
real-time measurements
operating parameters
diagnostic information
set-up menus
Outputs
Analogue
(located in SCU)
Logic
(located in SCU)
Analogue
measurements
Inputs
Three 4-20mA inputs for normalising
237 input impedance, 200V DC common
mode voltage range (three of these inputs
incorporate isolated 24V DC supplies to
power loop-powered 2 or 3-wire transducers)
Serial Port
(located in Station
Control unit)
Ambient Temperature
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Enclosures
Power Requirements
85-264V AC
47-62Hz
200VA
Dimensions
Transceiver and probe
Overall length
Widest diameter
Probe length
Transceiver Length
Transceiver diameter
Probe weight
Transceiver weight
2450mm
350mm
2150mm
300mm
350mm
68kg
28kg
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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.
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Unit
Cables
Function
SCU
CDC (if
required)
Gas
Control
Unit
No. of
Cores
Core Specification/
c.s. area
O/D
min/max
Screened
YES/NO
Mains
Supply
Multi-strand 16/0.2mm,
0.5mm2 min.
5mm/12.8mm
No
Serial
Comms
Multi-strand 16/0.2mm,
0.5mm2 min.
5mm/12.8mm
YES
Serial
Comms
Multi-strand 16/0.2mm,
0.5mm2 min.
5mm/12.8mm
YES
Normalising
inputs
Multi-strand 16/0.2mm,
0.5mm2 min.
5mm/12.8mm
YES
Analogue
outputs
Multi-strand 16/0.2mm,
0.5mm2 min.
5mm/12.8mm
YES
Fault alarm
Multi-strand 16/0.2mm,
0.5mm2 min.
5mm/12.8mm
YES
Note that screened cables should have the screen terminated as described in
Section 4. Installation. If steel wire armoured cable is used, the steel wire
sheath should be earthed at the analyser end only.
Other Materials
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Compressed air supply (10 l/mincleaned and dry to -20C) for (a)
measurement cell purge (2 l/sec on demand) and (b) purging of
the neutral zone (0.5 l/min/sec continuous). 10mm o/d. PTFE
tube is required.
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CODEL Supply -
Customer Supply -
Non-CODEL monitors/analysers
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3.4. Services
Electrical Power
85-264V AC
47-62Hz
200VA
Compressed Air
@ 5bar
Dry (to -20C)
Clean (better than 10m)
Consumption :
10 l/min during calibration
5 l/min continuous
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4. Installation
PLEASE BE SURE TO READ SECTION 3. Preparing for Installation
BEFORE PROCEEDING
Installation of the several units that make up a 4000 Series analyser may be
carried out in any order. However, the recommended order, reflected in this
manual, is:
-
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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:
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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.
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CAUTION!
THE WINDOWS MAY BE DAMAGED BY THERMAL
SHOCK. IF THE PLANT IS OPERATING, SLIDE THE PROBE IN
GR ADU ALLY, PAUSING
FREQUENTLY TO ALLOW
TEMPERATURES TO STABILISE.
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SCU
power
supply
purge gas
filtration &
drying
equipment
zero/span
calibration
gas equipment
Figure 14 : GCU
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Mount the GCU to a suitable load bearing surface wall using 4 x M8 bolts.
Mounting hole details are shown in Figure 3. Connect the compressed air input
line to the input connector and the air lines from the GCU to the neutral zone
and measurement zone of the probe. Connect any span gases to the span
inputs of the GCU.
Connect the nylon/PTFE tube to the GCU input and the outputs to the probe
(see Figure 15). When the tubes have been connected to the probe, turn on
the compressed air. Set the regulator to the neutral zone to 10psi and a flow
rate to the measurement zone of 10 l/min. The regulators are actuated by lifting
the black cap and turning; to lock, press the cap down. The compressed air
must be clean and dry as detailed in the Section 2. Summary Specification.
zero air
solenoid
span 1
solenoid
neutral
zone
supply
measurement
zone supply
flow rotometer
span 2
solenoid
purge air
IN
automatic drains
OUT
no connection
required
span gas 1
input
span gas 2
input
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temperature
2-core
pressure
2-core
oxygen
2-core
local bus to
GCU 4-core
red
blue
orange
pink
red
blue
orange
grey
+ve
-ve
yellow
white
0V
MISO
MOSI
+V
green
black
blue
brown
link
10 (9) core
cable from
transceiver
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cable
connection
block
address switch
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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 :
zero calibration
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
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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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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Some of the data displayed is in hexadecimal (base 16) notation, not decimal
(base 10). Check the values against the table below and change any that are
incorrect.
The 'Thermistor measured value' and 'Cooler current' should now display at
values close to those selected.
Variable
Thermistor target value
Proportional Gain
Integral Gain
Time Constant
Hex or decimal
Hex
Decimal
Decimal
Decimal
Value
3800*
50
70
1
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Click Read to update the display values. Ensure that the green message
received LED illuminates to confirm that the data is current. Check these values
against those shown in the following table and adjust if necessary.
Function
Temperature target value
Proportional constant
Integral Constant
Time Constant
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Decimal
Decimal
Decimal
Decimal
Value
6700
50
70
2
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Hex or Decimal
Decimal
Decimal
Decimal
Decimal
Value
5500*
128
4
5
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.
transceiver mount
alignment flange
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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
Lock position
first maximum peak signal
fall-of
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e) Select detector wave forms in the Function box and the following
screen should be displayed.
2)
3)
1)
4)
Sample 2 start
6)
Sample 3
start
5)
Sample 3
end
7)
Sample 2 end
Sample 1 start
Comms. lights
Sample 1 end
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5) The displayed signal should look as shown below, with the six
lines protruding form it. These lines denote the three start and
three stop points of the sampling. At this point the sampling
positions made, need to be adjusted; this can be checked as
follows:
Space 1 should equal space 2.
1
2
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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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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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2)
3)
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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)
6)
7)
Click Apply.
8)
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 receive a continuous update set the 'Auto Update rate' and press 'Start'.
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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 :
0 - 4mA :
Data invalid :
Zero
Averaging value :
Span :
Zero :
Relay output
Abs. data location :
Averaging value :
Direction :
Alarm level :
Source :
2 byte
is
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Time in
minutes
1
2
3
4
5
6
7
8
9
10
11
12
Hexadecimal
value
0014
0028
003C
0050
0064
0078
008C
00A0
00B4
00C8
00DC
00FO
Refer to Appendix 2 - Output Memory Map for output location memory map.
To deduce what the factory settings for the analyser channels are, employ the
following method. Select 'Read' in the 'Function' box to view the following
screen. Select 'Master' in the 'Target destination' box, type 7EF8 in the 'Start
address' box and type 7 in the 'Number of bytes box. Click on 'Read' and data
should appear in the Data Access Window. If not, click on 'Read' until it does.
The data displayed in two number blocks relates to the species at each
channel.
1
2
3
4
5
6
7
8
9
0A
0B
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CO
CO2
NO
NO2
not used
SO2
not used
UHC/CH4
not used
H2O
HCL
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NO
CO2
CO
SO2
H20
HCL
Not used
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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
Monitoring Position
Installation Date
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CODEL
Zero: 0/4mA
Average
Units
Span
Fault Cond.
Set Zero
Set Span
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CODEL
OPS. 080
Issue : B
Revision :
70
CODEL
OPS. 080
Issue : B
Revision :
71
CODEL
b)
c)
OPS. 080
Issue : B
Revision :
72
CODEL
d)
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.
OPS. 080
Issue : B
Revision :
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CODEL
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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CODEL
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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CODE
L
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1
]
]
Ch2
]
]
Ch3
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
Ch1
]
]
Ch2
]
]
Ch3
] x Minute response
]
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
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CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01A0
Memory Map: mg/Nm3 data
******************************************************************************
Location
Description
01A0
}
Ch1
]
01A1
}
]
01A2
}
Ch2
]
01A3
}
]
3min
01A4
(Analyser} response)
]
Ch3
01A5
}
]
01A6
}
]
Ch4
01A7
}
]
01A8
}
]
Ch5
01A9
}
]
01AA
}
Ch6
01AB
}
] ]
01AC
}
Ch7
01AD
}
] ]
01AE
}
Dust
01AF
}
] ]
01B0
}
Ch1
01B1
}
]
]
01B2
}
Ch2
01B3
}
]
]
01B4
}
Ch3
01B5
}
]
] x Minute response
01B6
}
Ch4
01B7
}
]
]
01B8
}
Ch5
01B9
}
]
01BA
}
]
Ch6
01BB
}
]
01BC
}
Ch7
]
01BD
}
]
01BE
}
Dust
]
01BF
}
]
]
OPS. 080
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CODE
L
**********************************************************************
Model: SCU SmartCem Software ID: D07-019A Module:
MM01C0
Memory Map: mass flow:- kg/hr,g/s,g/h or Tonnes/year data
******************************************************************************
Location
Description
01C0
}
Ch1
01C1
}
01C2
}
Ch2
01C3
}
3min
01C4
(Analyser response)
}
Ch3
01C5
}
01C6
}
Ch4
01C7
}
01C8
}
Ch5
01C9
}
01CA
}
Ch6
01CB
}
01CC
}
Ch7
01CD
}
01CE
}
Dust
01CF
}
01D0
}
Ch1
01D1
}
01D2
}
Ch2
01D3
}
01D4
}
Ch3
01D5
}
01D6
}
Ch4
01D7
}
01D8
}
Ch5
01D9
}
01DA
}
Ch6
01DB
}
01DC
}
Ch7
01DD
}
01DE
}
Dust
01DF
}
]
]
]
]
]
]
]
]
]
]
] ]
] ]
] ]
]
]
]
]
]
]
] x Minute response
]
]
]
]
]
]
]
]
]
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CODEL
**********************************************************************
Model: SCU SmartCem Software ID: D07-019A Module:
MM01E0
Memory Map: Other data
******************************************************************************
Location
01E0
01E1
01E2
01E3
01E4
01E5
01E6
01E7
01E8
01E9
01EA
01EB
01EC
01ED
01EE
01EF
01F0
01F1
01F2
01F3
01F4
01F5
01F6
01F7
01F8
01F9
01FA
01FB
01FC
01FD
01FE
01FF
OPS. 080
Issue : B
Revision :
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Temperature degC
Oxygen/CO2 dry %(*10)
Pressure kPa
Water Vapour %(*10)
Opacity %(*100)
Extinction (*10000)
Flow m/s(*10)
Flow Nm/s(*10)
Flow m3/s
80
CODE
L
**********************************************************************
Model: SCU smartcem Software ID: D07-019A Module:
MM0100
Memory Map: Gcem 4000 data
******************************************************************************
Location
0100
0101
0102
0103
0104
0105
0106
0107
0108
0109
010A
010B
010C
010D
010E
010F
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
011A
011B
011C
011D
011E
011F
OPS. 080
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1 ppm
Ch2 ppm
Ch3 ppm
Ch4 ppm
Ch5 ppm
Ch6 ppm
Ch7 ppm
Temperature }
}
Oxygen
}
} Normalising data
Pressure
}
}
Water Vapour }
}
81
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CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0120
Memory Map: Dcem 2000 data
******************************************************************************
Location
0120
0121
0122
0123
0124
0125
0126
0127
0128
0129
012A
012B
012C
012D
012E
012F
0130
0131
0132
0133
0134
0135
0136
0137
0138
0139
013A
013B
013C
013D
013E
013F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Data Valid
Calibration in progress
Plant Status
Head identifier 05= Dcem2000
Reserved for SIU comms validation 00 = o.k., FF =
fail
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L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0140
Memory Map: Vcem 5000 data
******************************************************************************
Location
0140
0141
0142
0143
0144
0145
0146
0147
0148
0149
014A
014B
014C
014D
014E
014F
0150
0151
0152
0153
0154
0155
0156
0157
0158
0159
015A
015B
015C
015D
015E
015F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
x sec
}
}
y min
z hour
d day
x sec
y min
z hour
d day
}
} Flow m/s(*10)
}
}
}
}
}
}
}
} Flow m^3/s(*10)
}
}
}
}
Data Valid
Calibration in progress
Plant Status
Head identifier 06= Vcem0100
Reserved for SIU comms validation 00 = o.k., FF =
fail
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CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0160
Memory Map: Icem file
******************************************************************************
Location
0160
0161
0162
0163
0164
0165
data 0166
0167
0168
0169
016A
016B
016C
016D
016E
016F
0170
0171
0172
0173
0174
0175
0176
0177
0178
0179
017A
017B
017C
017D
017E
fail 017F
OPS. 080
Issue : B
Revision :
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1 ]
]
Ch2 ]
]
Ch3 ]
] Analogue input
Ch4 ]
]
Ch5 ]
]
Ch6 ]
]
Ch7 ]
]
Ch8 ]
]
Ch1 ]
Ch2 ]
Ch3 ]Logic input data
Ch4 ]
Ch5 ]
Ch6 ]
Ch7 ]
Ch8 ]
Data Valid
Calibration in progress
Plant Status
Head identifier 07= Icem0100
Reserved for SIU comms validation 00 = o.k., FF =
84
CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM0180
Memory Map: vpm data
******************************************************************************
Location
0180
0181
0182
0183
0184
0185
0186
0187
0188
0189
018A
018B
018C
018D
018E
018F
0190
0191
0192
0193
0194
0195
0196
0197
0198
0199
019A
019B
019C
019D
019E
019F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Ch1
]
]
Ch2
]
]
Ch3
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
Ch1
]
]
Ch2
]
]
Ch3
] x Minute response
]
Ch4
]
]
Ch5
]
]
Ch6
]
]
Ch7
]
]
Opacity ]
]
OPS. 080
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
85
CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01A0
Memory Map: mg/Nm3 data
******************************************************************************
Location
Description
01A0
}
Ch1
]
01A1
}
]
01A2
}
Ch2
]
01A3
}
]
3min
01A4
(Analyser} response)
]
Ch3
01A5
}
]
01A6
}
]
Ch4
01A7
}
]
01A8
}
]
Ch5
01A9
}
]
01AA
}
Ch6
01AB
}
] ]
01AC
}
Ch7
01AD
}
] ]
01AE
}
Dust
01AF
}
] ]
01B0
}
Ch1
01B1
}
]
]
01B2
}
Ch2
01B3
}
]
]
01B4
}
Ch3
01B5
}
]
] x Minute response
01B6
}
Ch4
01B7
}
]
]
01B8
}
Ch5
01B9
}
]
01BA
}
]
Ch6
01BB
}
]
01BC
}
Ch7
]
01BD
}
]
01BE
}
Dust
]
01BF
}
]
]
OPS. 080
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Date : September 2002
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CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01C0
Memory Map: mass flow:- kg/hr,g/s,g/h or Tonnes/year data
******************************************************************************
Location
Description
01C0
}
Ch1
01C1
}
01C2
}
Ch2
01C3
}
3min
01C4
(Analyser response)
}
Ch3
01C5
}
01C6
}
Ch4
01C7
}
01C8
}
Ch5
01C9
}
01CA
}
Ch6
01CB
}
01CC
}
Ch7
01CD
}
01CE
}
Dust
01CF
}
01D0
}
Ch1
01D1
}
01D2
}
Ch2
01D3
}
01D4
}
Ch3
01D5
}
01D6
}
Ch4
01D7
}
01D8
}
Ch5
01D9
}
01DA
}
Ch6
01DB
}
01DC
}
Ch7
01DD
}
01DE
}
Dust
01DF
}
]
]
]
]
]
]
]
]
]
]
] ]
] ]
] ]
]
]
]
]
]
]
] x Minute response
]
]
]
]
]
]
]
]
]
OPS. 080
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
87
CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01C0
Memory Map: mass flow:- kg/hr,g/s,g/h or Tonnes/year data
******************************************************************************
Location
Description
01C0
}
Ch1
]
01C1
}
]
01C2
}
Ch2
]
01C3
}
]
3min
01C4
(Analyser}response)
]
Ch3
01C5
}
]
01C6
}
]
Ch4
01C7
}
]
01C8
}
]
Ch5
01C9
}
]
01CA
}
Ch6
01CB
}
] ]
01CC
}
Ch7
01CD
}
] ]
01CE
}
Dust
01CF
}
] ]
01D0
}
Ch1
01D1
}
]
]
01D2
}
Ch2
01D3
}
]
]
01D4
}
Ch3
01D5
}
]
] x Minute response
01D6
}
Ch4
01D7
}
]
]
01D8
}
Ch5
01D9
}
]
01DA
}
]
Ch6
01DB
}
]
01DC
}
Ch7
]
01DD
}
]
01DE
}
Dust
]
01DF
}
]
]
OPS. 080
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Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM01E0
Memory Map: Other data
******************************************************************************
Location
01E0
01E1
01E2
01E3
01E4
01E5
01E6
01E7
01E8
01E9
01EA
01EB
01EC
01ED
01EE
01EF
01F0
01F1
01F2
01F3
01F4
01F5
01F6
01F7
01F8
01F9
01FA
01FB
01FC
01FD
01FE
01FF
OPS. 080
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Temperature degC
Oxygen/CO2 dry %(*10)
Pressure kPa
Water Vapour %(*10)
Opacity %(*100)
Extinction (*10000)
Flow m/s(*10)
Flow Nm/s(*10)
Flow m3/s
89
Issue : B
Revision :
Date : September 2002
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CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7E00
Memory Map: Internal EEROM
******************************************************************************
Location
Description
7E00
No. of heads connected to
SIU 7E01
7E02
}
7E03
}
7E04
}
7E05
}
7E06
}
7E07
}
7E08
}
Head #1 output file
location 7E09
}
7E0A
}
Head #2 output file
location 7E0B
}
7E0C
}
Head #3 output file
location 7E0D
}
7E0E
}
Head #4 output file
location 7E0F
}
7E10
7E11
7E12
7E13
7E14
7E15
7E16
7E17
7E18
7E19
7E1A
7E1B
7E1C
7E1D
7E1E
7E1F
Reference EEROM Location
OPS. 080
Issue : B
Revision :
90
CODE
L
******************************************************************************
Model:SCU smartcem Software ID: D07-019A Module: MM7EE0
Memory Map: Internal EEROM
******************************************************************************
Location
7EE0
7EE1
7EE2
7EE3
7EE4
7EE5
7EE6
7EE7
7EE8
7EE9
7EEA
7EEB
7EEC
7EED
7EEE
7EEF
7EF0
7EF1
7EF2
7EF3
7EF4
7EF5
7EF6
7EF7
7EF8
7EF9
7EFA
7EFB
7EFC
7EFD
7EFE
7EFF
OPS. 080
Description
Ch.1 definition
Ch.2 definition
Ch.3 definition
Ch.4 definition
Ch.5 definition
Ch.6 definition
Ch.7 definition
91
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
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) 7F07O2/CO2 dry/wet flag (00=DRY, 01=WET)
7F08
} Temperature }
7F09
}
}
7F0A
} Oxygen %(*10) }
Normalisation 7F0B
}
}
Standard levels 7F0C }
Pressure }
7F0D
}
}
7F0E
Water Vapour } (Water Vapour wet/dry flag)
7F0F
}
7F10
} Dust factor A }
7F11
}
} Dust calculated as [Aext'n +
B]ext'n 7F12
} Dust factor B }
7F13
}
}
7F14
} Cross Sectional Area m2
(*100) 7F15 }
for volumetric
flow
7F16
7F17
7F18
7F19
7F1A
7F1B
7F1C
7F1D
7F1E
7F1F
Reference EEROM Location (01 = SET DEFAULT VALUES AT POWER UP)
OPS. 080
Issue : B
Revision :
92
CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F20
Memory Map: Internal EEROM
******************************************************************************
Location
7F20
7F21
7F22
7F23
7F24
7F25
7F26
7F27
7F28
7F29
7F2A
7F2B
7F2C
7F2D
7F2E
7F2F
7F30
7F31
7F32
7F33
7F34
7F35
7F36
7F37
7F38
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
Divisor
]
] Mass flow ch1 = mg/m3 * vol. flow *
Multiplier
Multiplier
]
--------]
Divisor
Divisor
]
]Mass flow ch2
Multiplier ]
]
Divisor ]
] Mass flow ch3
Multiplier ]
]
Divisor
]
]Mass flow ch4
Multiplier ]
]
Divisor ]
] Mass flow ch5
Multiplier ]
]
Divisor
]
]Mass flow ch6
Multiplier ]
]
Divisor ]
7F39
}
] Mass flow
ch7 7F3A } Multiplier ]
7F3B
}
]
7F3C
} Divisor
]
7F3D
}
]Mass flow
ch8 7F3E } Multiplier ]
7F3F
}
]
OPS. 080
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
93
CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F40
Memory Map: Internal EEROM :- O/P parameters
******************************************************************************
Location
7F40
7F41
7F42
7F43
7F44
7F45
7F46
7F47
7F48
7F49
7F4A
7F4B
7F4C
7F4D
7F4E
7F4F
7F50
7F51
7F52
7F53
7F54
7F55
7F56
7F57
7F58
}
3mins 7F59
7F5A
7F5B
7F5C
7F5D
7F5E
7F5F
OPS. 080
Issue : B
Revision :
Description
Averaging rate #0h
Averaging rate #1h
Averaging rate #2h
Averaging rate #3h
Averaging rate #4h
Averaging rate #5h
Averaging rate #6h
Averaging rate #7h
Averaging rate #8h
Averaging rate #9h
Averaging rate #Ah
Averaging rate #Bh
Averaging rate #Ch
Averaging rate #Dh
Averaging rate #Eh
Averaging rate #Fh
Averaging rate #10h
Averaging rate #11h
Averaging rate #12h
Averaging rate #13h
Averaging rate #14h
Averaging rate #15h
Averaging rate #16h
Averaging rate #17h
ave update counter
(686 * 262.14ms = 179.828s) approx
}
94
CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F60
Memory Map: Internal EEROM :- DAC Calibration Data
******************************************************************************
Location
7F60
7F61
7F62
7F63
7F64
7F65
7F66
7F67
7F68
7F69
7F6A
7F6B
7F6C
7F6D
7F6E
7F6F
7F70
7F71
7F72
7F73
7F74
7F75
7F76
7F77
7F78
7F79
7F7A
7F7B
7F7C
7F7D
7F7E
7F7F
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
DAC span }
} Ch.1
DAC zero }
}
DAC span }
}Ch.2
DAC zero }
}
DAC span }
} Ch.3
DAC zero }
}
DAC span }
}Ch.4
DAC zero }
}
DAC span }
} Ch.5
DAC zero }
}
DAC span }
}Ch.6
DAC zero }
}
DAC span }
} Ch.7
DAC zero }
}
DAC span }
}Ch.8
DAC zero }
}
OPS. 080
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
95
CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7F80
Memory Map: Internal EEROM :******************************************************************************
Location
7F80
7F81
7F82
7F83
7F84
7F85
7F86
7F87
7F88
7F89
7F8A
7F8B
7F8C
7F8D
7F8E
7F8F
7F90
7F91
7F92
7F93
7F94
7F95
7F96
7F97
7F98
7F99
7F9A
7F9B
7F9C
7F9D
7F9E
7F9F
OPS. 080
Issue : B
Revision :
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
96
CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7FA0
Memory Map: Internal EEROM :******************************************************************************
Location
7FA0
7FA1
7FA2
7FA3
7FA4
7FA5
7FA6
7FA7
7FA8
7FA9
7FAA
7FAB
7FAC
7FAD
7FAE
7FAF
7FB0
7FB1
7FB2
7FB3
7FB4
7FB5
7FB6
7FB7
7FB8
7FB9
7FBA
7FBB
7FBC
7FBD
7FBE
7FBF
OPS. 080
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
97
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
CODEL
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module:
MM7FC0
Memory Map: Internal EEROM :******************************************************************************
Location
7FC0
7FC1
7FC2
7FC3
7FC4
7FC5
7FC6
7FC7
7FC8
7FC9
7FCA
7FCB
7FCC
7FCD
7FCE
7FCF
7FD0
7FD1
7FD2
7FD3
7FD4
7FD5
7FD6
7FD7
7FD8
7FD9
7FDA
7FDB
7FDC
7FDD
7FDE
7FDF
OPS. 080
Issue : B
Revision :
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
98
CODE
L
******************************************************************************
Model: SCU SmartCem Software ID: D07-019A Module: MM7FE0
Memory Map: Internal EEROM :******************************************************************************
Location
7FE0
7FE1
7FE2
7FE3
7FE4
7FE5
7FE6
7FE7
7FE8
7FE9
7FEA
7FEB
7FEC
7FED
7FEE
7FEF
7FF0
7FF1
7FF2
7FF3
7FF4
7FF5
7FF6
7FF7
7FF8
7FF9
7FFA
7FFB
7FFC
7FFD
7FFE
7FFF
OPS. 080
Description
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
}
99
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
CODEL
List of Figures
Figure 1 : Typical SmartCEM System Arrangement
13
14
16
21
21
22
22
24
25
27
28
Figure 14 : GCU
29
30
33
34
35
35
36
36
38
41
42
49
OPS. 080
Issue : B
Revision :
Date : September 2002
Doc i/d : 0080/6
100