Teledyne ULTRAFLOW 150 Operation Manual
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Teledyne ULTRAFLOW 150 Operation Manual

Gas flow and temperature monitor
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ULTRAFLOW 150
GAS FLOW AND TEMPERATURE MONITOR
OPERATIONS MANUAL
SERIAL NUMBER: _________________________

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Summary of Contents for Teledyne 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 JANUARY 2014 Proprietary Information. All rights reserved by Teledyne Monitor 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PAGE 1.0 SAFETY ............................1-1 1.1 Internationally Recognized Symbols Used on Teledyne Monitor Labs Equipment ..... 1-1 2.0 SYSTEM OVERVIEW ......................... 2-1 2.1 System Description, Standard Equipment ................... 2-1 2.1.1 Transducer Interface Enclosure (TIE) ................2-1 2.1.2 Purge Nozzle Assemblies ..................... 2-1 2.1.3 Protective Purge System ....................
  • Page 5 TABLE OF CONTENTS (Continued) PAGE 6.4.2 Main Display Screen ....................6-10 6.4.3 Main Menu Screen ...................... 6-11 6.4.4 Service Data Menu ...................... 6-12 6.4.5 Status Code Help ......................6-12 6.4.6 Output Cal Tests ......................6-13 6.4.7 Output Module Configuration Menu ................6-16 6.4.8 Display Properties Menu .....................
  • Page 6 10 of 12 Ultraflow 150DI Long Range (14/20Khz) X-Pattern Direct Interface Wiring Diagram (115/230 VAC) 1900-0004 11 of 12 Ultraflow 150 50Khz Std. Wiring Diagram (No J-Boxes) – 115/230V 1900-0004 12 of 12 Ultraflow 150DI 50Khz Direct Interface Wiring Diagram (No J-Boxes) –...
  • Page 7 TABLE OF CONTENTS (Continued) Drawing No. Sheet Description 1901-0008-05 5 of 5 Purge Nozzle and Mtg. Plate Installation-150, Extended Long Range LR007, 14Khz w/Horn 1903-0000 3 of 4 Transducer Interface Enclosure Std. Wiring Diagram 1903-0000 4 of 4 Transducer Interface Enclosure Direct Interface Wiring Diagram 1903-0010-01 1 of 1...

  • Page 8: Safety

    This equipment is intended only for the purposes specified in this manual. Safety protections inherent in this equipment may be impaired if the Ultraflow 150 is used in a manner different than specified herein. The following are internationally recognized symbols used on the Ultraflow 150 along with specific cautions applicable to the equipment.
  • 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.

  • Page 10: System Overview

    Enhanced Remote Panel (ERP) (Not supplied with a 560DI, see section 3.5) As shown on the Ultraflow 150 Installation Drawings, the first three above are located on the stack. The Enhanced Remote Panel Assembly is typically located in the plant Control Room or CEMS Shelter.
  • Page 11 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 accuracy at short to moderate pathlengths and in low to moderate acoustic attenuation conditions.

  • Page 12: Protective Purge System

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 2.1.2.1.3 Extended Long Range Transducers (LR004 through LR007) As pathlength, temperature, velocities and medium molecular weight increase, the acoustic attenuation increases vigorously. As these factors combine to challenge the signal strength of the Long Range Transducer LR003, the Extended Long Range Transducers are used to obtain satisfactory operation in these conditions.
  • Page 13 RJ45 connector socket in the 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.

  • Page 14: Optional Equipment

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 3.0 OPTIONAL EQUIPMENT The components listed below are optional on the Ultraflow 150 system. They are not included on a standard system. Please consult the Site Specification Data sheets in the back of this manual for the details of your particular system.

  • Page 15: Dual Analog Input Board

    3.3 DUAL ANALOG INPUT BOARD The Dual Analog Input Board option is required when the user wishes to have the Ultraflow 150 take in external information on stack pressure and temperature in order to convert the stack flow volume values to standard conditions.

  • Page 16: External Temperature Measurement

    J4 Terminals 3(+) and 2(-) 3.3.2 External Temperature Measurement The Ultraflow 150 can measure medium temperature in two manners: INTERNAL MEDIUM TEMPERATURE: This measurement uses the speed of sound data derived from the time of flights between the upstream and downstream ultrasonic transducers. Since speed of...

  • Page 17: Link Rod

    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 their ports.

  • Page 18: 6Pt I/O Pc Board Option For 150Di

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 3.5 6PT I/O PC BOARD OPTION FOR 150DI The Six Point I/O Board is an optional device intended to provide a low cost Direct Interface feature to the Ultraflow 150DI where analog output and control signals are supplied directly from the Transducer Interface Enclosure (TIE) Assembly.

  • Page 19: Theory Of Operation

    Each effluent path monitored by the Transducer Interface Enclosure (TIE) uses two transducers placed on opposite sides of the stack or duct (see Ultraflow 150 System Installation Drawing, Appendix D). The transducers are pointed at each other with one transducer located diagonally upstream from the other.
  • Page 20 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 4.1.1.1 Flow Velocity Measurement The root measurement of the Ultraflow 150 is transit time. The difference between upstream and downstream transit times through the gas stream is directly proportional to the velocity of the gas stream. From transit time and the following physical equations the TIE calculates flow velocity.

  • Page 21: Flow Volume Measurement

    (reference) conditions are 68 F and 29.92 in. Hg for English units and C and 101.32 Kpa for metric units. The Ultraflow 150 has the ability to take inputs from an external pressure transducer and a temperature device. The monitor’s internal temperature measurement may also be used for correction.

  • Page 22: Monitor Specific Theory

    4.2 MONITOR SPECIFIC THEORY 4.2.1 Box Car Integration At the heart of the Ultraflow 150 is a signal conditioning technique known as “Boxcar Integration”. Each time a tone burst traverses the stack a 16 millisecond window of interest within the receive signal is digitized by an A/D converter in 0.5 microsecond intervals.
  • Page 23 SECTION 4.0, Theory of operation 4.2.2.2 ZERO Calibration The mode code for ZERO mode is 4. During the ZERO mode the TIE processes the signals in a slightly different manner. When both a ZERO and SPAN calibration have been completed, a comprehensive full system evaluation check has been done.
  • Page 24 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR (This page intentionally left blank.)

  • Page 25: Transducer Interface Enclosure (Tie)

    The Transducer Interface Enclosure houses the electronics that control the stack- mounted portion of the Ultraflow 150. Each Ultraflow 150 TIE has the ability to monitor two separate paths on the same stack. The TIE will take a full set of measurements from each path as well as calculate average values of the two paths combined.

  • Page 26: Electrical Description

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 5.2 ELECTRICAL DESCRIPTION The TIE can be powered with either 115 VAC or 230 VAC feeds. The power supply is auto ranging and will function normally with inputs from 85 VAC to 265 VAC, 50-60HZ. The power ON/OFF switch is located inside on the External Interface Board.
  • Page 27 SECTION 5.0, TRANSDUCER INTERFACE ENCLOSURE SBC332 Board Buffer From Preamp RS232 & Purge Switch Port Connector Circuits TPU I/O Network IRQ5 Boxcar Overflow Measurement Complete Boxcar RAM Busy Mode_1 3.3V Clock Mode_2 Test Point Wait / Measure* 12 Bit CONFIG_DONE &...
  • Page 28 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 5.2.3.1 Configuration Devices The Flow Mother Board FPGA is SRAM-based; therefore its internal memory is volatile. Consequently, it must be configured each time power is cycled. This is done automatically with an IC known as a Configuration Device. The Configuration Device U5 is a flash memory that contains additional circuitry to control the serial loading of configuration data into the FPGA.
  • Page 29 SECTION 5.0, TRANSDUCER INTERFACE ENCLOSURE Figure 5-3A Figure 5-3B E S Transducer Drive (50 KHZ) LR003 Transducer Drive (20 -100 -100 Note: The scales of the “X” axes are not the same. 5.2.3.3 Receive Signal Select, Gain, Digitization, Integration and Storage When the FPGA determines it is time to read the receive signal from a particular transducer/preamp it sends the appropriate channel select code to the four channel multiplexer.
  • Page 30 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 5.2.3.4 Diagnostic Waveforms Circuit The Flow Mother Board has an important built in diagnostic feature. Eight different signals can be viewed from test point 21 (TP21) depending on the configuration of the diagnostic jumpers of JU8. The FPGA places the digital data selected by JU8 (positions A, B or C) on a twelve-bit buss that connects to a digital to analog converter (DAC).
  • Page 31 5.2.3.8 External Serial Data Connections The Flow Mother Board supports both synchronous and asynchronous serial devices. All synchronous serial devices are for use by Ultraflow 150 components, most of which are on TIE circuit boards external to the Flow Mother Board.

  • Page 32: Preamp Boards

    This Preamp Board can be used on monitors with the Electrostatic or Long Range Transducers. However, it must be used in conjunction with an Ultraflow150 Flow Buffer Board. The Ultraflow 150 Flow Preamp/Driver Board also plugs directly into the preamp slots in the Flow Mother Board. It is connected to the Flow...

  • Page 33: Optional) Dual Analog Input Board

    DC voltage loop. It can take three types of barometric pressure signals; a custom Teledyne Monitor Labs module, a 4-20 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).
  • Page 34 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR Table 5-3A U Bank (User Data Bank) Code Description, (Inst/Avg), Units E Button Action Actual Velocity, Instantaneous, ft/s or m/s NO EFFECT Actual Velocity, Average, ft/s or m/s NO EFFECT Actual Volume, Instantaneous, various units...

  • Page 35: Individual Button Function (When Pressed By Themselves)

    SECTION 5.0, TRANSDUCER INTERFACE ENCLOSURE Table 5-3C A Bank (Auxiliary Data Bank) Code Description, (Inst/Avg), Units E Button Action Medium Internal Temperature, Instantaneous, deg. C or F NO EFFECT Medium Internal Temperature, Average, deg. C or F NO EFFECT Medium External Temperature, Instantaneous, deg. F or C NO EFFECT Medium External Temperature, Average, deg.

  • Page 36: Combinations Of Buttons

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR NORMAL: Places instrument in NORMAL mode. PATH: Since each TIE has two measurement paths (A and B) but only one display, a means is needed to toggle the single display between Path A data and Path B. This button performs this function.

  • Page 37: Enhanced Remote Panel W / Multi I/O Module

    SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE 6.0 ENHANCED REMOTE PANEL W / MULTI I/O MODULE (NOT SUPPLIED WITH 560DI) 6.1 OVERVIEW The Enhanced Remote Panel is menu driven. It features a touch sensitive keypad, a 4 ½” (11.4 cm) LCD display, key lockout, RS-232 and RS-422/485 serial communication capability, and a commercial network communication node.

  • Page 38: Electrical Description

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR Power Entry Module Keypad/Front Panel Assembly 6.3 ELECTRICAL DESCRIPTION 6.3.1 Input Power Requirement The Enhanced Remote Panel has been designed to operate over a wide range of international power supply ranges and frequencies without the need for modifications or adjustments.
  • Page 39 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE 6.3.2.5 Power Supply Board The Power Supply Board produces the +5 VDC logic power for the Enhanced Remote Panel. It has two connectors - one for input and one for output. The input wires come from the input power module that contains the line cord connector power switch, and initial filtering.
  • Page 40 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR internal jumper located on the Mother Board. However, the RS-485 port communication protocol does not support addressability. The communication parameters of both ports are fixed. They are listed in Table 6-1. Table 6-1...
  • Page 41 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE Figure 6-1 Mother Board Block Diagram, 1803-0200 RS 232 Surge Serial port t ti Reset Buffe To keypad rows driver Processor Processor interface To keypad columns Buffe drive processor Serial comm. port 422 or 485 Intensity Surge...
  • Page 42 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR Table 6-3A Enhanced Remote Display Mother Board Jumper Definitions Jumper # Selections Functional Description IRQ1 IRQ2 IRQ3 IRQ4 IRQ6 Out Selects IRQ for reset signal IRQ5 IRQ1 IRQ2 IRQ3 IRQ4 IRQ5 IRQ6 RS422/485 Receive IRQ...
  • Page 43 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE 6.3.2.9 Multi I/O Board (Hardware) The Multi I/O Board is a peripheral hardware interface. It communicates with the other devices in the system via a network interface. It gathers information from the TIE(s) and the Enhanced Remote Display via the network. It processes this information together with its digital inputs and site specific configuration to control its outputs.
  • Page 44 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR Table 6-4A Multi I/O Jumper Definitions Jumper # Selections Functional Description 4--20 0--20 0—24 Jumpers JU & JU configure the range of the analog outputs for channel #1. Configures the range of analog output #2...

  • Page 45: Operational Description-Menu Structure And User Interface

    SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE Table 6-4B Multi I/O Test Point Descriptions Test Point # Functional Description Output isolated drive voltage for analog output #1. Referenced to TP GND reference for TP and all points within #1 output circuit Output #1 &...

  • Page 46: Main Display Screen

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 6.4.2 Main Display Screen This is the screen that is typically displayed during normal operation. The screen has a total of twelve pages accessible by the “Page Up” and “Page Down” keys. There are two pages for each TIE/path. One of the two pages has large block numbers appropriate for continuous display.

  • Page 47: Main Menu Screen

    SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE Figure 6-2 Ultraflow 150 Menu Tree Page #5 Page #6 Page #3 Page #4 Page #1 Page #2 TIE#2 PathA TIE#2 PathA TIE#1 PathB TIE#1 PathB TIE#1 PathA TIE#1 PathA large #s...

  • Page 48: Service Data Menu

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR particular submenu use the UP and DOWN arrow keys to highlight the selection then press the “↵” key to select. This will bring up the next menu screen as described in the appropriate section. The ESC key will take you back to the previous screen.

  • Page 49: Status Code Help

    SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE 6.4.5 Status Code Help This screen is view only. No password is required. The information displayed is useful in determining the status of the monitor. The screen contains the five-digit STATUS word and a decoded list of the individual status conditions.
  • Page 50 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR by pressing the “Page Up” and “Page Down” keys until the desired mode appears. Press ENTER to move the highlight bar to the “SEND THIS COMMAND” line then press ENTER to send the mode change request.
  • Page 51 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE SPANHIGH Initiates a SPANHIGH-ACQUIRE mode at the The MIO goes into SPANHIGH-ACQUIRE mode after the beginning of the next integration period after TIE’s first full integration period in SPANHIGH- Initiated by: Digital Inputs, the request was received.

  • Page 52: Output Module Configuration Menu

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR CAL CYCLE Initiates an internally timed calibration cycle consisting of the The MIO mode follows the TIE mode. It Initiated by: three CALIBRATION modes and their supporting ACQUIRE changes modes when it sees that the TIE Digital Inputs, modes.
  • Page 53 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE Figure 6-6 ANALOG OUTPUT CONFIG 1 & 2 Description With Cal. OUTPUT MODULE CONFIG 1 : xxxx xxxxxx xx Path : xxxx x xxxx x Value at 4ma : x.xxE+xx Value at 20ma : x.xxE+xx 2 : xxxx xxxxxx xx Path : xxx x xxxx x...
  • Page 54 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR The WITH CAL field can be "YES", "NO" or “EXP”. Use the “Page- up/Page-down” keys to find the parameter you want and press ENTER to select. The action of each selection is explained below.

  • Page 55: Display Properties Menu

    SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE 6.4.7.3 Relay Assignments This screen is password protected. This menu screen sets the condition for closure for each of the eight output relays on the Multi I/O Board. While the assignment for a particular relay is highlighted, scroll to the desired condition using the “Page-Up”...
  • Page 56 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR The first selection under the System Properties Menu will permit setting of the number of TIE boxes in the system You may move the “↓” key to highlight the “SELECT TIE:” option. You may toggle through the possible choices by using the “Page Up”...
  • Page 57 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE appropriate month abbreviation (Jan, Feb, Mar, etc.) After the proper month is displayed, the“ ↵” key will select the month and highlight the year. Enter the year information in the 4-digit format. AVERAGING PROPERTIES: Sets response time.
  • Page 58 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR equation applied to the actual flow velocity as derived from measured times of flight and the Geometry Properties parameters (see System Calibration and Adjustment, Section 8.0, for additional details). The linearizer is helpful for correcting for stratification, nonaxial flow or other effects.
  • Page 59 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE Counts at Point 1 Temperature at Point 2 Counts at Point 2 Reference Temperature ALARM PROPERTIES: This screen contains the alarm thresholds, actuating variable and operating mode of the flow volume and temperature alarms.

  • Page 60: View Trending Data

    A full description of these errors is beyond the scope of this manual. If necessary, please consult Teledyne Monitor Labs technical support for more information. 6.4.13 View Status History This Screen has up to twelve pages depending on the number of system status changes that have taken place.

  • Page 61: View Alarms History

    SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE 6.4.14 View Alarms History The View Alarms History screen can have as many as twenty pages. The "Page-Up" and "Page-Down" keys move you to the next or previous page. This screen stores the previous 100 alarm events. An alarm event consists of setting or clearing any of the alarms that are defined in the SYSTEM PROPERTIES Menu.

  • Page 62: Digital Inputs

    ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 3. WITH CAL = EXP: Calibration data will be sent to that output when a calibration request is processed. Scaling for the SPANHIGH and SPANLOW calibration data will be the same as the Normal mode scaling entered under VALUE AT ZERO SCALE and VALUE AT FULL SCALE.
  • Page 63 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE The digital output selections are self-explanatory except for the Data Valid, Fault, and Fatal Fault selections. Data is considered valid in all Multi I/O modes except TEST FULL SCALE, TEST MID SCALE, TEST ZERO SCALE, DIAGNOSTIC, and UNKNOWN when a Fatal Fault is not present.
  • Page 64 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR All other combinations of Inputs #1 through #6. No action results. These are considered invalid command requests. Note: In the above table, a “1” designates actuation of an Isolator Input and “0” designates de-actuation.
  • Page 65 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE SPAN SPAN PURGE SN RATIO DN SN RATIO DN PURGE HIGHorACQ ON HIGHorACQ ON FAILURE ALARM TIE1B ALARM TIE1B FAILURE TIE2B AO TIE1 AO TIE2 TIE1B SPAN SPAN SN RATIO BOTH SN RATIO BOTH CAL FAILURE CAL FAILURE LOWorACQ ON...
  • Page 66 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR Table 6-10 Parameters for Analog Output NOTE: Each of the parameters for output can carry data from either TIE and either path or the average of the two paths. The TIE and path are selected on the output configuration screen.
  • Page 67 SECTION 6.0, ENHANCED REMOTE PANEL W/MULTI I/O MODULE Parameters for Analog Output (continued) Parameter Name Functional Description This parameter is an average of the instantaneous zero values as measured by the monitor during a number of Integration Periods. The number of periods is set by the AVG ZERO “periods for averaging”...
  • Page 68 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR Figure 6-7 Relay Sequence & Timing Output TIE & MIO Changes Mode MIO Changes Mode Normal TIE Changes Relay Mode Normal or Acq Relay Analog Zero Output Relay Zero or Normal Acq Relay...

  • Page 69: Installation

    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.

  • Page 70: Site Selection

    Please consult the Teledyne Monitor Labs factory for details.

  • Page 71: Equipment Mounting Considerations

    Teledyne Monitor Labs Drawing ULTRAFLOW 150 FLANGE INSTALLATION for details. Care must be taken in reporting the information requested by Teledyne Monitor Labs in the “Ultraflow 150 Installation Guide & Checklist”. This will ensure that sufficient clearances exist to install and remove the Purge Nozzle Assemblies, which house the transducers.

  • Page 72: Purge System, Reference Purge Ass'y Mtg., Plumbing & Clearance Requirements Drawing

    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.

  • Page 73: Transducer Interface Enclosure Assembly, Reference Xducer Interface Enclosure Installation Drawing

    Before applying power to the Transducer Interface Enclosure be certain that all electrical connections have been made to the stack equipment. Refer to Teledyne Monitor Labs Drawing ULTRAFLOW 150 STD. WIRING DIAGRAM. 7.3.5 Junction Box, Reference JUNCTION BOX MTG. METHODS AND...

  • Page 74: Enhanced Remote Panel Assembly, Reference Enhanced Remote Panel Assembly Drawing

    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.
  • Page 75 SECTION 7.0, INSTALLATION (This page intentionally left blank.)

  • Page 77: System Calibration And Adjustment

    SECTION 8.0, SYSTEM CALIBRATION AND ADJUSTMENT 8.0 SYSTEM CALIBRATION AND ADJUSTMENT The calibration of the Ultraflow 150 system at the Teledyne Monitor Labs factory consists primarily of configuring the Transducer Interface Enclosure (TIE) and Enhanced Remote Panel (ERP) variables to accurately represent the actual physical dimensions at the user’s site.
  • Page 78 Integration Periods in Auto Cycle Zero Typically, for maximum accuracy in Continuous Emission Monitoring Systems (CEMS), the Ultraflow 150 is field calibrated versus a multipoint pitot tube flow measurement done according to US EPA Reference Method 40CFR60 Appendix A Methods 1 and 2 (extractive test). While...
  • Page 79 SECTION 8.0, SYSTEM CALIBRATION AND ADJUSTMENT Flow Correction Curve Properties:  Look Up Table (LUT):  Polynomial (POLY): Table 8-1 ULTRAFLOW 150 Flow Look Up Table Linearizer X3, Y3 Reference Continues X2, Y2 Method, X2,Y2 & X3,Y3 Actual slope &...
  • Page 80 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 data over differing load conditions.
  • Page 81 1250 1300 Cs, Speed of Sound, ft/sec The Ultraflow 150 measures temperature via time of flight of sound (Internal Medium Temperature) or by use of an external temperature sensor. The Internal Medium Temperature measurement is affected by the molecular weight and heat capacity of the medium.
  • Page 82 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR (3) must always be used. See Section 6, Temp. Calibration Properties, for additional details. Standard Pressure Properties:  Standard Pressure Correction: ENABLE/DISABLE  Pressure at Point 1  Current at Point 1 ...
  • Page 83 Downstream A  Upstream A Signal to Noise Ratio Alarm Threshold:  Downstream A  Upstream A Figure 8-1 INSIDE DIAMETER DIAMETER Ultraflow 150 Downstream Nozzle Length Ultraflow 150 Offset Ultraflow 150 Trans. Trans. Distance Ultraflow 150 Upstream Nozzle Length...

  • Page 84: Transducer Interface Enclosure Electronics Adjustment

    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.
  • Page 85 SECTION 8.0, SYSTEM CALIBRATION AND ADJUSTMENT (This page intentionally left blank.)

  • Page 87: Maintenance

    If care is taken to perform simple inspections and take corrective action as required, the Teledyne Monitor Labs Ultraflow 150 system will provide accurate, reliable data to the user. 9.1 MAINTENANCE SCHEDULE It must be noted that the conditions under which the monitoring system operates varies widely from installation to installation.

  • Page 88: Troubleshooting Guide

    9.2 TROUBLESHOOTING GUIDE One of the design features of the Ultraflow 150 system is that all of the information necessary to troubleshoot the system to a subassembly level can be obtained from the Enhanced Remote Panel. The Status Codes together with the Service Data Values will define almost any system problem.
  • Page 89 APPENDIX A SITE SPECIFICATION DATA SHEETS...
  • Page 90 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR (This page intentionally left blank.)
  • Page 91 APPENDIX A, SITE SPECIFICATION DATA SHEETS Ultraflow 150 Site Specification Data Sheets Serial Number: SO Number: Stack/Unit ID: TIE number: Geometry: Active Paths: Volume: Transducer: System Type Nose Material: Coupling Length: Path A Path B Upstream DownStream LinkRod Length: (if applicable)
  • Page 92 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR PRE AMPS Path A Path B UpStream DownStream Jumper positions 1903-0400 Pre Amps (N/A for 1903-0200) JU1: JU2: JU3: JU4: Dual Analog Input Board Barometric Pressure Sensor: LON Modlue: External BP: External Temp.:...
  • Page 93 APPENDIX A, SITE SPECIFICATION DATA SHEETS 6PIO Analog Outputs 6PIO Relay Outputs K1 (JU12) Cal Type K2 (JU13) Path Zero Scale Full Scale Cal Type Path Zero Scale Full Scale Enhanced Remote Display Software Versions 332 version Panel Neuron MIO version Ethernet Module MAC Address: Neuron Version:...
  • Page 94 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR Cal Type Path Zero Scale Full Scale Cal Type Path Zero Scale Full Scale Relays Test Equipment Used Oscilloscope Chart Recorder...
  • Page 95 APPENDIX B MAINTENANCE CHECK SHEETS...
  • Page 96 (This page intentionally left blank.)
  • Page 97 APPENDIX B, MAINTENANCE CHECK SHEETS Rev. 9/8/11 TELEDYNE MONITOR LABS INC. MAINTENANCE CHECK SHEETS FOR THE ULTRAFLOW 150 Company Date: Time: Plant Name Service Person Location Load Level Unit ID Serial Number Path Reason for Service Data Invalid From Data Invalid To...
  • Page 98 2. Clean Down Stream Transducer and Mounting Tube. 3. Clean Up Stream Transducer and Mounting Tube. TIE ELECTRONICS Check the following Power Supply voltages on the Ultraflow 150 Mother Board. TP15 = DGND. (+120 VDC to 140 VDC) VAC ( < .005 VAC) +5 VDC ( ±...
  • Page 99 Enhanced Remote Panel. Record which one you are servicing. Some Ultraflow 150’s can have both a Path A and a Path B for each TIE. If the TIE you are working on has both, start a sheet for PATH B and the combined Path (PATH AB).
  • Page 100 Additional information is located in the body of the manual and is available from Teledyne Monitor Labs technical support via phone. Force a calibration cycle. Then go back and record data in the “After” columns of the data tables.
  • Page 101 APPENDIX C SPARE PARTS...
  • Page 102 (This page intentionally left blank.)
  • Page 103 APPENDIX C, RECOMMENDED SPARE PARTS RECOMMENDED SPARE PARTS Recommended spare parts for the Ultraflow 150 are organized into three categories. User can stock the appropriate parts for their level of maintenance. For the highest level of maintenance all three lists should be stocked. The three levels are: Startup ...
  • Page 104 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR TELEDYNE MONITOR LABS (TML) ULTRAFLOW 150 “EMERGENCY” RECOMMENDED SPARE PARTS (Parts which may be necessary to minimize instrument “Down Time” after power surges, lightning strikes, etc.) Quantity to Stock Mean Time 2 – 5...
  • Page 106 APPENDIX D DRAWINGS...
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  • Page 144 APPENDIX E ENHANCED SERIAL PORT COMMUNICATION PROTOCOL...
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  • Page 146 Appendix E, Enhanced serial port communication protocol ENHANCED SERIAL PORT COMMUNICATION PROTOCOL This enhanced serial port protocol is only available with Enhanced Remote Panel 332 version 1.10 or later. A short description of the original communication is described in the Enhanced Remote Display section of the manual.
  • Page 147 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR STATUS HISTORY PRINT OUT The information contained in the Status History screens can be acquired through serial port using the following commands: 991?<CR> will print out the Status History for TIE 1 992?<CR>...
  • Page 148 Appendix E, Enhanced serial port communication protocol ALARM HISTORY PRINT OUT The commands 993?<CR> and 994?<CR> prints out information from the Alarm History screens. An enumeration is used to define the alarms. The first value is for the Alarm Description and can be decoded from the table below. The second number tells you if the alarm was SET or CLEARED.
  • Page 149 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR INITIATION AND CONTROL OF CALIBRATIONS AND MODES OF OPERATION The system calibration may be initiated and controlled from the serial port. TIE1 and TIE2 may be controlled independently when both are present. The following command string may be used.
  • Page 150 Appendix E, Enhanced serial port communication protocol A SUMMARY OF THE ENHANCED COMMANDS AVIALABLE The program variables are listed later in this appendix. The 990, 998 and 999 commands described below are used with the matched-pair format. This variable is used to request variables in the matched-pair format. The following is the proper way to use this variable: 990, "VAR#",990,"VAR#"<CR>...
  • Page 151 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR BROADCAST MODE A screen on the Enhanced Remote Panel can be used to output data on a periodic basis. This allows a technician to log data without the need to request each data point independently. This serial transmission is only available on the RS-232 port and will only be in the matched-pair protocol.
  • Page 152 Appendix E, Enhanced serial port communication protocol MECHANICAL CONNECTIONS To fasten a laptop or other computer running a standard serial program to the serial port of the ENHANCED REMOTE PANEL you must use following hardware connections. RS-232 MECHANICAL CONNECTIONS The connections to the ENHANCED REMOTE PANEL are at the rear of the unit on a standard 9-pin "D"...
  • Page 153 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR VARIABLE LIST The following is a list of variables available from the Enhanced Remote Panel RS232 serial port. TML reserves the right to modify this list at any time. It is best to request a list from the Enhanced Remote Panel with 255? command and the 511? command.
  • Page 154 Appendix E, Enhanced serial port communication protocol 46 TimeOfFlightDnStrm1A: 0.015472 47 TimeOfFlightUpStrm1A: 0.015413 48 SpanHighOffSetTD1A: 19050 49 SpanLowOffSetTD1A: 18708 50 R_Factor1A: 0.000231 51 DnStrmNoiseThLevel1A: 0 52 UpStrmNoiseThLevel1A: 0 53 MIO_Ch_1: NO SELECTION 54 MIO_Ch_1 With Calib: NO 55 Path_Sel: TIE1 PATH A 56 MIO_Ch_1 Zero Scale: 0 57 MIO_Ch_1 Full Scale: 0 58 MIO_Ch_2: NO SELECTION...
  • Page 155 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 102 MinFlowVelocityTIE1: 0 103 MaxFlowVelocityTIE1: 100 104 SpanHighSetPointTIE1: 90 105 SpanLowSetPointTIE1: 60 106 ZeroSetPointTIE1: 0 107 CalibToleranceTIE1: 6 108 HourOfAutoCalTIE1: 25 109 MinuteOfAutoCalTIE1: 0 110 CalIntervalHourTIE1: 25 111 IPSpanHighTIE1: 8 112 IPSpanLowTIE1: 0...
  • Page 156 Appendix E, Enhanced serial port communication protocol 158 MinAnalogGainTIE1: 67 159 MaxAnalogGainTIE1: 4095 160 MinDigitalGainTIE1: 4 161 MaxDigitalGainTIE1: 255 162 AutoGainControlTIE1: DISABLE 163 PreAmpGainDn1A: 150 164 PreAmpGainUp1A: 60 165 DigitalGainDn1A: 5 166 DigitalGainUp1A: 5 167 TD_DnStream1A: 18000 168 TD_UpStream1A: 18000 169 InDelay1A: 0.00075 170 NozzleDnStream1A: 0.0006264 171 NozzleUpStream1A: 0.0006264...
  • Page 157 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 211 DnStrmNozzleLength1B: 0.707 212 UpStrmNozzleLength1B: 0.707 213 TranToTranDistance1B: 10.625 214 OffSet1B: 8 215 FlowCorrSource1B: POLYNOMIAL 216 LUT_Val_1B_X1: 1 217 LUT_Val_1B_Y1: 1 218 LUT_Val_1B_X2: 2 219 LUT_Val_1B_Y2: 2 220 LUT_Val_1B_X3: 3 221 LUT_Val_1B_Y3: 3...
  • Page 158 Appendix E, Enhanced serial port communication protocol TIE 2 Variables: 256 TIE2_DATE: 5-Sep-2000 257 TIE2_TIME: 4:42:38 258 InstLinVelocity2A: -2.7184 259 AvgLinVelocity2A: -2.6185 260 InstRawVelocity2A: -2.7184 261 AvgRawVelocity2A: -2.5927 262 InstActVolume2A: -17.229 263 AvgActVolume2A: -15.556 264 InstStdVolume2A: -7.7445 265 AvgStdVolume2A: -6.9926 266 SpanHighVolume2A: 0 267 SpanLowVolume2A: 0 268 ZeroVolume2A: 0...
  • Page 159 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 310 TIE2332Version: 1.11 311 TIE2NeuVersion: 1.53 312 MIOVersion: 1.53 313 TIE2FPGAVersion: 5.20 314 DnStrmNozzleLength2A: 0.707 315 UpStrmNozzleLength2A: 0.707 316 TranToTranDistance2A: 16 317 OffSet2A: 8 318 CrossSectAreaTIE2: 100 319 GeometryUnitsTIE2: FT 320 MeasurementPathsTIE2: PATH_A...
  • Page 160 Appendix E, Enhanced serial port communication protocol 366 StdTempSourceTIE2: EXT 367 StdTempCorrTIE2: ENABLE 368 TempAtPoint1TIE2: 68 369 A/DCntsAtPoint1TIE2: 32 370 TempAtPoint2TIE2: 429 371 A/DCntsAtPoint2TIE2: 500 372 ReferenceTempTIE2: 2945 373 FlowAlarmSelectTIE2: STDVOL_A 374 FlowAlarmModeTIE2: LESSER 375 InstFlowThreshTIE2: -50 376 AverFlowThreshTIE2: -50 377 TempAlarmSelectTIE2: INTTEMP_A 378 TempAlarmModeTIE2: GREATER 379 InstTempThreshTIE2: 201...
  • Page 161 ULTRAFLOW 150 GAS FLOW AND TEMPERATURE MONITOR 419 IntMedTempInst2B: 0 420 IntMedTempAver2B: 0 421 SnRatioDnStream2B: 0 422 SnRatioUpStream2B: 0 423 PeakRamCntsDnStrm2B: 0 424 PeakRamCntsUpStrm2B: 0 425 CalcRamCntsDnStrm2B: 0 426 CalcRamCntsUpStrm2B: 0 427 PreAmpGainDnStream2B: 0 428 PreAmpGainUpStream2B: 0 429 DigitalGainDnStrm2B: 0 430 DigitalGainUpStrm2B: 0 431 TimeOfFlightDnStrm2B: -0.0009678...
  • Page 162 Appendix E, Enhanced serial port communication protocol TIE 2 Combined Path AB Variables: 474 InstLinVelocity2AB: 0 475 InstRawVelocity2AB: 0 476 InstActVolume2AB: 0 477 InstStdVolume2AB: 0 478 SpanHighVolume2AB: 0 479 SpanLowVolume2AB: 0 480 ZeroVolume2AB: 0 INVALID VARIABLE NUMBER: 481 INVALID VARIABLE NUMBER: 482 INVALID VARIABLE NUMBER: 483 INVALID VARIABLE NUMBER: 484 INVALID VARIABLE NUMBER: 485...

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