TABLE OF CONTENTS SECTION 1 1.1 1.2 1.3 1.4 1.5 INTEK’S POWER INDUSTRY SERVICES................................................................. 1 INTRODUCTION .......................................................................................................... 2 PRINCIPLE OF OPERATION....................................................................................... 3 TECHNICAL SPECIFICATIONS .................................................................................
WARRANTY Intek, Inc.
SECTION 1 — GENERAL INFORMATION 1.1 INTEK’S POWER INDUSTRY SERVICES Intek manufactures RheoVac condenser and air in-leak monitor Rheotherm circulating water flow and fouling meters, flow meters, flow switches, as well as, temperature sensors and pressure probes. These specialty instruments for the power industry provide continuous monitoring of critical parameters that have historically been unavailable or inadequately measured since steam surface condensers were introduced.
1.2 INTRODUCTION RheoVac technology provides direct measurement of all necessary properties of the gases, in the condenser exhauster line, to give an accurate determination of air in-leakage and condenser performance related parameters. The RheoVac instrument is a part of Intek's services that provide the power industry with the most advantageous and complete measurement and diagnostic tools for condenser systems.
1.3 PRINCIPLE OF OPERATION The Rheotherm flow sensor is calibrated to measure the total mass flow of the gaseous water vapor/air mixture. From the other three measurements, the RheoVac electronics converts the total gas mass flow signal from the probe into two components, air mass flow rate and water vapor mass flow rate. The RheoVac system is fully calibrated at the factory under dynamic fluid conditions identical to those within the power plant vacuum line.
1.5 x x x x x x x x x x x x PRECAUTIONS AND RECOMMENDATIONS Read the entire manual before installing and operating the RheoVac system. WARNING — Be sure to power up your RheoVac instrument system and probe(s) for at least 30 minutes before inserting probes into the vent line hot taps. DO NOT leave probe in vent line without power or when flooding the condenser. Carefully select the best locations for installation of the probes.
SECTION 2 — INSTALLATION These instructions are general guidelines for the installation of RheoVac instruments in their standard configuration. Additional information pertaining to your unit is covered in SECTION 6 — CUSTOM INFORMATION. Carefully read these instructions prior to installing the equipment. Also, see preceding SECTION 1.5; PRECAUTIONS AND RECOMMENDATIONS. 2.1 RheoVac SYSTEM INSTALLATION/SITE SELECTION The standard RheoVac 950 can be configured with one, two or three probes.
x Check installation clearance. Each transducer probe is approximately 3 feet (0.9m) long and the hot tap assembly is approximately 13 inches (0.33m) long, therefore, allow minimum clearance of 4 feet (1.3m) for probe installation. Be sure there are no obstructions around the vacuum line that will interfere with probe insertion. Figure 3 shows the proper insertion angle. THIS ORIENTATION IS IMPORTANT FOR PROPER OPERATION.
2.1.2 Electronics Unit Site Selection The Model 950 typically has two or three electronics enclosures (see Figure 1). The processor enclosure and other electronics boxes should be installed in a convenient location and should be kept away from direct sources of heat, such as non-insulated steam lines, or moisture. The maximum temperature rating of electronics is 120(F; ensure that this temperature will not be exceeded inside the enclosure.
3. Check serial number (S/N). If more than one RheoVac system has been purchased, make sure the first five digits of the serial numbers of the probe(s) match the first five digits of the serial number of the main processor unit. The electronics and up to three probes are a matched set. Mismatched components will not work correctly. The dash number on the probe S/N is the probe number shown on the display. Record the probe number and installation location for future reference. 4.
A. Main Processor Unit (see Figure 5) 1. Sensor Power and Communication Line: Connect the distribution box to this main processor box using the RS-485 communications/power cable. Follow indicated connector color code. [communications: white (A), blue (B) and shield (SH); power: 24Vdc, red (+), and black ( )] 2. Main Power: Connect main power terminals to a dedicated 100-250Vac, single phase, 15-amp circuit. An external disconnect switch should be used for disconnecting power to the system during outages.
Figure 5 Output Connections and Set-up Figure 6 Serial Communication Interface - 10 -
B. Distribution Box (see Figure 7) 1. Connect the RS-485 wires (blue, white and shield) and 24Vdc power (red and black) from the main processor unit to screw terminal, JP1. 2. Install ½” liquid-tight conduit between the distribution enclosure and the probes unless ½” rigid conduit is used for long distance runs. Use a minimum of 6 feet of liquid-tight conduit at the probes. 3. The probe connector comes with an adapter which allows the attachment of the ½” flexible conduit connector. 4.
C. Transmitter Box (optional, see Figure 8) — For driving eight (8) remote 4-20 mA analog signals from one RS-485 input port. Note: Intek recommends using the network connection for all data transmissions and RheoVac communications. 1. Connect the RS-485 communications/power cable from the distribution box (RS-485: white and blue wires; 24Vdc power: red and black wires). 2. Connect up to eight (8) signal wire pairs to the indicated terminals for isolated 4-20mA outputs. Figure 8 Optional Transmitter Box 3.
Active Configuration Passive Configuration Vdd CAUTION: Do not move config. jumpers if instrument is powered. from RheoVac Supply R2 10 Ohm Terminal Terminal Q1 Q1 RFL2N05 or Equiv. RFL2N05 or Equiv.
D. Probe: CAUTION — Do not cross thread connection. The probe is supplied with a convenient plug-in connector. The male side of the connector comes installed in the probe junction box. The female side is usually shipped loose and must be installed onto the supplied DeviceNet™ type 5711 cable once it is run from the Distribution Box to the probe. The wiring detail for the female plug-in connector (Turck p/n B4151-0/9) can be seen in Figure 10.
SECTION 3 — OPERATION The RheoVac system is calibrated, compensated, and linearized for a wide range of flowing media temperatures, pressures, and water vapor contents. However, abrupt changes in these parameters can cause the instrument to temporarily read the flow rate improperly, which could lead to transient spikes in the flow indication. In particular, if liquid (water) hits the probe tips, there will be high flow indications until all the water vaporizes.
3.4 COMMUNICATIONS Typical RheoVac 950 instruments have an Ethernet port, two serial communications choices (RS-232 or RS-422) and optional eight 4-20 mA output signals for each probe. All 4-20 mA output signals are linearly scaled such that 4 mA represents 0% of the rated full scale value (except temperature, which is 0(C) and 20 mA represents 100% of the rated full scale value (temperature is 100(C). The standard full scale values and definitions of all process variables are listed in Table 3.
A. Using www.MyCondenser.com for plotting (Plotting tools are available free on our website for analyzing RheoVac Model 950 data). Must first register as user. 1. Open the website, www.MyCondenser.com. 2. If you are not registered, click the ‘register’ link at the bottom of the page and follow the on-screen instructions. 3. Log in to the website using the username and password created during the registration process. 4.
3. Public Forum Registration is not required for viewing access to the public forum. This forum is a way to freely exchange ideas and post questions (with registration) to professionals within the power industry. 4. Private Forum Through the private forum, the registrant will be able to communicate directly with Intek engineers regarding data analysis, condenser services, instrumentation, and other questions. Posts on this forum will only be visible by the user and Intek engineers. 5.
SECTION 4 — MAINTENANCE 4.1 CALIBRATION The RheoVac instrument is calibrated at the factory in a calibration system which replicates the condenser and vacuum line environment. The system is designed to simulate the temperature, pressure, water vapor relative saturation, and flow rate under the gaseous fluid conditions found within the power plant vacuum line. In general, calibrations should be valid over a two-year period if the probe is well maintained.
4.3 TROUBLESHOOTING 4.3.1 Diagnostic Messages Table 6 provides a guide for plant personnel to identify causes of problems and determine appropriate actions to resolve problems observed. If problems are encountered and factory assistance is desired, please contact the factory. Table 6 Troubleshooting Guide (Diagnostic Messages) MESSAGE CODE Description/Symptom PROBABLE CAUSE 2. 3. 4.
4.3.2 Software Communication Problems When using the RheoVac software on a PC, the software may give you a “Communication Error or Message.” Use the information in Table 7 and Table 8 to determine the source of this message and appropriate action. Table 7 Troubleshooting Guide (serial connection software communication errors) OBSERVATION Appears the first time the application was executed PROBABLE CAUSE 1. 2. 1.
4.3.3 Primary Signal Validation If the RheoVac instrument is operating without message indications but output readings are questionable, check your RheoVac instruments primary readings per Table 9. Please send to Intek by e-mail the following plant data: turbine back pressure, hotwell temperature, load, and inlet and outlet circulating water temperatures, along with at least 24 hours of data from the RheoVac instrument/probe for the same time period.
SECTION 5 — CUSTOMER SERVICE FROM THE CONDENSER EXPERTS Intek’s corporate philosophy is to help solve our customers’ difficult flow measurement problems. When you purchase a RheoVac system you also receive Intek’s dedicated customer service. For sales or product service, call your local representative or Intek directly at (614) 8950301 8AM to 5PM EST/EDT weekdays or fax us anytime at (614) 895-0319. E-mail inquiries should be sent to sales@intekflow.com or techsupport@intekflow.com.
Intek has many years of experience helping customers solve their complex condenser problems. Intek's monitoring services ensures plants have expert assistance with collecting, interpreting, and reporting on condenser operations. In many cases, excess back pressure problems can be predicted before have an affect on power production. If you would like a quotation on a complete condenser monitoring and reporting solution, please call. 5.
SECTION 6 — CUSTOM INFORMATION 6.1 UNIT IDENTIFICATION Model no.: Serial no.: Customer identification: 6.2 CONFIGURATION The marked (X) items denote the configuration of this unit as originally shipped from the factory.
APPENDIX A - RheoVac® Instrument User Interface Software A.1 INTRODUCTION User Interface Software (UIS) is provided on CD-ROM with every RheoVac instrument. This software is used to communicate with the RheoVac unit from a User Interface Computer (UIC). Some of the functions of the software can be performed using a serial cable, while all functions are available using an Ethernet connection.
Make sure the proper cable connection has been made and select the desired communication type by clicking on either green button. Figure A - Initial UIS computer Screen A.4 RS-232/422 COMMUNICATION This function requires a serial cable and connector, available on request, to connect the UIC and the RheoVac instrument electronics. This connection allows the user to view real time data of important parameters in a convenient gauge screen layout.
950" network ID). The user must select the network ID from the pull down menu following the selection of Ethernet Communication utility from the Main Menu. If the Network ID is not in the list, select Add New ID and enter the correct six character Network ID. When a new ID is added to the list, it will be saved as the default for later use. Selecting the correct ID will initiate communication with the RheoVac instrument.
Click on the small graph image to view a historical graph of that parameter. from all available probes by clicking on the Probe S/N menu. Select Figure B - User Interface Software Data Monitor Feature To do real-time graphing, select from the graph menu. The screen shown in Figure C appears. Figure C - User Interface Software Graph Feature I:\OFFICE\WPMANUAL\RV950 APPENDIX A3.
This screen can be divided into four parts: 1. The Chart (or charts) 2. The X-Axis Controls 3. The Legend 4. The User Menu These four parts work together in the following ways: As soon as the software is opened and valid communication is established, the data collected for each probe is plotted on the chart(s). The newest data points are displayed on the right of the chart and push older data points to the left, much like many old-style strip chart recorders.
to the user’s hard disk is stored in the “C:\RHEOVAC\DATA\” directory. The data is subdivided into folders for each probe. A new file for each probe will be created each day that data is archived. A.7 WARRANTY REGISTRATION/TECHNICAL SUPPORT Sending Data to Intek: IMPORTANT If the instrument is equipped with a portable USB data storage device as shown in Figure 5 (in the main manual), remove this storage device after one week of operation and send to "Intek, Inc.
APPENDIX B - RheoVac Model 950 Networking B.1 INTRODUCTION Use these instructions when making a peer-to-peer Ethernet connection between the RheoVac 950 and the User Interface Computer (UIC), or an Ethernet connection between the RheoVac 950 and a Local Area Network (LAN). Locate the section that covers your operating software. B.2 WINDOWS 98 OR WINDOWS ME OPERATING SYSTEM 1. Ethernet Cable: a.
4. Networking with the RheoVac 950: If all of the items above are completed successfully, the UIC or LAN computer should be able to network with the RheoVac 950. To search for the RheoVac 950 from the UIC or LAN computer: Method 1 a. Open Network Neighborhood. b. Each RheoVac instrument is identified by a unique Network ID. The ID is “R” plus the first five digits of the serial number found on the unit.
necessary. Note: The Windows installation disk may be needed as well as administrator security rights. a. Installing Client for Microsoft Networks: If Client for Microsoft Networks is not in the list of “The following network components are installed,” then do the following: i. Click the Install button below the list. ii. The Select Network Component Type dialog box will appear. iii. Select Client from the list then click the Add button. iv. Select Microsoft from the Manufacturers list. v.
3. Check for Installed Network Components: Click the Start button and select Control Panel. Right click on the Network Connections icon and select Open. Or, click the Start button, select Connect To, then select Show all connections. Highlight the Local Area Connection that represents the Ethernet adapter. Right click the icon and select Properties.
Appendix C – Optional Features for RheoVac Model 950 Wireless Interface for RheoVac Model 950 C.1.1 INTRODUCTION The wireless option for the RheoVac Model 950 consists of a high powered 802.11 b/g USB interface antenna connected to the main electronics and a handheld user interface (HUI). With this option installed, users will be able to view real time and graphed measurements from the RheoVac probe on the HUI as they move around the plant within the transmission range.
C.1.2.B Charging the HUI A USB cable supplied with the HUI is used for charging and data transfer. The HUI can be charged from any computer with a USB port. The HUI can also be charged from the RheoVac Model 950 electronics, as shown in Figure C1.3. Figure C1.3: Charging the HUI with the RheoVac Model 950 C.1.2.C Using the Touch Screen on the HUI 1. Application selection: This is done by pressing an icon as though it were a button (Figure C1.2 right-most image). 2.
Figure C1.4: Wireless Antenna Connection Figure C1.5: Typical Wireless Antenna Signal Range The following instructions assume the main electronics are on and connected to a RheoVac probe, the HUI is on and unlocked, and that the wireless antenna is connected. C.1.3.A HUI Wi-Fi Settings 1. From the HUI home screen, choose settings . . 2. Select Wi-Fi 3. Under ‘Choose a Network’, make sure the Rxxxxx_AP network is selected. (Note: xxxxx is the serial number of the main electronics.) 4.
C.1.4.A C.1.4.B C.1.4.C C.1.4.D C.1.4.E Real time display tab : Six parameters are displayed on the screen. Click/touch any of the displayed values to switch to the plotting view. Graphing tab : It is used for real time trending of RheoVac outputs. To change X-axis scale and Y-axis limits, see Figure C1.7, 1st and 2nd columns Probe under view : To change probe under view, see Figure C1.7, 3rd column.
Serial Modbus for RheoVac Model 950 C.2.1 INTRODUCTION Modbus protocol is a messaging structure developed by Modicon in 1979. It is used to establish masterslave/client-server communication between intelligent devices. Modbus is used in multiple master-slave applications to monitor and program devices, to communicate between intelligent devices and sensors and instruments, to monitor field devices using PCs and HMIs. The RheoVac Model 950 supports the Modbus protocol over RS-232, acting as a slave device.
Address 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 C.2.3 Table C2.1: Modbus Server Global Settings Description Allowed Values Default Format Restart Modbus Server Write ‘1’ to restart 0 16-bit unsigned RheoVac Serial Port Set to ‘0’ internally by 0 16-bit unsigned RheoVac System Baud Rate 2400,4800,9600,14400, 9600 16-bit unsigned 19200 bps Data Bits 7 or 8 8 16-bit unsigned Stop Bits 0 = 1 stop bit 2 16-bit unsigned 1 = 1.
To allow for future expansion and up to three different probes, each probe is allocated a space of 100 registers, with the registers for the first probe beginning at address 0101. Registers for the second probe begin at address 0201, and the third probe begins at register address 0301. Table C2.3 details the RheoVac Model 950 data register setup when in Multiplier Integer mode. Address 0101 – 0105 0106 0111 0112 0113 0114 0115 0116 0117 0118 0119 0120 0121 0122 0123 0124 0125 0126 0127 0128 0129 0130 C.2.
Table C2.4: Modbus Data Registers (Single Float Mode) Description Format Probe Serial Number 10 ASCII characters Error Code: see Section C.2.
using the 3-button simultaneous push “Close RV950: System Will Reboot” function or a power cycle for the changes to take effect. CAUTION: Modifying any of the other settings in this file could result in undesired behavior. Figure C2.1: Sample serial.ini file C.2.8 MODBUS TROUBLESHOOTING Problem No response from RheoVac Model 950 Not enough data Causes 1. Solution 1. System not set for Modbus communication See Figure C2.1, verify [SerialBurst], Status=0 is set in Serial.ini 2.
OPC for RheoVac Model 950 C.3.1 INTRODUCTION The RheoVac Model 950 also incorporates an OPC Server to provide access to Process Variables (PVs) through the OPC standard. OPC provides the functionality for accessing (reading and writing) data from various networked devices via a standard set of interfaces.
As an example, consider a RheoVac Model 950 with the Network ID “r09613” and two probes connected with names of “99261-1” and “99261-2”.
Figure C4.2 4. 5. Copy the RHEOVAC.zip file to a computer for analysis. For data plotting, tools are available at www.MyCondenser.com. For further support email data and questions to techsupport@intekflow.com; a service contract may be required. Replace USB stick to its storage position inside lid of the electronics enclosure. -C12I:\OFFICE\WPMANUAL\RV950A Appendix C revB.doc Feb.
