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Teledyne ULTRAFLOW 150 Operation Manual Download Page 69

SECTION 7.0, INSTALLATION 

 

 

7.0 INSTALLATION 

The installation overview of the Ultraflow 150 system is shown in 
Drawings ULTRAFLOW 150 FLANGE INSTALLATION, and ULTRA 
FLOW 150 SYSTEM INSTALLATION.  It is important that the 
centerline of the two transducers be maintained so that the installed 
transducers can be pointed directly at each other. 

7.1 PRE-INSTALLATION PLANNING AND PREPARATION 

The engineering that precedes installation of the Ultraflow 150 is vital to 
successful operation of the instrument and must be performed in 
consultation with responsible Teledyne Monitor Labs representatives.  
Key factors that must be considered include: 

Location of the Purge Nozzle and Mounting Plate Assembly, and 

Transducer Interface Enclosure (TIE).  Items such as vibration, heat 
range, stream turbulence, installation and maintenance access, and 
protection from environmental and mechanical hazards must be 
considered. 

Proper installation and location of the Purge Assembly (as per installation 

drawing). 

Electrical power source, cable and conduit runs, overload protection, and 

provisions for safety disconnect. 

Signal cable run (distance, routing, and proximity to other electrical 

equipment). 

Location of the Enhanced Remote Panel.  Auxiliary circuits such as 

alarms, auxiliary indicator/displays, etc., must be considered. 

An installation packet containing a number of Teledyne Monitor Labs 
drawings and a document titled, "Ultraflow 150 Installation Guide & 
Checklist", is provided to the user soon after the purchase order for the 
equipment is received by Teledyne Monitor Labs.  The mounting plates, 
which are supplied by Teledyne Monitor Labs as part of the system, may 
be shipped at the same time if requested by the customer.  The installation 
checklist contains a number of questions that must be answered by the 
user before assembly and calibration of the system may begin at the 
Teledyne Monitor Labs factory. 

7-1 

 
 

Summary of Contents for ULTRAFLOW 150

Page 1: ...ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR OPERATIONS MANUAL SERIAL NUMBER _________________________ ...

Page 2: ...DOCUMENT NO 1900 0100 01 REV E ...

Page 3: ...tor Labs No part of this book may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying taping or information storage and retrieval systems without written permission of the publisher Made in the United States of America ...

Page 4: ...1 3 Wet Basis and Dry Basis Measurements 4 3 4 1 4 Correction to Standard Temperature and Pressure 4 3 4 2 Monitor Specific Theory 4 4 4 2 1 Box Car Integration 4 4 4 2 2 Operational Modes of the Transducer Interface Enclosure 4 4 5 0 TRANSDUCER INTERFACE ENCLOSURE TIE 5 1 5 1 Mechanical Description 5 1 5 2 Electrical Description 5 2 5 2 1 External Interface PC Board 5 2 5 2 2 Power Supply Board 5...

Page 5: ... 1 Flange and Mounting Tube Installation 7 2 7 3 2 Purge System Reference PURGE ASS Y MTG PLUMBING CLEARANCE REQUIREMENTS Drawing 7 3 7 3 3 Purge Nozzle and Mounting Flange Assembly Reference PURGE NOZZLE AND MTG PLATE INSTALLATION 150 Drawing 7 4 7 3 4 Transducer Interface Enclosure Assembly Reference XDUCER INTERFACE ENCLOSURE INSTALLATION Drawing 7 5 7 3 5 Junction Box Reference JUNCTION BOX MT...

Page 6: ...traflow 150 X Pattern Wiring Diagram 115 230 VAC 1900 0004 5 of 12 F Ultraflow 150DI X Pattern Direct Interface Wiring Diagram 115 230 VAC 1900 0004 6 of 12 F Ultraflow 150 Long Range 14 20Khz Wiring Diagram 115 230 VAC 1900 0004 7 of 12 F Ultraflow 150DI Long Range 14 20Khz Direct Interface Wiring Diagram 115 230 VAC 1900 0004 8 of 12 F Ultraflow 150 Long Range 20 14Khz X Pattern Wiring Diagram 1...

Page 7: ...ssy Dual 42CFM Blowers 1904 0000 01 1 of 2 A Purge System Assy Single 110CFM Blower 1904 0000 02 2 of 2 A Purge System Assy Single 42CFM Blower 1906 0010 01 1 of 2 A Junction Box Mtg Methods and Clearances 20 14Khz 1906 0010 02 2 of 2 A Junction Box Mtg Methods and Clearances 50Khz 1803 2003 02 2 of 2 H Enhanced Remote Panel Customer Drawing 1903 0012 02 2 of 2 B UF150 Subpanel Assy Upgrade Instal...

Page 8: ...ure TIE and Junction Box Covers are to be opened only by trained service personnel 3 This equipment must be installed by a qualified electrician as per applicable local electrical codes 4 The Protective Purge System blowers both Single and Dual are permanently connected devices whose overcurrent protection and supply disconnection must be provided externally and installed by a qualified electricia...

Page 9: ...SECTION 1 0 SAFETY Label Standard Number ISO 3864 DIN 4844 2 D W026 Meaning CAUTION HOT SURFACE DO NOT TOUCH This caution refers only to the single blower style of Protective Purge System 1 2 ...

Page 10: ...ontains sophisticated sampling electronics that control the transmit and receive signals from the transducers and calculates the flow velocity flow volume and temperature It also provides power for the purge fail sensors These measurement data are transmitted to the Enhanced Remote Panel via a commercial network communication protocol Each TIE is capable of controlling and performing analysis of u...

Page 11: ...ory configuration and checkout Documentation of the transducer type for your particular monitor is included as part of Appendix A of this manual 2 1 2 1 1 Electrostatic Transducer The Electrostatic Transducer is used in the majority of all Ultraflow 150 applications It is typically employed in instrument pathlengths less than 26 feet 8 meters Its electrostatic characteristics maximize sampling acc...

Page 12: ...wo Purge Nozzle Assemblies This configuration can be employed where the effluent pressures are negative to modestly positive Use of the single Protective Purge Air may not be recommended in cases of high positive stack pressures Long range uses a dual blower system The Purge System provides filtered air to keep the effluent from contacting the transducers The air is injected into the stack through...

Page 13: ...rear panel of the ERP The module will provide web browser based remote access configuration and control of the Ultraflow 150 At the same time the Ethernet Module can provide HTML web pages for user interface and fast Modbus TCP access to instrument data and parameters The details of this powerful ERP feature are described in its own instruction manual which is provided with the instrument The cust...

Page 14: ... range installations Consult the Site Specification Data sheet of Appendix A for information on the configuration of your individual monitor 3 2 LOCAL USER INTERFACE KEY PAD AND DISPLAY The Local User Interface Key Pad and Display option provides an operator interface capability at the Transducer Interface Enclosure TIE on the stack This is a Local User Interface that will provide the ability to e...

Page 15: ...Interface Enclosure via a sealed vent line This approach is recommended only for applications in which the static gage pressure of the process is not likely to undergo dramatic changes For cases where static pressure varies widely a pressure transducer measuring the actual process pressure will deliver maximum accuracy See the System Properties Menu section Section 6 0 of this manual for external ...

Page 16: ...ue include flow monitoring of single fuel utility boiler stack gas emissions cement kiln combustion emissions secondary combustion air and process steam boiler emissions EXTERNAL MEDIUM TEMPERATURE This measurement utilizes external non ultrasonic sensors to establish medium temperature This technique is recommended when the concentrations of the major constituent gases usually O2 CO2 H20 and N2 c...

Page 17: ...ohms Selects the 1000 ohm RTD for operations 3 4 LINK ROD For stacks with an annulus or thick outer walls that must be bridged by the Ultraflow 150 Purge Nozzle Assemblies Teledyne Monitor Labs offers the Link Rod option whenever the Purge Nozzle Assemblies would exceed 72 inches 183 cm in length Beyond this length the standard assemblies become unwieldy and are difficult to align in the center of...

Page 18: ...TPUTS Number 2 Isolation Type Optical capacitive barriers channel to channel channel to circuit common earth Minimum Isolation Voltage 500Vpeak 500VDC Output Type 4 20mA with live 4mA zero OR 0 20mA w o live zero Maximum Load Resistance 900 ohms Maximum Offset 0 05 of full scale Total Output Error 0 30 of full scale SIX POINT I O BOARD DIGITAL INPUTS Number 2 Modes Isolated and Non isolated Isolat...

Page 19: ...aves passing through the centroid of the stack or duct to the other transducer This makes the measurements a line average of the tone burst path length When a tone burst is sent through the gas stream from the upstream transducer to the downstream transducer the movement of the gas stream reduces the time required to traverse the distance When the tone burst is traveling against the gas stream fro...

Page 20: ...city measurement is inherently independent of the temperature density viscosity and particulate concentration since these terms drop out of the simplified equations 1 Velocity of Sound from Upstream to Downstream Transducer 2 Velocity of Sound From Downstream to Upstream Transducer Where Cs The Speed of Sound Fν Flue Gas Velocity θ Transducer Angle to Flow V Velocity of Respective Tone Bursts 3 Su...

Page 21: ...r Metric per hour minute or second according to a software selection 4 1 3 Wet Basis and Dry Basis Measurements The Ultraflow 150 gives a wet basis reading only A wet basis measurement is one that includes the water vapor component of the effluent in the measurement A dry basis measurement is one that removes the water vapor and makes the measurement on the remaining components of the effluent 4 1...

Page 22: ...he true receive signals occur at virtually the same time boxcar for each tone burst in the average period and are always positive thus add up faster than the background noise which is random in time At the end of the integration period the resulting window of 32 768 data bits is sent through the digital signal processing algorithms and the boxcar integrator reset for the next integration period Th...

Page 23: ...ow indication However in the SPAN HIGH mode every other received tone burst is delayed by a predetermined amount This means that the TIE sees a difference in the time required for the upstream and downstream tone bursts to traverse the gas stream Small fluctuations in the downstream transmit and upstream receive properties or electronics shifts will show changes in the expected flow readings 4 2 2...

Page 24: ...ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR This page intentionally left blank 4 6 ...

Page 25: ...ounted to a removable back plate A field wire terminal block board External Interface Board with power ON OFF switch is mounted to the right inside of the enclosure Please see the assembly and installation drawings in Appendix D Figure 5 1 Transducer Interface Enclosure Block Diagram Flow Motherboar Four DB Connectors SPI and analog SPI Power Connector 68332 Computer Module Optional Six Point I O ...

Page 26: ...face wires A double pole power ON OFF switch is also located here The board has direct connections to the Power Supply Board Flow Mother Board and optional Six Point I O Board Consult the Site Specification Data sheet of Appendix A for information on the configuration of your individual monitor 5 2 2 Power Supply Board The Power Supply Board is located in the upper right corner of the enclosure It...

Page 27: ... Xcvr s D0 to D15 R W A0 to A18 CS6 7 9 10 IRQ5 TPU I O TPU I O SBC332 Board ADC Data Input D0 to D15 A0 to A18 CS6 7 9 10 R W NEURON Circuit FTT10A Network Wires Bus Xcvr Renew Real Time Clock DB Connector DB Connector To 6 Point I O To Display Control 128Kx8 SRAM Buffer ESD Network SPI Clock Data Slave Selects 12 Bit Parallel DAC312 Test Point like TP4 Diagnostic Output 12 lines RESET Sync A out...

Page 28: ...e Table 5 1 Table 5 1 Configuration Device U5 versus Transducer Type TRANSDUCER TYPE REQUIRED CONFIGURATION DEVICE U5 ES Labeled as X 50 LR003 Labeled as X 20 LR004 through LR007 Labeled as X 14 where X is number that changes based on the firmware version of U5 In the Enhanced Remote the System Properties Intrinsic Properties parameter Transducer Type can be selected via menu control This selectio...

Page 29: ...ified and added to the appropriate boxcar in the RAM Another start signal is then issued and the ADC starts another conversion cycle This continues for 32 384 cycles creating a sixteen millisecond wide window of 0 5 µsec filtered digital averages The RAM has a separate boxcar window for each transducer After the digitized window is complete the FPGA channel select requests a different transducer p...

Page 30: ...tegrated receive data that exists only in the digital realm DIAG_2 JU8C DIAG_1 JU8B DIAG_0 JU8A Diagnostic Output 0 0 0 A D Output 0 0 1 Filter ABS 0 1 0 Boxcar 6 17 0 1 1 Boxcar 7 18 1 0 0 Boxcar 9 20 1 0 1 Boxcar 10 21 1 1 0 Boxcar 11 22 1 1 1 Boxcar 12 23 Figure 5 4B Figure 5 4C Note The sample diagnostic waveforms above were taken from TP21 during normal mode with the scope triggered on TP34 5...

Page 31: ...asynchronous serial port for use with Teledyne Monitor Labs PC to Modbus software This port is accessible through DB9 connector J9 5 2 3 8 1 Synchronous Serial Devices The Flow Mother Board employs 11 synchronous serial device channels The Serial Peripheral Interface SPI standard is used to convey data to the I O devices The Computer Module Board acts as the master SPI device and hence controls ac...

Page 32: ...ards The TIE can control up to four transducers Each transducer has a Preamp Board associated with it There are two different types of Preamp Boards the Electrostatic Preamp and the Flow Preamp Driver Board Consult the Site Specification Data sheet of Appendix A for information on the configuration of your individual monitor 5 2 4 1 Electrostatic Preamp Driver Board The Electrostatic Preamp Driver...

Page 33: ...ge loop It can take three types of barometric pressure signals a custom Teledyne Monitor Labs module a 4 20ma current loop or a DC voltage loop The board plugs into a connector on the bottom of the Flow Mother Board The information is transferred via Serial Peripheral Interface SPI 5 2 6 Optional Local User Interface Key Pad and Display Assembly The optional Local User Interface Standard on a 560D...

Page 34: ...ge various units EXPONENT UA Zero Volume Instantaneous various units EXPONENT UB Zero Volume Average various units EXPONENT UC Mode dimensionless NO EFFECT UD Primary Status dimensionless EXTENDED UE Extended Status dimensionless EXTENDED Table 5 3B S Bank Service Data Bank Code Description Inst Avg Units E Button Action S0 S N Ratio Downstream NO EFFECT S1 S N Ratio Upstream NO EFFECT S2 Peak RAM...

Page 35: ...NO EFFECT 5 2 7 Individual Button Function When Pressed by Themselves When pressed and released it has one of three actions NO EFFECT Nothing happens EXPONENT The VALUE digits of the LED display show the exponent portion of the floating point number corresponding to the bank code When pressed and released again the VALUE digits of the LED display show the mantissa of the number and the CODE digits...

Page 36: ... activity the display defaults back to the User data bank U Repeat functions are supported for this combination of buttons DISPLAY INC Increments the variable number displayed i e U0 becomes U1 F0 becomes F1 etc Repeat functions are supported for this combination of buttons DISPLAY DEC Decrements the variable number displayed i e U5 becomes U4 S5 becomes S4 etc Repeat functions are supported for t...

Page 37: ...onnections are made from the back panel with pluggable connectors Access to the inside of the unit is through a removable top panel The top panel is removed by taking out four screws Inside the enclosure there are seven circuit boards a power entry module several interconnect cables and the Liquid Crystal Display LCD board The LCD Driver Board is integral to the display and the keypad is built int...

Page 38: ...dent software and a unique network address They share a common power supply and chassis The Enhanced Remote Display acts as the operator interface The Multi I O Board is the peripheral hardware interface 6 3 2 1 Liquid Crystal Display LCD The display is a graphics capable 240x128 pixel back lit LCD The Display Driver Board is integral with the LCD and communicates to the Mother Board via ribbon ca...

Page 39: ... or by connector group 6 3 2 7 Enhanced Remote Panel Mother Board The Enhanced Remote Panel Mother Board has two microprocessors a 68332 and an LTM 10 Each is laid out on a separate Daughter Board that plugs horizontally into the Mother Board The Mother Board has circuits to perform the following Interface the two processors Buffer the data bus Adjust contrast and brightness outputs to the display...

Page 40: ...or The nnn values of 255 and 511 have special significance see below All other characters are ignored and will cause the Enhanced Remote Display serial port to respond with an error message A time delay of more than 10 seconds between characters will cause the previously sent characters to be discarded Table 6 2 is a summary of the possible user requests followed by some examples Table 6 2 USER RE...

Page 41: ...Data Buss buffe Surge Protection D A converte r LCD Intensity driver LCD Back light driver Serial comm port 422 or 485 Processor interface U7 processor To overlay LED s Key switch To Keypad Buffe r driver Buffe r drive To keypad rows To keypad columns Surge t ti Control lines to each processor Reset Reset D C to D C Converter 20vdc 24 5vdc RS 232 Serial port 6 5 ...

Page 42: ...LCD contrast adjustment Table 6 3B 68332 Processor SBC332 Board Jumper Definitions Jumper Selections Functional Description J2A 1 2 2 3 J2A through J2F configure the Computer Module Board for the type of memory used Standard settings are highlighted J2B 1 2 2 3 J2C 1 2 2 3 J2D 1 2 2 3 J2E 1 2 2 3 J2F 1 2 2 3 J3 1 2 Enabled 2 3 Disabled J3 enables or disables the 68332 s watchdog timer J9 1 2 2 3 1...

Page 43: ... digital outputs dry relay contacts and four analog outputs It can read up to eight digital inputs The digital inputs are jumper configurable to be either dry contacts or 0 5 VDC signals Dry contacts are standard The analog outputs are jumper configurable to be 4 20 mA 0 20 mA or 0 24 mA current loop signals 0 20 mA is the standard jumper setting though the standard current output range is 4mA to ...

Page 44: ... 1 2 3 Configures digital input 7 hardware JU16 1 2 3 1 2 3 Configures digital input 8 hardware Ram 128K Ram 32K ROM 128K ROM 64K ROM 32K Flash 128K Flash 64K Flash 32K JU17 A A B B B B B B Jumpers JU17 JU18 together select the type of memory chips to be used JU18 D D C C B C C A JU19 IN OUT Double terminated IN OUT Single terminated Selects whether the network termination will be single or double...

Page 45: ...TP13 24vdc isolated drive voltage for analog output 4 Referenced to TP14 Output 4 TP14 GND reference for TP13 and all points within 4 output circuit TP15 TP15 TP16 are on opposite sides of a 100Ω resistor that is in series with the output 4 current loop Measure the DC voltage across these test points and divide by 100 to calculate the actual output current of channel 4 TP16 6 4 OPERATIONAL DESCRIP...

Page 46: ...e last integration period specified in the average The STATUS text and STATUS code fields are updated immediately on any change in the monitor status If multiple malfunctions are indicated you can scroll through the STATUS text field errors by pressing either arrow button or once After scrolling is completed the STATUS text field will stop and continuously display the most significant error The NE...

Page 47: ...ndicated by the figure above To select a Page 2 TIE 1 PathA All Data Page 3 TIE 1 PathB large s Page 5 TIE 2 PathA large s Page 6 TIE 2 PathA All Data Page 4 TIE 1 PathB All Data Page 8 TIE 2 PathB large s Page 1 TIE 1 PathA large s Page 9 TIE 1 PathAB large s Page 7 TIE 2 PathB large s Page 10 TIE 1 PathAB All Data Page 11 TIE 2 PathAB large s Page 12 TIE 2 PathAB All Data ALARMS HISTORY MAIN MEN...

Page 48: ...se the group you wish to look at and press ENTER The parameter names and values will appear on the display The screen is configured to update live Each time new data is received at the end of the sample integration cycle it is posted to the screen Within the NETWORK CONFIG DATA screen you can choose different indexed segments of the network variables for display This information is for factory lev...

Page 49: ...e system into different modes of operation When the screen comes up the COMMAND MODE line will be highlighted Scroll through the modes PRIMARY STATUS CODES 00001 Purge Failure Dn Stream 00002 Purge Failure Up Stream 00004 Out Of Service 00010 FPGA Config Fault 00020 Temp Out Of Range 00040 Min Signal Energy DnSt 00100 Min Signal Energy UpSt 00200 Span High Offset TD Cal CURRENT STATUS XXXXX PRIMAR...

Page 50: ...RMAL ACQUIRE mode at the beginning of the next integration period and sends its mode out on the network This mode will last for the number of integration periods specified in the averager At the end of NORMAL ACQUIRE the TIE will indicate NORMAL mode The TIE will continue in this mode until it gets another mode change request The analog outputs will trend from whatever mode data they were displayi...

Page 51: ...fference between the periods for SPANLOW variable and the periods for averaging variable After the last period the TIE will indicate SPANLOW mode and continue in that mode until another mode request is received The MIO goes into SPANLOW ACQUIRE mode after the TIE s first full integration period in SPANLOW ACQUIRE The MIO will remain in this mode until the end of the TIE s first integration period ...

Page 52: ... mode request It will remain in whatever mode it was in This is an MIO test only The MIO enters this mode on receipt of the request This mode will drive all analog outputs regardless of configuration to their MID scale If actuated the NORMAL relay will drop out to indicate that other than NORMAL data is present on the outputs The MIO will stay in this mode until another mode request is issued TEST...

Page 53: ...ll be highlighted Use the Page Up and Page Down keys to find the parameter you want Press to choose and move to the next property OUTPUT MODULE CONFIG Choose Configuration Screen RELAY ASSIGNMENTS PRESENT ASSIGNMENT 1 xxxx xxxxx xxx 2 xxxx xxxxx xxx 3 xxxx xxxxx xxx 4 xxxx xxxxx xxx 5 xxxx xxxxx xxx 6 xxxx xxxxx xxx 7 xxxx xxxxx xxx 8 xxxx xxxxx xxx SAVE THIS CONFIG ANALOG OUTPUT CONFIG 3 4 Descri...

Page 54: ...ER to select and move to the next field The field labeled VALUE AT ZERO SCALE is the numerical value that will correspond to 4mA output VALUE AT FULL SCALE is the numerical value at full scale 20mA output These values are what you would change to rescale the output if needed Enter the numbers desired through the keypad Press to move to the next field The second half of this screen offers the same ...

Page 55: ...SAVE THIS CONFIG and press the key The ESC key will take you back to the I O configuration menu 6 4 8 Display Properties Menu This screen permits adjustment of the Brightness and Contrast of the Display Use the keys to select the parameter you want to adjust Then use the Page up and Page Down keys to increase or decrease The screen should visually change while pressing these keys When the screen l...

Page 56: ...meters in each group of properties and a flavor for their significance Fundamental Properties are emphasized Only one Advanced Properties screen is discussed as all the others are either troubleshooting in nature or require understanding outside the scope of this manual 6 4 10 1 Fundamental Properties Menu GEOMETRY PROPERTIES Contains most stack geometry parameters with the exception of Cross Sect...

Page 57: ...ONTENTS Integration Period seconds Integration Periods in Average dimensionless MEDIUM PROPERTIES Contains the expected extremes of temperature and flow velocity in the stack or duct medium under measure CONTENTS Minimum Medium Temperature Maximum Medium Temperature Minimum Flow Velocity Maximum Flow Velocity CALIBRATION PROPERTIES Establishes set points and error tolerance for SPANHIGH SPANLOW an...

Page 58: ... a function of the speed of sound R Factors are the desired outputs at the three speed of sound points R Factors are directly proportional to the molecular weight of the medium and inversely proportional to heat capacity CONTENTS R1 R2 R3 R Factor Points CS1 CS2 CS3 Speed of Sound Points STD PRESSURE PROPERTIES This screen contains the two point calibration curve for the optional external pressure...

Page 59: ... RATIO ALARMS This screen contains the thresholds for the Signal to Noise SN Ratio Alarms These alarms are useful for giving early warning of impending transducer failure Some important points about these alarms are Site specific alarm threshold values may be developed by recording SN Ratio data for the most challenging typically highest flow velocity and temperature measurement medium conditions ...

Page 60: ...s that keep a tally of the number of times each of the eight possible network errors occurs These are specific errors defined by the network protocol Each time one of the errors occurs at the Enhanced Remote Display node an error message is issued and the network status log value for that error is incremented by one These errors do not necessarily require corrective action but happen due to networ...

Page 61: ...cted Both ZERO and FULL scale may be chosen for each output Also each output may be configured to allow calibration cycles to appear on it The MIO has calibration values available in Flow Volume units and Velocity units If an analog output is set to carry Flow Volume data and Calibration data is desired on that output one of the Flow Volume calibration points must be chosen for the output Likewise...

Page 62: ...I O analog outputs can be forced to diagnostic status TEST FULL SCALE TEST ZERO SCALE etc from two sources digital inputs seven and eight and the Enhanced Remote Display keypad The operation of the digital inputs is described in Table 6 8 Digital Inputs for Analog Output Control The keypad display commands are described in the section on menu structure If the Multi I O receives conflicting or over...

Page 63: ...Calibration Failure Signal Energy Ratio 3X SPAN HIGH Calibration Failure SN Ratio Warning Upstream ZERO Calibration bad SN Ratio Warning Downstream SPAN LOW Offset TD bad Purge Failure Upstream Side SPAN HIGH Offset TD bad Purge Failure Downstream Side Minimum Signal Energy Not Achieved Upstream Noise Threshold Disabled Minimum Signal Energy Not Achieved Downstream Temperature Out of Range FPGA Co...

Page 64: ...NST VOLUME ALARM TIE2 SPAN HIGH ON AO TIE1 SPAN HIGH ON AO TIE2 DATA VALID TIE1A DATA VALID TIE2A AVG VOLUME ALARM TIE1 AVG VOLUME ALARM TIE2 SPAN LOW ON AO TIE1 SPAN LOW ON AO TIE2 NONFATAL FAULT TIE1A NONFATAL FAULT TIE2A INST MED TEMP ALARM TIE1 INST MED TEMP ALARM TIE2 ZERO ON AO TIE1 ZERO ON AO TIE2 FATAL FAULT TIE1A FATAL FAULT TIE2A AVG MED TEMP ALARM TIE1 AVG MED TEMP ALARM TIE2 NORMAL ON ...

Page 65: ... ALARM TIE1AorB SN RATIO UP ALARM TIE2AorB ZERO OR ACQ ON AO TIE1 ZERO OR ACQ ON AO TIE2 DATA VALID TIE1AorB DATA VALID TIE2AorB SN RATIO DN ALARM TIE1AorB SN RATIO DN ALARM TIE2AorB NORMAL OR ACQ ON AO TIE1 NORMAL OR ACQ ON AO TIE2 NONFATAL FAULT TIE1AorB NONFATAL FAULT TIE2AorB SN RATIO BOTH ALARM T1AorB SN RATIO BOTH ALARM T2AorB CAL OR ACQ ON AO TIE1 CAL OR ACQ ON AO TIE2 FATAL FAULT TIE1AorB ...

Page 66: ...single integration period It is linearized per the curve developed from site testing and corrected to standard temperature and or pressure conditions AVE STD VOLUME This parameter is an average of the linearized instantaneous standard volume values from a number of integration periods The number of periods is set by the periods for averaging variable The length of the averaging period will be seco...

Page 67: ... selected See note PEAK RAM CNTS DNSTREAM This is a number between 0 and 32 767 which represents the downstream box car RAM count with the single largest value as measured at the end of each Integration Period of the TIE path selected See note CALC RAM CNTS UPSTREAM This is a number between 0 and 32 767 which represents the peak RAM count of the upstream receive signal box car as calculated by the...

Page 68: ... Fatal Fault Relay Relay Non Non Fatal Fatal Fault Relay FaultRelay Zero Acq Zero SpanLow Acq SpanHigh Acq SpanLow SpanHigh Normal Acq Normal Test Zero Scale Test Mid Scale Test Full Scale Normal Reconfig Normal Normal Normal Put out of service Put in service Diagnostic Reset Normal Unknown Interference Interference Test Relay TestRelay Purge Failure Upstream Purge Failure Downstream Zero Cal Bad ...

Page 69: ...rom environmental and mechanical hazards must be considered Proper installation and location of the Purge Assembly as per installation drawing Electrical power source cable and conduit runs overload protection and provisions for safety disconnect Signal cable run distance routing and proximity to other electrical equipment Location of the Enhanced Remote Panel Auxiliary circuits such as alarms aux...

Page 70: ...the flow characteristics at the site location is solely that of the user Please consult the Teledyne Monitor Labs factory for details 7 2 2 Access to Sampling Location Ease of access to the stack mounted equipment is a factor that is nearly always underrated when deciding on an installation site If the monitor location is only accessible via vertical ladders with extensive climbing involved or in ...

Page 71: ...ANGE INSTALLATION drawing This drawing also contains a number of calculations that must be performed in order to accurately determine the angle and size of the penetrations into the stack or duct The actual penetrations should be made with some additional clearance so that the prefabricated mounting tube and plate may be inserted as a unit and temporarily held in place Insert one mounting tube fir...

Page 72: ...ations CAUTION During initial start up the purge system must be in full operating condition and the hoses supplying the purge air connected before the Purge Nozzle Assemblies are inserted into the mounting tubes Failure to do so will void the Teledyne Monitor Labs warranty on the stack equipment 7 3 3 Purge Nozzle and Mounting Flange Assembly Reference PURGE NOZZLE AND MTG PLATE INSTALLATION 150 D...

Page 73: ...h nuts should be locked in place Removal of the nozzle for maintenance is accomplished by undoing the four draw latches Use of the draw latches insures proper alignment when nozzles are reinserted 7 3 4 Transducer Interface Enclosure Assembly Reference XDUCER INTERFACE ENCLOSURE INSTALLATION Drawing Location and clearance requirements for the Transducer Interface Enclosure Assembly are found in Te...

Page 74: ...interested personnel to view the displays or output devices readily Access to the panel by installation and maintenance personnel must also be provided for Reference Teledyne Monitor Labs Drawing ENHANCED REMOTE PANEL ASSEMBLY for mounting dimensions Reference Teledyne Monitor Labs Drawing ULTRAFLOW 150 STD WIRING DIAGRAM for proper electrical connections to the Enhanced Remote Panel Assembly 7 6 ...

Page 75: ...SECTION 7 0 INSTALLATION This page intentionally left blank 7 7 ...

Page 76: ......

Page 77: ...backed up RAM while some are stored in Flash memory This allows the variables to be field modified and remain in the microprocessor after the power is turned off It may be necessary to modify some variables at the users site at the time of instrument start up or after reference method testing NOTE The user must maintain adequate documentation on any variables modified after factory calibration In ...

Page 78: ...s among the best methods for flow measurement in difficult applications there are situations where its response is not perfectly linear and does not exactly match the Reference Method Flow stratification and cross flow i e nonzero pitch angles are the most common sources of departure from linearity Also the aforementioned Reference Methods 1 and 2 can be significant sources of error themselves The...

Page 79: ... X3 Y3 slope intercept The points for the Look Up Table must be derived through reference method testing Each point consists of an Ulraflow 150 value X and an associated reference method test value Y The Ultraflow value is then derived as a straight line approximation using up to three line segments The first segment has zero as its origin and ends at the first Ultraflow reference method pair of n...

Page 80: ...3x2 1 4005E 00x 2 9843E 12 0 5 10 15 20 25 30 35 40 45 50 0 20 40 60 Ultraflow 150 RAW Actual Velocity ft sec Reference Method Actual Velocity ft sec The Polynomial A0 through A5 contain the coefficients of a 5th order Polynomial least squares correction curve fit which may be employed to modify the velocity output of the Ultraflow 150 to more closely correlate with the reference method testing da...

Page 81: ... capacity of the medium When these medium properties are function of the speed of sound typical of single fuel stack gases from combustion processes it is possible to adjust the temperature calibration with a Look Up Table LUT correction The above figure demonstrates the relationship between R Factor and speed of sound Cs for the LUT Three breakpoints are provided 1 R1 Cs1 2 R2 Cs2 and 3 R3 Cs3 Ty...

Page 82: ...oint 1 Temperature at Point 2 Current at Point 2 Reference Temperature Alarm Properties Flow Alarm Selection Actual Volume A Standard Volume A Actual Volume B Standard Volume B Actual Volume AB Standard Volume AB Flow Alarm Mode LESSER GREATER Instantaneous Flow Alarm Threshold Average Flow Alarm Threshold Temp Alarm Selection Internal Temperature A Internal Temperature B Internal Temperature AB E...

Page 83: ...s Time Delay Downstream A Time Delay Upstream A Intrinsic Delay A Nozzle Delay Downstream A Nozzle Delay Upstream A Noise Threshold Levels Auto Noise Threshold A ENABLE DISABLE Downstream A Upstream A Signal to Noise Ratio Alarm Threshold Downstream A Upstream A Figure 8 1 INSIDE DIAMETER DIAMETER Ultraflow 150 Offset Ultraflow 150 Trans Trans Distance Ultraflow 150 Upstream Nozzle Length Ultraflo...

Page 84: ...3 1 Remote Program Variables The configuration of the Enhanced Remote Panel is controlled by the entering of the program variables Appendix A may be consulted for the values entered by Teledyne Monitor Labs at the time of factory calibration As was mentioned previously these values may also be user modified to reflect differing or changing site conditions Additional information on the Enhanced Rem...

Page 85: ...SECTION 8 0 SYSTEM CALIBRATION AND ADJUSTMENT This page intentionally left blank 8 9 ...

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Page 87: ...edyne Monitor Labs recommends that the Teledyne Monitor Labs Maintenance Check Sheets for the Ultraflow 150 be used to record the data collected while performing this maintenance The Teledyne Monitor Labs Maintenance Check Sheets for the Ultraflow 150 and Teledyne Monitor Labs Procedure for Maintenance Check Sheets for the Ultraflow 150 are located in Appendix B 9 1 2 Normal Maintenance Under norm...

Page 88: ...ect a problem Go to the Enhanced Remote Panel and write down the status word and Service Data values Decode the status word according to the help screen or tables of section four This alone may point to the problem Compare the Service Data readings to the readings from your last maintenance check sheet If at this point the problem is not apparent Go through the maintenance check sheet procedure Ap...

Page 89: ...APPENDIX A SITE SPECIFICATION DATA SHEETS ...

Page 90: ...ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR This page intentionally left blank ...

Page 91: ...n in LinkRod Length if applicable Path A Path B Upstream in in DownStream in in Junction Box Assemblies Buffer Board Path A Path B UpStream PN PN SN SN DownStream PN PN SN SN Jumper Positions JU1 JU2 TIE Enclosure PN Motherboard PN SN CPU Board PN SN Software Versions 332 version Neuron version FPGA version Motherboard Test Point VDC VAC TP2 TP3 TP9 TP12 TP13 TP16 Ultraflow 150 Site Specification ...

Page 92: ... Pressure Sensor LON Modlue External BP External Temp Averaging Properties Integration Per Sec Acquire Mode Avg Integration Per Avg Auto Cal Cycle CAL Time Hour CAL Time Min CAL Interval Hour Span HI Set Point Span LO Set Point Zero Set Point Cal Tolerance IP Auto Span HI IP Auto Span LO IP Auto Zero LUI Display Board PN SN 6PIO Board PN SN Jumper Positions JU1 JU9 JU2 JU10 JU3 JU11 JU4 JU12 JU5 J...

Page 93: ...al Type Path Zero Scale Full Scale Enhanced Remote Display PN SN Software Versions 332 version Panel Neuron MIO version Ethernet Module PN SN MAC Address Neuron Version WEB Server Version Remote Motherboard PN SN CPU Board PN SN MIO Board PN SN Analog Outputs 1 Cal Type Path Zero Scale Full Scale 2 Cal Type Path Zero Scale Full Scale A 3 ...

Page 94: ...AFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 3 Cal Type Path Zero Scale Full Scale 4 Cal Type Path Zero Scale Full Scale Relays K1 K2 K3 K4 K5 K6 K7 K8 Test Equipment Used DMM Oscilloscope Chart Recorder A 4 ...

Page 95: ...APPENDIX B MAINTENANCE CHECK SHEETS ...

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Page 97: ...se UpStream PreAmp Gain DnStream PreAmp Gain UpStream Digital Gain DnStream Digital Gain UpStream DnStream Noise Threshold UpStream Noise Threshold NUMERICAL DATA Flow Data Record only the Average values Before After Linearized Velocity Raw Velocity Actual Volume Standard Volume Span High Volume Span Low Volume Zero Volume Internal Temperature Data Record only the Average values Before After Speed...

Page 98: ...GND TP2 120 VDC to 140 VDC VDC VAC 005 VAC TP3 5 VDC 15 VDC VDC VAC 005 VAC TP9 15 VDC 30 VDC VDC VAC 005 VAC TP12 15 VDC 30 VDC VDC VAC 005 VAC TP13 3 3 VDC 15 VDC VDC VAC 005 VAC TP16 2 5 VDC 10 VDC VDC VAC 005 VAC If this maintenance is just prior to a RATA or is being done as part of an Emergency Repair 1 Compare the System Properties to the last recorded parameters 2 Check and adjust the Pres...

Page 99: ...TWARE VERSIONS can easily be found by pressing the enter button once from the Main Display and then using the down arrow to get to the Software Versions screen Record the values before any maintenance is done The STATUS HISTORY and ALARM HISTORY screens both may contain several pages They can be found by pressing the enter button once from the Main display and using the down arrow to get to the bo...

Page 100: ...f the Analog Outputs The Analog Outputs can easily be forced to 4 mA 12 mA and 20 mA from the Output and Cal Tests screen in the Enhanced Remote Display They should respectively correspond to zero mid and full scale on the end recording device Additional information is located in the body of the manual and is available from Teledyne Monitor Labs technical support via phone Force a calibration cycl...

Page 101: ...APPENDIX C SPARE PARTS ...

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Page 103: ...ite 5 10 on Site Mean Time Between Replacement Fuse 527438 Enhanced Remote Panel 5 5 10 N A Fuse 527441 Power Supply in TIE 5 5 10 N A TELEDYNE MONITOR LABS TML ULTRAFLOW 150 MAINTENANCE RECOMMENDED SPARE PARTS Parts which are used during the normal operation of the monitors over time Quantity to Stock Part Name TML Part No System Location 1 on Site 2 5 on Site 5 10 on Site Mean Time Between Repla...

Page 104: ... PCB Remote 1803 0300 02 Enhanced Remote Panel 1 1 2 N A Power Supply PCB TIE 1860 1100 02 TIE Box 1 1 2 N A TIE Mother Board Standard w Computer Module 1903 0100 01 TIE Box 1 1 2 N A TIE Mother Board Long Range w Computer Module 1903 0100 02 TIE Box 1 1 2 N A TIE Mother Board Extended Long Range w Computer Module 1903 0100 03 TIE Box 1 1 2 N A External Interface PCB 1903 1500 01 TIE Box 1 1 2 N A...

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Page 106: ...APPENDIX D DRAWINGS ...

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Page 144: ...APPENDIX E ENHANCED SERIAL PORT COMMUNICATION PROTOCOL ...

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Page 146: ...neers It consists of four values separated by commas ending in a Carriage Return and Line Feed The first and third values must match exactly The second and fourth values must also match exactly If either of these two conditions are not met then the Enhanced Remote Panel will ignore the data stream as an input In a similar manner a DAS should ignore any data streams which do not have matching pairs...

Page 147: ... at the top of the list The date and time that the status code happened is included on the same line A value of zero 0 means that all faults were cleared If there are no entries in a specific set of status history screens then nothing will be listed under its heading The following is an example what the print out looks like 991 TIE1 PATHA PRIMARY STATUS TIE1 PATHA EXTENDED STATUS 0 1 Mar 2006 8 22...

Page 148: ...rm for Path A 14 TIE2 Instantaneous Standardized Flow Alarm for Path A 15 TIE2 Average Standardized Flow Alarm for Path A 16 TIE2 Instantaneous Flow Actual Alarm for Path B 17 TIE2 Average Flow Actual Alarm for Path B 18 TIE2 Instantaneous Standardized Flow Alarm for Path B 19 TIE2 Average Standardized Flow Alarm for Path B 20 TIE2 Instantaneous Flow Actual Alarm for Paths A B combined 21 TIE2 Ave...

Page 149: ...ation cycle typically consisting of both Zero and Span High modes and then returning to Normal operation 10 PUT_OUT_OF_SERVICE may be used to indicate when maintenance is done on the monitor 11 PUT_IN_SERVICE may be used to indicate when the monitor is finished having maintenance done on it 12 RESET sends a command to reset the TIE 13 RECONFIG sends a command to reconfigure the FPGA MIO stands for...

Page 150: ... to request the STATUS HISTORY of TIE2 Proper usage is 992 CR The ERP will respond by printing the STATUS HISTORY in a similar format as on the ERP screen display 993 This variable is used to request the ALARM HISTORY of TIE1 Proper usage is 993 CR The ERP will respond by printing the ALARM HISTORY in a similar format as on the ERP screen display 994 This variable is used to request the ALARM HIST...

Page 151: ... means that if the value of 10 is entered for the FAST group rate then ALL of the variables in the FAST list will be transmitted every 10 seconds If a value of 6 is entered for the SLOW group rate then ALL of the variables in the SLOW list will be transmitted every 6 minutes Each group rate may be independently entered by the technician The technician may enter the desired variable numbers into ei...

Page 152: ... the RS232 cable used to connect with the Enhanced Remote Panel s J16 J16 is a DB9 female connection on the back of the Enhanced Remote Panel RS 422 MECHANICAL CONNECTIONS The connections to the ENHANCED REMOTE PANEL are at the rear of the unit on a standard 15 pin D connector labeled J17 Only a 4 wire protocol is supported J17 pin 3 Receive A J17 pin 15 Receive B J17 pin 2 Transmit A J17 pin 14 T...

Page 153: ...lume1A 0 147725 14 primary_status1A 23 15 extended_status1A 40 16 NetworkStatus Network Normal 17 TIE1_MODE NORMAL 18 SpeedOfSndInst1A 944 486 19 SpeedOfSndAver1A 944 423 20 IntMedTempInst1A 88 5497 21 IntMedTempAver1A 88 4591 22 ExtMedTempInstTIE1 713 911 23 ExtMedTempAverTIE1 713 911 24 ExtMedPressInstTIE1 29 9285 25 ExtMedPressAverTIE1 29 9174 26 MIO_StatusTIE1 0 27 XmitErrorsTIE1 11 28 TransTi...

Page 154: ...O SELECTION 69 MIO_Ch_4 With Calib NO 70 Path_Sel TIE1 PATH A 71 MIO_Ch_4 Zero Scale 0 72 MIO_Ch_4 Full Scale 0 73 Dig_Out_1 NO SELECTION 74 Dig_Out_2 NO SELECTION 75 Dig_Out_3 NO SELECTION 76 Dig_Out_4 NO SELECTION 77 Dig_Out_5 NO SELECTION 78 Dig_Out_6 NO SELECTION 79 Dig_Out_7 NO SELECTION 80 Dig_Out_8 NO SELECTION 81 Panel332Version 1 11 82 PanelNeuVersion 1 53 83 TIE1332Version 1 11 84 TIE1Ne...

Page 155: ...000231 128 TemperatureCS1_1A 1000 129 TemperatureR2_1A 0 000231 130 TemperatureCS2_1A 1100 131 TemperatureR3_1A 0 000231 132 TemperatureCS3_1A 1200 133 StdPressureCorrTIE1 ENABLE 134 RefPressureTIE1 29 92 135 PressureAtPoint1TIE1 0 136 A DCntsAtPoint1TIE1 819 137 PressureAtPoint2TIE1 29 54 138 A DCntsAtPoint2TIE1 3480 139 StdTempSourceTIE1 EXT 140 StdTempCorrTIE1 ENABLE 141 TempAtPoint1TIE1 68 142...

Page 156: ...ocity1B 0 180 AvgRawVelocity1B 0 181 InstActVolume1B 0 182 AvgActVolume1B 0 183 InstStdVolume1B 0 184 AvgStdVolume1B 0 185 SpanHighVolume1B 5 26802E 15 186 SpanLowVolume1B 1 66204E 13 187 ZeroVolume1B 0 0438843 188 primary_status1B 0 189 extended_status1B 0 190 SpeedOfSndInst1B 0 191 SpeedOfSndAver1B 0 192 IntMedTempInst1B 0 193 IntMedTempAver1B 0 194 SnRatioDnStream1B 0 195 SnRatioUpStream1B 0 19...

Page 157: ...30 TemperatureR21B 0 000231 231 TemperatureCS2_1B 1100 232 TemperatureR3_1B 0 000231 233 TemperatureCS3_1B 1200 234 PreAmpGainDn1B 70 235 PreAmpGainUp1B 70 236 DigitalGainDn1B 5 237 DigitalGainUp1B 5 238 TD_DnStream1B 1000 239 TD_UpStream1B 1000 240 InDelay1B 0 000215 241 NozzleDnStream1B 0 0006264 242 NozzleUpStream1B 0 0006264 243 NoiseThDnStream1B 1 244 NoiseThUpStream1B 1 245 SnNoiseRDnStream1...

Page 158: ... 278 ExtMedTempAverTIE2 713 911 279 ExtMedPressInstTIE2 29 9174 280 ExtMedPressAverTIE2 29 9119 281 MIO_StatusTIE2 0 282 XmitErrorsTIE2 11 283 TransTimeOutsTIE2 2103 284 RcvTransFullTIE2 0 285 LostMsgsTIE2 0 286 MissedMsgsTIE2 0 287 ResetCauseTIE2 1 288 NodeStateTIE2 4 289 VersionNumberNTWK 122 290 ErrorLogTIE2 1 291 SnRatioDnStream2A 76 5926 292 SnRatioUpStream2A 74 6818 293 PeakRamCntsDnStrm2A 1...

Page 159: ...tTIE2 60 333 ZeroSetPointTIE2 0 334 CalibToleranceTIE2 6 335 HourOfAutoCalTIE2 25 336 MinuteOfAutoCalTIE2 0 337 CalIntervalHourTIE2 25 338 IPSpanHighTIE2 8 339 IPSpanLowTIE2 0 340 IPAutoZeroTIE2 8 341 FlowCorrSource2A POLYNOMIAL 342 LUT_Val_2A_X1 1 343 LUT_Val_2A_Y1 1 344 LUT_Val_2A_X2 2 345 LUT_Val_2A_Y2 2 346 LUT_Val_2A_X3 3 347 LUT_Val_2A_Y3 3 348 Polynomial_2A_A0 0 349 Polynomial_2A_A1 1 350 P...

Page 160: ... MaxAnalogGainTIE2 4095 387 MinDigitalGainTIE2 4 388 MaxDigitalGainTIE2 255 389 AutoGainControlTIE2 DISABLE 390 PreAmpGainDn2A 150 391 PreAmpGainUp2A 60 392 DigitalGainDn2A 5 393 DigitalGainUp2A 5 394 TD_DnStream2A 18000 395 TD_UpStream2A 18000 396 InDelay2A 0 00075 397 NozzleDnStream2A 0 0006264 398 NozzleUpStream2A 0 0006264 399 NoiseThreshold2A ENABLE 400 NoiseThDnStream2A 1 401 NoiseThUpStream...

Page 161: ...TranToTranDistance2B 10 625 441 OffSet2B 8 442 FlowCorrSource2B POLYNOMIAL 443 LUT_Val_2B_X1 1 444 LUT_Val_2B_Y1 1 445 LUT_Val_2B_X2 2 446 LUT_Val_2B_Y2 2 447 LUT_Val_2B_X3 3 448 LUT_Val_2B_Y3 3 449 Polynomial_2B_A0 0 450 Polynomial_2B_A1 1 451 Polynomial_2B_A2 0 452 Polynomial_2B_A3 0 453 Polynomial_2B_A4 0 454 Polynomial_2B_A5 0 455 TemperatureR1_2B 0 000231 456 TemperatureCS1_2B 1000 457 Temper...

Page 162: ...LE NUMBER 488 INVALID VARIABLE NUMBER 489 INVALID VARIABLE NUMBER 490 INVALID VARIABLE NUMBER 491 INVALID VARIABLE NUMBER 492 INVALID VARIABLE NUMBER 493 INVALID VARIABLE NUMBER 494 INVALID VARIABLE NUMBER 495 INVALID VARIABLE NUMBER 496 INVALID VARIABLE NUMBER 497 INVALID VARIABLE NUMBER 498 INVALID VARIABLE NUMBER 499 INVALID VARIABLE NUMBER 500 INVALID VARIABLE NUMBER 501 INVALID VARIABLE NUMBE...

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