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1. etae tue otto s aede ao ID 21 Figure 20 Removing the End Cap from Course Filter Tube sess 24 Figure 21 Removing the Spring from Course Filter 24 Figure 22 Removing the Filter Rod from Course Filter Tube 24 Figure 23 Coarse Filter eene nnne nennen nnne 25 Figure 24 Removing the End Cap from Fine Filter Fitting 25 Figure 23 FANG 25 Figure 26 Optics Shield Outer Retaining SCrewsS ccccccccsssesseecceeeeeeeeeeseeeeeeeseueaseeeeeeeeeesseaseeeeeeeesssaaaaeess 26 Figure 27 Optics Shield Inner Retaining 26 Figure 28 Probe and Gas Sensor nennen nnne nnne nnns nani nnns 27 Table C T2100 System Ope6IlICallOHS ssec eren eben e ee 6 Table 2 Gas Sensor Power Connector Wiring nennen nnne 7 Table S Modbus Register 14 CT2100 On Stack Emissions Sensor User Manual Page 4 of 27 D 7010 0005 Revision 1 14th November 2008 1 Introduction 1 4 Customer Information This manual contains all the
2. xn E a OENE ance 12 Position o i 8 ns M M Es Ape E g Be P C Vertical right 17 i C UN x c AR pasa 2 EE Em EA 0 8 16 X 5 Mox M EERE REE pede 0 6 Scale 1900 15 fa NETT Ir Eo N E FERES 0 4 Position 14 d EE mr EUM 0 2 gem oo Lo S gt e e n o 302 Scale 1 v Time Date Message 11 51 47 12 11 2008 Sensors Sensor CT2100 initialised CT2000_HighSpeed 1 12 1 5 3 1 2 8 6 mitsui 127 0 1 1 Nov 12 12 10 35 2008 Figure 14 Graphed Data with Automatic Scaling CT2100 On Stack Emissions Sensor User Manual Page 18 of 27 D 7010 0005 Revision 1 14th November 2008 You can change the vertical scale manually by clicking on the Vertical or Vertical right check boxes and setting your desired scales Similarly the horizontal scale can be manually set between one second and ten minutes By default the Horizontal position displays the latest measurement on the graph This can be moved by enteri
3. ADC 10f 1 1102 1103 The value returned by ADC on sensor E g ADC 201 1 1104 1105 The value returned by ADC x sensor E g Gas Do Sensor temperature The number of gases on sensor one number increments GasConcentration 10f 1 1202 1203 1204 1205 1206 1207 1208 1209 50 1 12tu 12vw Table 3 Modbus Register Mapping CT2100 On Stack Emissions Sensor User Manual Page 14 of 27 D 7010 0005 Revision 1 14th November 2008 4 Operation The 2410 system should be installed and interconnected as detailed the previous sections prior to operation 4 1 System Start Up Do not power up or try to operate the Gas Sensor when it is not securely bolted to the CT2100 Probe with all connectors to probe and Control P C in place It is also important to power up the Gas Sensor probe and Ethernet switch if used before powering up the Control P C 4 2 CT2100 Probe The probe filters heat exchanger and sample are heated 160 C to prevent contaminants from building up on the surfaces The power to the probe heaters and their temperature 15 set from the Temperature Control Box For installation on a stack while it is in operation it is recommended that the mounted Gas Sensor and probe are powered up as soon as possible to prevent deposits building up on the unheated probe filters 4 3 Gas Sensor The Gas Sensor has no display and is entirely ope
4. 9 3 4 Physical 10 CIR AU ree 11 HAS tn ees 11 13 od set ut M E 13 SA OM em RE Torre 13 95d 13 el SOLS 13 GOO P 14 ERES 14 MER OS ele RET UTITUR 15 NES LI uberius 15 P EE TIU d E 15 team ete cee ee 15 5o MEE roii Na Pe a 15 4 5 Running the Gas Sensor 245 nns 16 ASG AOI WIEN MOO 16 45 2 Running with without MOODUS ce 16 4 6 Using the Gas Sensor Software cccccccscsscccccccccessssseceeecceeeeaseceeecesseeaseeeeeeesseeaasseeeeeeessseasseeeess 16 ciencia 17 052 INE E UTE 19 Ey a OO VR 20 44 1 Xraphindg and Saving hast otn 20 Zoo external Data Logger 21 System 22 5 1 Removing the Gas Sensor from the 22 52 the PEODS S
5. the cap replaced and tightened 6 3 Gas Sensor Dust may eventually accumulate on the Gas Sensor window and optics over time This will require the removal of the Optics Shield from the Gas Sensor This is achieved by removing the four Shield retaining cap screws as shown in the following figures Retaining screws Log T String University traceat NOLOGIES SEMS X T RJ lt rs 22 z opes 0 Figure 26 Optics Shield Outer Retaining Screws ps Shield a Figure 27 Optics Shield Inner Retaining Screws The windows on the orange box the sample cell and the two mirrors should be wiped clean using a lint free cloth The cleaning frequency is dependent on the environment around your stack 6 4 Control P C The Control P C should require no maintenance other than periodic exterior cleaning to remove surface dust T Troubleshooting CT2100 On Stack Emissions Sensor User Manual Page 26 of 27 D 7010 0005 Revision 1 14th November 2008 Appendix Probe and Gas Sensor Mounting 130 113395 NOlIO3rONd PONY GHIHL GEL NYOS ONIMWNG 3195 ION OG Jl vd ONINO OT Cy HSIN 15 OL 2 9 9 15 CTJAA JOYIS 2 V 00 NOILY TIV ISNI 000cLO 13 OL NOIIVOOI ONIdSVIS IV CIC 14M 39 OL Ads ON 31 99159 4114 NIW WWS X WYWWOSC X 066 dl NOIL
6. 8 External Data Logger Position Vertical right Scale Position Horizontal Scale 105 gt Position 0 T The external data logger is not supplied by Cascade Technologies Refer to your data logger documentation for further information on how to connect to and read from a Modbus server device over Ethernet User Manual D 7010 0005 Revision 1 14th November 2008 CT2100 On Stack Emissions Sensor Page 21 of 27 5 System Removal The following procedures should be followed when indicated in the Maintenance and Troubleshooting sections and for complete removal of the system from the stack The sample gas filters can be changed without the need to remove either the Gas Sensor from the CT2100 Probe or the Probe from the Stack 5 1 Removing the Gas Sensor from the Probe 1 Ensure that the Gas Sensor is stopped and powered down Reverse exactly the installation instructions detailed in the previous Gas Sensor installation section Care should be taken with the Gas Sensor while it is removed from the CT2100 Probe to ensure it does not undergo any physical damage 5 2 Removing the Probe from Stack The CT2100 Probe should only need to be removed from the stack for a complete system removal 1 The 2100 Probe must only removed once the emission source for that stack has been shut down and tagged off This is to ensure that no poisonous gases escape from the stabbing during maintenance The stabbing and pro
7. Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 23 of 27 Figure 20 Removing the End Cap from Course Filter Tube 2 Remove the spring from the course filter tube x ME Figure 21 Removing the Spring from Course Filter Tube 9 Hemove the filter rod from the course filter tube my Figure 22 Removing the Filter Rod from Course Filter Tube 4 The course filter can then be gently tapped to remove most of the dust Rinsing the filters under running water or cleaning with a stiff brush should remove the remaining contaminants Damaged filters should be replaced It is recommended that the filters be replaced annually CT2100 On Stack Emissions Sensor User Manual Page 24 of 27 D 7010 0005 Revision 1 14th November 2008 Figure 23 Coarse Filter Assembly S The course sintered filter and rod can then be reassembled and returned to the course filter tube reversing the procedure described above 6 2 2 Probe Fine Filter 1 Remove the end from the fine filter fitting as shown the Figure below Figure 24 Removing the End Cap from Fine Filter Fitting 2 The fine sintered filter can then be removed for cleaning in the same manner as the course filter Figure 25 Fine Filter User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 25 of 27 di The fine sintered filter is then placed back in the fitting
8. IO aussie ces SO Rm E Ut t 22 6 2 5 egg esca gus 23 Sat sat 23 51 2 7 23 ume TUE ee eee eee 23 om 1 AN ed 23 521 Probe COUISE 23 622 FNE es A aceon ns earner TII ete 25 26 GOMMONE c Lu M A 26 User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 3 of 27 Ts 1 92 aveo eu e cou tcu e 26 Appendix Probe and Gas Sensor Mounting 27 Figure 1 CT2100 On Stack Emission Sensor Overview 6 Figure 2 Typical o T2100 oett pred eb ite itu tbe asumen 9 Figure Typical Gas SONS Ol eal mens 10 Figure 4 Typical Temperature Control 10 Figure System ASSeTIPb Iy tae taraen t iata 11 Figure 6 Gas Sens
9. Revision 1 14th November 2008 Contents 1 Introduction 5 vias 57 O a a pi 5 125 5 5 1 4 Compliance Approvals 5 DONEC CINES TNT m 6 1 6 System anaa ia 6 2 SING Preparation csi 7 21 CXE2400 Probe Gas aces 7 21 4 StaCk Stabbing RNC IET TE 7 SION cadet 7 ACE UE Crean eee ER TCE EO 8 en MEME e ee 8 eaten le 8 EN 8 3 a a vest cus 9 Sela MOOISCOUIN CC UIT 9 3 2 Handling Precautions 9 3 3 Materials
10. for each Gas Sensor must be run from a suitable marine approved Ethernet switch to each stabbing installation point and back to the Control P C An Ethernet switch is not a Cascade supplied device Reference should therefore be made to the documentation that is supplied with the Ethernet switch for full installation requirements In all cases the Ethernet cables must be secured at regular intervals along their length and should not restrict any gangway or access or cause a trip hazard 2 2 Control P C 2 2 1 Location The Control for the CT2100 is designed for installation within a control room environment that meets the System Specification parameters listed previously In addition the environment should also 1 2 2 2 2 Be free from risk of direct liquid spillage and away from hot air vent For critical continuous monitoring applications power should be provided via a suitable marine approved uninterrupted power supply UPS capable of supplying 300W for the likely period of outage Power The Control P C requires its own power supply with isolating switch Refer to the System Specification parameters for the wattage required when specifying the current rating of a suitable circuit breaker The power cable should be marine approved and similar to 3 core round CMA code 3183Y 1 25 The power connecior for the Gas Sensor should be an IEC 60320 C13 socket Ethernet The Ethernet cab
11. quit at any time without damaging the Gas Sensor The last recorded concentration is displayed as shown below while the Gas Sensor is running and after clicking on the Stop button gt E Start Stop Background Preferences Quit NO2 ppm EtalonTemperature Pressure Torr Probe Temperature 0 00160367 18 4225 59 732 866 21841 7 22 UE f Plots Vertical Y m Position 0 600 uva dive uuo Uo g Vertical right EM Scale 1000 200 4 pM ID SS v ty Scale 105 hd Time Position 0 E Date Message 11 51 47 12 11 2008 Sensors Sensor CT2100 initialised CT2000 HighSpeed 1 12 1 5 3 1 v 2 8 6 mitsui 127 0 1 1 Wed Nov 12 11 56 18 2008 Figure 12 Analysing Gas Concentrations 4 6 1 Graphing Data To view the data graphically click on one of the displayed concentrations and drag it on to the Vertical left or Vertical right sections of the window This enables you to have two different scales User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th Novemb
12. 1994 5 1994 3260 This regulation implements into UK Law the Council directive 2006 95 EC the Low Voltage Directive Other approvals are pending User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 5 of 27 1 5 System Overview The 2100 On Stack Emission Sensor is a flexible continuous emissions monitoring system that be configured to measure the concentrations of multiple gases on multiple stacks simultaneously It consists of one or more gas sensor units mounted on stack to sample probes an Ethernet switch and a Control P C A Modbus interface is available from the Control P C for long term data logging In most cases within this manual reference to one probe can also be taken to apply to multiple probes The whole system can operate from an 110V or 240V A C supply Funnel Space Control Room Gas i Sensor ri 3 External Data Logger Ethernet Switch Ethernet Cables Ethernet Ethernet Modbus Stack Ethernet Cables to Additional Sensors Fibre Cable Figure 1 2100 On Stack Emission Sensor Overview Gas concentrations are measured using mid infra red optical absorption spectroscopy The light sources are quantum cascade lasers which are operated to produce wavelength sweeps that cover the absorption lines of the gases The las
13. CASCADE TECHNOLOGIES User Manual CT2100 On Stack Emissions Sensor Document Number D 7010 0005 Revision 1 14th November 2008 Published by Cascade Technologies Ltd All possible care has been taken in the preparation of this publication but Cascade Technologies its agents and distributors accept no liability for any inaccuracies that may be found This manual reflects the state of the product at the issue date below but further enhancements while in service may mean that the manual does not reflect your particular system Cascade Technologies reserves the right to make changes without notice both to this publication and the products which it describes Document Number D 7010 0005 Revision 1 14th November 2008 Cascade Technologies Ltd 2008 No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the express prior written permission of the copyright holder Cascade Technologies Limited Unit A Logie Court Stirling University Innovation Park Stirling FK9 4NF United Kingdom All trademarks used within this document are the property of their respective owners Caution use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure CT2100 On Stack Emissions Sensor User Manual Page 2 of 27 D 7010 0005
14. CT2100 On Stack Emissions Sensor system 2 1 CT2100 Probe and Gas Sensor 2 1 1 Stack Stabbing Location The CT2100 Emission Sensor is designed to be installed in the often harsh environment around the stack While this means the probe and Gas Sensor are extremely robust to cope with that environment there are still limits which must be considered when selecting an installation location Further details can be found in Appendix A Probe and Gas Sensor Mounting and these should be referred to in conjunction with the instructions below 1 2 1 2 The stack must be fitted with a stabbing and mounting flange preferably positioned at least five minimum three times the stack diameter from any upstream bends and two minimum 1 5 stack diameters from any downstream bends There must be easy access to the stabbing with sufficient clearance to the side and behind for the insertion and removal of the probe A suitable blanking flange and high temperature gasket is required to seal off the stub pipe when the CT2100 Probe is not mounted At least 0 5m free space between the bottom of the stub pipe and any obstructions Power Each Gas Sensor requires its own power supply as does the CT2100 Probe which receives its power from the Temperature Control Box 1 2 1 3 User Manual The power supply for the Gas Sensor and CT2100 Probe must be sufficient for the total load they generate Refer to the System Specification section f
15. Sensor Gas Sensor Ethernet Switch Control P C with DHCP Server i Customer Supplied Ethernet External Cables Data Logger A Gas Sensor Gas Sensor TE erver Ethernet EU Hal Allocated Modbus 18 Addresses Ethernet Cables to Additional Sensors Figure 9 Network Connectivity 3 5 4 Modbus If a Modbus enabled client for example a data logger is to be used with the system it can be connected to the same Ethernet switch if the device is configured to take its address from the Control If the Modbus client is on a fixed address is assigned an address from another DHCP server on the site network then a second Ethernet port on the Control P C must be used to connect to the Modbus client and DHCP disabled on that port on the Control P C Concentration and other system information are provided via the Modbus registers The structure of the numbering is shown in the table below All the Modbus registers for your particular installation can also be viewed using the Modbus Test Client utility supplied on the control P C Gas Sensor Software major version Gas Sensor Software minor version patchVersion Gas Sensor Software patch version numberOfSensors 10 11 The number of sensors connected to the Control P C The number of ADCs on sensor one number increments NS 1000 for the next subsequent sensors
16. V TIVISNI SW Y d0VOSVvo 3001706 14 SIvAOsddVv soaiBolouuoa appospo 33 SNOISN3IAIQO ASV 359314 9 9591 ONIGGV1D WON JONV3V112 WW06 NIW tn ch gt gt HOLMS YAOMIFNOL SAINOY LINYIHL 3199 I3N33HI3 33AAOd JINOY 199 IGIAONd 5 5 eO lt JdO HAN3 3OSN3S XVW 025 gt 2 Pu TNL 1439 OL J2NV3V31O MOTIV N SOd 9 8l JO NOILVTIVISNI 304 SS322 V 34VS 14 5 4 ION 4 4081 9 IGOHOnOMHLM313W VIO YANNIWWLOL Jdid ONISSVIS uP JONV14 OL Nd VAAG JOV4 JONV ld OL 12 VIS OLT OSI QalsHO3s4 OLI SAIDOTONHDAL 30 v 2 v JO NOISSIVw334 N3LISAA JIOHAA 1494 NI NOWONGOdddd S3IOOTONH231l 30 v 2 v2 A1334O34 3105 SI ONIM WAC NI O3NIV INO NOLUVYAIIONI 400 310 10NH231 30 v 25 2 IHSOIAdO2 Page 27 of 27 Figure 28 Probe and Gas Sensor Mounting CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 User Manual
17. ange box 11 The power plugs to the Temperature Control Box and the orange box can then be connected to the mains power supply 4 s Figure 8 Connections on Orange 3 4 3 Ethernet Switch The switch and enclosure if supplied should be mounted as described in the previous Ethernet location section The Ethernet cables from the Gas Sensors and Control P C should be connected to the Ethernet switch The power cable to the switch can then be connected and power turned on 3 4 4 Control P C The Control P C can be connected like any normal P C at its final site of installation with the addition of the UPS where required The cable between the Ethernet switch and the Control P C can also be connected at this time System Configuration 3 5 1 Gas Sensor The Gas Sensor is supplied with its configuration pre set from Cascade Each Gas Sensor picks up its address from the DHCP server on the Control P C 3 5 2 Ethernet Switch This device should require no user configuration since it is simply a way to connect the Gas Sensors to the Control P C User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 13 of 27 3 5 3 Control The Gas Sensors take their Addresses from the DHCP server on the Control Once physically connected via Ethernet the Gas Sensors should require no further configuration at installation Gas
18. ar the Probe and Gas Sensors could weigh 30kg which will require at least two persons to carry and install The Gas Care should be taken to observe sensible manual handling precautions when transporting and AN Sensors should be handled with particular care to avoid any internal damage to the instruments 3 3 Materials Supplied The supplied CT2100 system Temperature Control Box cables and Control P C should be inspected to ensure they have not been damaged during transit Figure 2 Typical CT2100 Probe User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 9 of 27 Figure 3 Typical Gas Sensor Figure 4 Typical Temperature Control Box 3 4 Physical Installation The following sections detail how to install the hardware components that comprise the CT2100 On Stack Emissions Sensor CT2100 On Stack Emissions Sensor User Manual Page 10 of 27 D 7010 0005 Revision 1 14th November 2008 3 4 1 CT2100 Probe The probe must only be installed once the emission source for that stack has been shut down and tagged off This is to ensure that no poisonous gases escape from the stabbing during installation The stack and mounting flange may be hot it is important to check the flange temperature has cooled to a safe level before removing the blanking plate and installing the probe The blanking flange and gasket sealing the stabbing prior to installing the probe must be retained c
19. be may be hot after disconnecting power to the probe it is important to check that the flange and stabbing temperature has cooled to a safe level before removing the probe from the stack Once the probe has been exposed its temperature should be checked to ensure it is cool enough for handling 2 Carefully loosen and remove the seven M16 or 5 8 nuts and bolts that hold the probe in the stabbing The probe can then be pulled from the stabbing Care should be taken with the probe while it is removed from the stack to ensure that no physical damage occurs to the sample tubes on the probe 5 The stabbing should then be sealed using a suitable gasket blanking flange and the bolts used to retain the CT2100 Probe CT2100 On Stack Emissions Sensor User Manual Page 22 of 27 D 7010 0005 Revision 1 14th November 2008 6 The 2100 Emission Sensor system is inherently reliable and maintenance free due to having no consumables and high specification solid state components Most maintenance requirements arise from the harsh environment surrounding the typical installation site of a CT2100 In all cases the CT2100 system must be stopped and powered down before performing the maintenance procedures described below Once the required service operation has been completed the probe and Gas Sensor can be reinstalled by following the Physical Installation and System Start Up instructions 6 1 Schedule The fo
20. d gas which ever is smaller to the Control P C hard disk or a USB flash drive connected to the Control P C The data is downloaded in CSV format for easy import to any spreadsheet application Look in 2 home user Desktop o o O9 d E Computer user Filename 502 Data Download Files of type Cancel Figure 16 Saving Data to a USB Flash Drive The recorded data is held in a buffer in the Control P C s memory and not written to any permanent storage device until exported as described above It is therefore very important to Export any data for which you wish to keep a permanent record since it will be discarded upon closing the Gas Sensor Software or overwritten by the latest recorded data after 600 readings or 10 minutes whichever is smaller User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 19 of 27 It is therefore recommended that the Stop button is pressed once you have the data you require in order to prevent it being overwritten by later measurements and then Export the data for later analysis 4 7 Modbus Test Client A software utility is supplied on the Control P C that allows the data written to the Modbus registers to be viewed on screen when the Modbus output option is chosen on running the Gas Sensor Software Server 127 004 Port 502 a Deviceld a Scale 1000 i Position
21. er 2008 Page 17 of 27 on the graph which can be useful when there is large difference the concentrations of the gases being measured A radio button will appear as shown in the Figure below to indicate which recorded values are being graphed in this case SOs NO radio button will be added once the dragged concentration is dropped on the Vertical right section Ek Start Stop Background Prefarences Oui c02 pem No ppm NCE ppm 502 gem Entent ompa 6 Pesaro Pets Tener 0 9 00142497 0 00150367 13 6242 59 732 998 21837 3 22 dorizontal Scale 1 Position 0 E 1151 47 12 11 2008 Sensors Sensor CT2100 initialised 72 00 HighSpeed 1 12 1 5 3 1 Figure 13 Dragging Data to be Graphed By default the vertical axes are scaled automatically as shown in the Figure below Clicking on one of the radio buttons allows you to remove the data from the graph for the selected measurement by clicking on the Remove button Start Stop Background Preferences Quit Sensor CO2 ppm NO ppm ppm ppm ppm 502 ppm ppm C Pressure Torr Probe Temperature C 0 00124206 0 446211 0 00160367 14 9152 732 372 21832 8 22 21 inal ee ee 16 Plots Vertical left 20 OERS Pe 1 4 Scale 1000 19 eens
22. ers are mounted in the Gas Sensor and light is directed into the measurement cell where it is partially absorbed by the gas from the stack The reflected light from the cell is detected by a receiver in the Gas Sensor The variation in the intensity of the light in the vicinity of the absorption lines is measured and the concentration is determined using a comprehensive spectral fitting routine 1 6 System Specification The 2100 is highly configurable in the gases that can be detected and their range of concentrations For your particular application please refer to the specification sheet that was supplied with your system The following tables show the general characteristics of the CT2100 On Stack Emissions Sensor system Typical Probe Temperature 80 a Sensor kg Sensor Gas Sensor Temperature Range 20 to 60 Control P C Dimensions 19 xAUx451mm B siad Width x height x depth and rack mounted pn Gi KomiPC TemesweRage b amp b Control Power Consumption 300 W _ Table 1 CT2100 System Specifications CT2100 On Stack Emissions Sensor User Manual Page 6 of 27 D 7010 0005 Revision 1 14th November 2008 2 Site Preparation The following sections detail the infrastructure that must be in place to allow the installation and commissioning of the
23. information required to install operate and maintain the CT2100 Please read the manual carefully before you start work on the Emission Sensor since it contains important information that must be followed to guarantee the correct operation of the CT2100 and the safety of personnel The manual is divided into sections which should allow users to rapidly find the information they need for any stage in the CT2100 s life cycle Cascade Technologies is committed to continuously improving its products and documentation Every effort will be made to include any Emission Sensor modifications by the manufacturer in the documentation However it should be noted that this document reflects the supplied Emission Sensor as of the revision number and date on the front cover Should you require further information or should particular problems arise that are not covered within this manual help can be requested from Cascade Technologies or their distribution partners 1 2 Safety Precautions Certain parts of the CT2100 Emissions Sensor carry dangerous voltages All housings must be closed the Gas Sensor mounted and connected to the probe before switching on Death personal injury and or damage to persons and or property may result if this is not observed Caution use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure The CT2100 described in this manual has been q
24. le from the Gas Sensor or Ethernet switch if multiple Gas Sensors must be long enough to reach the Ethernet port on the back of the Control P C If a data logger is required a second Ethernet cable shall be required from the second Ethernet port on the back of the Control P C to the data logger The same Ethernet cable length constraints apply as listed in the System Specification section A data logger is not a Cascade supplied device Reference should therefore be made to the documentation that is supplied with the data logger for installation and connection requirements CT2100 On Stack Emissions Sensor User Manual Page 8 of 27 D 7010 0005 Revision 1 14th November 2008 Installation The Site Preparation for the CT2100 Probe Gas Sensor and Control P C must be complete before attempting installation of the CT2100 On Stack Emissions Sensor system 3 1 Tools Required The following tools are typically required for system installation 1 The standard flange on the CT2100 Probe requires spanners for M16 bolts Your particular installation may have a custom flange size with different mounting holes diameters e A temperature measuring device for checking that the probe has cooled down to a safe temperature before being handled Heat resistant gloves for handling a hot probe Suitable gas masks are also a sensible precaution 3 2 Handling Precautions installing the CT2100 Probe Gas Sensor and Control P C In particul
25. llowing are maintenance activities and their suggested frequency The wide variation in customer sites may require these activities to be performed more or less often than indicated Details of the actions to be performed are contained in subsequent sections 6 1 1 As Required The 2400 is inherently tolerant to high levels of optical contamination without a reduction in performance However it is advisable to periodically follow the directions in the Gas Sensor optics cleaning section if the exterior of the CT2400 has a significant build up of dust and contaminants since it is likely that a smaller amount of the same contaminants are covering the Gas Sensor optics 6 1 2 Quarterly Inspect and clean the two sintered Probe Filters 6 2 Probe Filters The CT2100 Probe filters must only be removed once the emission source for that stack has been shut down and tagged off This is to ensure that no poisonous gases escape from the stabbing during maintenance The stabbing and probe may also be very hot After disconnecting power to the probe it is important to check that the flange and stabbing temperature has cooled to a safe level before attempting any filter change The only maintenance required on the CT2100 Probe is inspecting cleaning and possibly replacing the two sintered sample gas filters 6 2 1 Probe Course Filter 1 Remove the end cap from the course filter tube as shown in the Figure below User Manual CT2100 On Stack
26. lose to the stabbing for use when ever the probe is removed from the stabbing The CT2100 Probe is secured in the stack with a PN6 flange and seven M16 or 5 8 nuts and bolts as shown in Appendix A Probe and Gas Sensor Mounting Ensure that the supplied gasket is fitted between the mounting flanges The probe flange has more mounting holes than required to securely mount the probe This is to allow the correct orientation of the probe for the gas flow in the stack The probe should be fitted so that the connectors on the Gas Sensor point towards the source of the exhaust flow when the sensor is reattached to the probe 3 4 2 Gas Sensor At no time should the cover on the Gas Sensor be removed There are no user serviceable parts within the Gas Sensor Opening the cover will invalidate your warranty and may cause damage to components The Gas Sensor slides onto the top rail of the CT2100 Probe as far as necessary to line up the securing holes in the Gas Sensor mounting plate and the top slide rail on the Probe The assembly is then secured in position using two M8 cap screws with flat and spring washers fitted through the top of the Gas Sensor mounting plate into the top slide rail on the Probe Figure 5 CT2100 System Assembly The Figure below shows the Position of the Gas Sensor mounting plate when correctly positioned and screwed to the top slide rail of the Probe User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revi
27. ng a value for Horizontal Position to display any portion of the recorded data up to the last 600 or ten minutes of readings E J Start Stop Background Preferences Quit Sensor CO2 ppm NO ppm NO2 ppm 502 ppm EtalonTemperature C Pressure Probe C Temperature C 6121001 0 00124206 0 954246 000136012 15 5717 59 732 371 21831 5 22 ipo cum ME E E E Plots Vertical left 18 S WENN TEN REN c NEN Remove Scale 1000 17 alia M NM Loans Position 0 16 E WERE MM MESE PES ime e am TEM cct 0 6 X Vertical right 15 att a P ge bg mM 14 1 PIU i nd RR Position 0 i Horizontal lI Y LE P 74 O sS s mm o6 Time 3 Date Message 11 51 47 12 11 2008 Sensors Sensor CT2100 initialised CT2000_HighSpeed 1 12 1 5 3 1 lv 2 8 6 mitsui 127 0 1 1 Wed Nov 12 12 14 56 2008 Figure 15 Graphed Data with Manual Scaling 4 6 2 Saving Data Clicking on the Export button instead of the Remove button allows you to download the last 600 readings or the last ten minutes of readings for the selecte
28. o Horizontal E 1 eh 0 Time Position Figure 17 Modbus Test Client Click on the Open button to start displaying the Names Values and Registerlds available to an Ethernet Modbus client Server Vertical left Port n Scale 1000 Position pee c wu Vertical right Deviceld Scale 1000 Lond m Position Concentration 0 00100983 S TM ES emen Concentration 2 12 Concentration 0 00136012 MEME Ls 1 Concentratio 1 Position 0 Figure 18 Modbus Server Opened 4 7 1 Graphing and Saving Data The data graphing and exporting functionality available in the Gas Sensor Software is also available in the Modbus Test Client The only difference is that the Registerld rather than the Value is dragged on to the Vertical left or Vertical right sections of the window as shown in the Figure below CT2100 On Stack Emissions Sensor User Manual Page 20 of 27 D 7010 0005 Revision 1 14th November 2008 Server 7 0 0 Concentration 0 00119274 Concentration 1 70387 1204 ar ids Concentration 0 00160345 1206 Concentration 9 16261 1208 2 5 i 1 5 ee tree cee Core ere errr reer ere reece eer Figure 19 Modbus Data Graphed 4
29. only be achieved by suitably trained personnel The various sections of the Gas Sensor Software can be resized by clicking on their border and dragging with the mouse There are no user configurable settings available from the Control P C The options available under the Preferences and Background buttons are for the use of trained service personnel only CT2100 On Stack Emissions Sensor User Manual Page 16 of 27 D 7010 0005 Revision 1 14th November 2008 Click on the green Start button shown above start analysing gas concentrations E Sta Stop Background Preferences Quit NO ppm NO2 ppm 1502 ppm EtalonTemperature Pressure Probe Temperature C CO2 ppm 7 Vertical The other data recorded can vary name number and type depending on the configuration of your particular system Sensor analysing concentrations System messages i Position 200 sectio n of display T rrPUPPPYYTTTYS Horizontal 0 ee ee Se ee Button to start the Gas 5 Position 0 Date 11 51 47 12 11 2008 Sensors Sensor CT2100 initialised CT2000_HighSpeed 1 12 1 5 3 1 v 2 8 6 mitsui 127 0 1 1 Wed Nov 12 11 55 26 2008 Figure 11 Initial Gas Sensor Software Screen The Gas Sensor Software can be started stopped and
30. or Mounting Position on Probe Slide 12 mie 7 Gas Sensor CONNECCION S m T 12 Figure g Connections Orange ve epi tu eos byte erui ine abe e ET e E 13 Figure G Network Cone CllVIDy 14 Figure o Contro POs M N 16 Figure 11 Initial Gas Sensor Software Screen 17 Figure T2 Analysing Gas Concentrations eos v ve eee a in e En ense ue ede ees vae crei 17 Figure 13 Dragging Data to be Grape 2 decisa ean aa Rocio edlen ente dus 18 Figure 14 Graphed Data with Automatic Scaling cccccccccsseeeeecceeeeeceeeeeeeeceeesaeeeseeeeeeesseseaeeeeeeeeessaaagaees 18 Figure 15 Graphed Data with Manual SCaling ccccccccccccsesssseeceeeeceeeeeseeeeeeeeeeeesseeeeesesseueaaeseeeeesssaaaaasss 19 Figure 16 Saving Data to a USB Flash Drive 005 cccccceeccceeseeeececeesccccuseeececteccoseseeeeececaecceseeeeseenectocesees 19 Figure t7 Modbus Fest Olei a casti date sesto ceni di e bag ed dea 20 Figure 18 Modbus Server Opened tied intus cea a center ledig scs peti ls Loa rds da 20 Figure 19 Modbus Data Graphe a Sem ease
31. or their power requirements A suitable power switch must be installed close to the Gas Sensor system to allow it to be powered down prior to connecting and disconnecting the power cable from the system Power cables for each Gas Sensor system must be run from their distribution point to each stabbing installation point The cables must be secured at regular intervals along their length and should not restrict any gangway or access or cause a trip hazard The power cables should be marine approved and similar to 3 core round CMA code 3183Y 1 25 The power connector for the Gas Sensor should be Amphenol Part No T3109 200 straight cable socket PG13 5 16 The power cable should be wired to the terminals in the power connector as shown in the table below Blue Blue Not connected Not applicable Earth Green yellow Table 2 Gas Sensor Power Connector Wiring Ethernet It is important for the operation of the CT2100 system to have a dedicated Ethernet Cat 5e cable connection between the Gas Sensor s and the Control P C In all cases the maximum Ethernet cable length should not exceed that listed in the System Specification section CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 7 of 27 For sites with a single Gas Sensor a cross over Ethernet cable may be used to connect the Gas Sensor to the Control P C For sites with multiple Gas Sensors Ethernet cables
32. out Modbus Click on menu item to run the Modbus Test Client Add Remove Figure 10 Control P C Desktop 4 5 Running the Gas Sensor Software Before running the software make sure the Gas Sensor is switched on You then have two options when running the software either with or without the gas concentrations being available via Modbus In both cases you must only run one instance of the Gas Sensor Software at a time 4 5 1 Running with Modbus Click on the icon in the centre of the tool bar to start the Gas Sensor software as shown in the Figure above This will ensure that the gas concentrations can be requested by other Modbus client devices connected via Ethernet to the Control P C Running with Modbus enabled does not affect the performance of the CT2100 4 5 2 Running with without Modbus Start the Gas Sensor Launcher by clicking on the menu item as shown in the Figure above From the Launcher application you can select to Run the Gas Sensor Software If needed different configurations can be added to the Launcher window 4 6 Using the Gas Sensor Software The display on the Control P C shows the last gas concentrations measured and buttons to start stop quit the Gas Sensor Software The gases that will be measured are listed in alphabetical order from left to right The rate at which the CT2100 measures gas concentrations is set during manufacture Changing the measurement rate is possible on site but can
33. rated from the Control P C The Ethernet cable must be connected between the Gas Sensor and the Control P C in order for the Gas Sensor Software to recognise and properly configure the Gas Sensor The Gas Sensor takes gas concentration measurements at a rate defined by the configuration settings on the Control P C The flow rate of sample gas through the CT2100 is set during manufacture and is not user configurable For your particular application please refer to the specification sheet that was supplied with your system 4 4 Control P C The Control P C runs the Ubuntu distribution of Linux Upon powering up the Control P C you will be asked for a username and password to login You should enter the following username user password gassensor Once logged in you will see the Desktop shown in the Figure below User Manual CT2100 On Stack Emissions Sensor D 7010 0005 Revision 1 14th November 2008 Page 15 of 27 Places System Q 4 x m Ef Cascade Technologies User 9 Wed Nov 12 12 39 PM rer pplications ay Accessories v Cascade 1 GasSensor Launche Games GasSensor ModBus TestClient Graphics gt Internet D Office gt Sound amp Video Erud Button to shutdown or restart the Control P C Click on icon to run the Gas Sensor Software with Modbus Click the menu item to run the Gas Sensor Software with
34. sion 1 14th November 2008 Page 11 of 27 FKB hed 44 44 77 Fad Seiten TECHNOLOGIES Figure 6 Gas Sensor Mounting Position on Probe Slide Rail The following connections can then be made as illustrated in the following figures 1 Connect gas inlet pipe to sample cell 2 Connect gas outlet pipe to pump 3 Connect temperature sensor cable to sample cell 4 2 6 8 7 Figure 7 Gas Sensor Connections 4 Connect pressure sensor cable to underside of orange box as shown in the following Figure Connect the four heater plugs from the CT2100 Probe to the sockets on the power distribution box on the Gas Sensor ensuring you match the names on the plugs to those on the sockets 2100 On Stack Emissions Sensor User Manual Page 12 of 27 D 7010 0005 Revision 1 14th November 2008 3 5 6 Connect the two mains power plugs from the Temperature Control Box to the sockets on the power distribution box on the Gas Sensor ensuring you match the names on the plugs to those on the sockets Connect the plug from the pump to the socket on the power distribution box on the Sensor Connect the main power plug from the Temperature Control Box to the socket on the power distribution box on the Gas Sensor 9 Connect the Ethernet cable to socket the underside of the Orange box 10 Connect the mains power plug to the power socket on the underside of the or
35. uality control tested and left the manufacturer in perfect condition To achieve the correct and safe operation of the product it must be transported installed operated and maintained as described by the manufacturer All lasers used within the Emission Sensor are of class 1 The emitted laser light is invisible mid infrared and the pulse duration so short that the unprotected eye will not be damaged The nature of the laser beam path and beam width furthers ensures that it should be impossible to cause any eye damage The Emission Sensor has warning labels at appropriate positions according to USA 21 CFR 1040 10 1 3 Qualified Personnel This manual has been prepared for technically qualified personnel who are familiar with this manual and have been specially trained or who possess appropriate knowledge in the field of instrumentation and control Knowledge of the safety information within this manual and its technically correct implementation are prerequisites for danger free installation commissioning operation and maintenance of the Emission Sensor Only qualified persons have the required specific knowledge to correctly interpret the general safety information and warnings given in this manual and thus apply them to the particular application 1 4 Compliance Approvals This product complies with USA 21 CFR 1040 10 All Cascade Technologies products are designed and tested to comply with the UK Electrical Equipment Safety Regulations

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