Teledyne Deltaflow DF180 User manual

January, 2018 Page 2
This document contains information proprietary to Teledyne Monitor Labs and is furnished with the
express condition that the information contained herein will not be used for second source procurement
or directly or indirectly in any way detrimental to the interests of Teledyne Monitor Labs.
Please contact your local Teledyne Monitor Labs regional sales or service representative, or call our
home office, if you require assistance.
Sales 800-422-1499
Technical Support 800-846-6062
Parts 800-934-2319
Transfer of EAR99 technical
information
Use and Disclosure of Data
Information contained herein is classified as EAR99 under the U.S. Export
Administration Regulations. Export, reexport or diversion contrary to U.S. law
is prohibited.

January, 2018 Page 3
Table of Contents
Table of Contents.......................................................................................................................................... 3
Specifications ................................................................................................................................................ 6
1 System Description ............................................................................................................................... 7
1.1 Instrument Panel........................................................................................................................... 7
1.1.1 Controller .............................................................................................................................. 7
1.1.2 Differential Pressure (DP) Transmitter.................................................................................. 9
1.1.3 Push Buttons ......................................................................................................................... 9
1.1.4 Valve Manifold Assembly...................................................................................................... 9
1.1.5 Absolute Pressure Transmitter ...........................................................................................10
1.1.6 Temperature Transmitter ...................................................................................................10
1.1.7 Precision Differential Pressure Switch ................................................................................ 11
1.1.8 Sample Filters......................................................................................................................12
1.1.9 Power Supplies.................................................................................................................... 12
1.1.10 Precision Regulator ............................................................................................................. 12
1.2 Probe........................................................................................................................................... 13
1.3 Sample Line ................................................................................................................................. 13
2 Theory of Operation............................................................................................................................14
3 Installation .......................................................................................................................................... 16
3.1 Pre-Installation Planning and Preparation..................................................................................16
3.2 Site Selection...............................................................................................................................16
3.2.1 Representative Sampling Location......................................................................................16
3.2.2 Access to Sampling Location...............................................................................................16
3.2.3 Environmental Conditions at Instrument Panel Location................................................... 17
4 Web Interface .....................................................................................................................................17
4.1 Data.............................................................................................................................................19
4.1.1 Data: Values ........................................................................................................................ 19
4.1.2 Data: Alarms........................................................................................................................ 20
4.1.3 Data: Calibrations................................................................................................................ 20
4.1.4 Data: Modbus Map ............................................................................................................. 20

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4.1.5 Data: Tools .......................................................................................................................... 21
4.2 Control ........................................................................................................................................22
4.3 Configuration .............................................................................................................................. 23
4.3.1 Configuration: General........................................................................................................ 23
4.3.2 Configuration: Inputs .......................................................................................................... 24
4.3.2.1 Configuration: Inputs: Analog .........................................................................................24
4.3.2.2 Configuration: Inputs: Modbus....................................................................................... 25
4.3.2.3 Configuration: Inputs: Digital..........................................................................................25
4.3.2.4 Configuration: Inputs: Temperature...............................................................................25
4.3.3 Configuration: Outputs ....................................................................................................... 25
4.3.3.1 Configuration: Outputs: Computed ................................................................................ 25
4.3.3.1.1 Configuration: Outputs: Computed: Raw Velocity ...................................................25
4.3.3.1.2 Configuration: Outputs: Computed: Velocity ...........................................................25
4.3.3.1.3 Configuration: Outputs: Computed: Actual Volumetric Flow................................... 26
4.3.3.1.4 Configuration: Outputs: Computed: Standard Volumetric Flow .............................. 26
4.3.3.2 Configuration: Outputs: Analog ......................................................................................27
4.3.4 Configuration: Calibrations ................................................................................................. 27
4.3.4.1 Configuration: Calibrations: Timing ................................................................................27
4.3.4.2 Configuration: Calibrations: Evaluations......................................................................... 28
4.4 Administrator.............................................................................................................................. 29
5 Operation ............................................................................................................................................29
5.1 Calibration and Adjustment........................................................................................................29
5.2 Interference Check...................................................................................................................... 30
5.3 Creating a Correction Curve........................................................................................................ 30
5.4 Long-Term Shutdown.................................................................................................................. 31
6 Maintenance ....................................................................................................................................... 32
6.1 Scheduled Preventative Maintenance Chart ..............................................................................32
6.2 Pitot Tube Cleaning Procedure ...................................................................................................32
6.3 Sample Line Cleaning Procedure ................................................................................................32
6.4 Filter Media Replacement Procedure.........................................................................................33

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6.5 System Leak Test Procedure .......................................................................................................33
7 Troubleshooting.................................................................................................................................. 34
Appendix A: Spare Parts.............................................................................................................................. 35
Appendix B: Drawings ................................................................................................................................. 36

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Specifications
Flow Measurement:
Range:
0-300ft/sec (0-91m/sec)
Long-Term Repeatability:
+/-0.3ft/sec (+/-0.1 m/sec)
Relative Accuracy:
(vs. EPA Test Method 2)
Site dependent, see Commercial Performance
Warranty. Typically <5% above 10 ft/sec
Response Time:
8 sec
Drift:
+/- 1.5% of span over operating temperature range of instrument panel
Media Conditions:
Temperature:
-40°to 1000°F (-40°to +343°C)
Pressure:
-2 to 2 psig (-13.8 to 13.8 kPa)
Moisture:
Dry to saturated, including condensed water
Particulate:
</=3000 mg/m3
Duct Size:
Diameter:
From 3 - 45 Ft. (0.9 – 14m) Dia.
Temperature
Measurement:
Accuracy:
+/- 6 °F (3.3°C)
Long-Term Repeatability:
+/- 0.5% of span per year
Power:
100-240 VAC, 50/60Hz, Single Phase, 70 VA Maximum
Environment:
Ambient Temp. Limits:
Probe Assembly: -40°F to +160°F (-40°to 71°C)
Instrument Enclosure: +20°F to 104°F (-7°C to +40°C)
Relative Humidity:
Probe Assembly: 5% to 100% humidity, condensing
Instrument Enclosure: 0 to 95% non-condensing
Instrument Enclosure
Ratings:
NEMA 4/IP66 is standard, Ex Py purge protection can be
added as an option for Class I Division 2, and Zone 2
applications.
Mounting:
Process Connection:
4” 150# ANSI flange
Sizes & Weights:
Instrument Enclosure
Size: 30H x 24W x 12D (inches)
76H x 61W x 30.5D (cm)
Weight: 135 lbs. (61 kg)
Probe Assembly
Size: Application dependent
Weight: 26 lbs. (11.8 kg), typical, application dependent
I/O:
Communication Protocol:
Modbus TCP/IP
Analog Outputs:
Two Outputs, 4-20mA current, one for differential pressure
and one for temperature
Digital Inputs:
4 Inputs, dry contact Inputs are configurable to initiate
blow back, calibrations, Unit On, etc.
Relay Outputs:
Four configurable Outputs, Form C, (Single Pole Double
Throw)
Contact Voltage: 120/240VAC
Maximum Contact Current: 10 Amps AC

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1System Description
The DeltaFlow 180 is an EPA compliant Pitot tube based flow monitoring system. The three main
components of the system are the instrument panel, probe, and sample line. This section describes in
detail each of these components.
1.1 Instrument Panel
The Instrument panel is typically mounted in a climate controlled area, and can be provided with or
without an enclosure. All the electronics, indicators, and valves for the system are located here.
Fig. 1-1 Deltaflow Instrument Panel
1.1.1 Controller
Daily quality assurance checks, signal processing, and monitor configuration are all handled by the
controller. The controller module I/O consists of 8 relays and 8 digital inputs. The relays are used to
control solenoid valves located on the instrument panel during calibration checks, interference checks,
and blowback sequences. The digital inputs are used to initiate different modes such calibration,
interference check, blowback, and maintenance. These modes can be initiated by the buttons located
on the instrument panel or by external dry contact signals from a plant distributed control system (DCS)
that are wired to the Deltaflow instrument panel terminal blocks.
Fig. 1-2 Deltaflow Controller, Analog Module, and Form C Relay Module

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The controller has two external modules, the analog module and the form C relay module. The analog
module is used to take in 4-20mA signals from the various sensors on the instrument panel, and
transmit analog signals out of the instrument panel, such as velocity and temperature. The form C relay
module is used to relay status signals, such as fault or sample valid. Terminated on the form C relay
module is a temperature sensor that measures the ambient temperature of the instrument panel. Table
1-1 shows a complete I/O list for all the modules.
Table 1-1. Deltaflow Controller I/O list
Main Controller Module
Channel
Description
Relay 1
Solenoid Valve 1 – Impact Line Purge
Relay 2
Solenoid Valve 2 – Static Line Purge
Relay 3
Solenoid Valve 3 – Isolate DP Transmitter Low Side
Relay 4
Solenoid Valve 4 – Isolate DP Transmitter High Side
Relay 5
Solenoid Valve 5 – Span Calibration
Relay 6
Solenoid Valve 6 – Span Calibration (Low Pressure Instrument Air Delivery)
Relay 7
Solenoid Valve 7 – Span Calibration (Isolate DP Pressure Switch)
Relay 8
Not Used
Digital input 1
External Calibration Start
Digital input 2
External Interference Check Start
Digital input 3
External Blowback Start
Digital input 4
Maintenance
Digital input 5
Calibration Start
Digital input 6
Interference Check Start
Digital input 7
Blowback Start
Digital input 8
Not Used
Analog Module
Input 1
Differential Pressure
Input 2
Stack Temperature
Input 3
Stack Pressure
Input4
User defined
Output 1
Configurable – Differential Pressure, Stack Temperature, Stack Pressure, Velocity, Raw
Velocity, Actual Volumetric Flow, Standard Volumetric Flow, any user defined parameter
Output 2
Configurable – Differential Pressure, Stack Temperature, Stack Pressure, Velocity, Raw
Velocity, Actual Volumetric Flow, Standard Volumetric Flow, any user define parameter
Form C Relay
Relay 1
In Calibration Mode
Relay 2
In Sample Mode
Relay 3
CEMS Fault (reverse logic, 1 = OK: 0 = Fault)
Relay 4
Value Based Alarm (e.g. based on user defined alarm limits)

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1.1.2 Differential Pressure (DP) Transmitter
This device converts the pneumatic differential pressure signal measured by the probe to a 4-20mA
signal. It also provides a gauge style display to aid in troubleshooting the electrical signal. The gauge
needle can be zeroed and the 4-20mA signal can be calibrated at the display. Various ranges are
available; a TML Engineer selects the range based on process parameters of the application. See
Appendix A: Spare Parts for a complete list of all available ranges.
Fig. 1-3 Differential Pressure Transmitter with Display
1.1.3 Push Buttons
These buttons allow the user to start a blowback sequence, calibration check, interference check, or put
the Deltaflow into maintenance mode. Once pressed, the blowback sequence will start immediately.
Calibration and interference checks will start at the top of the next minute according to the controller
clock. Once pressed, the maintenance button will illuminate red and will put the Deltaflow into
maintenance mode until the button is pressed again. Maintenance mode causes the Deltaflow
controller to flag its’ data as invalid.
1.1.4 Valve Manifold Assembly
This assembly consists of 7 solenoid valves installed on a custom designed manifold. Static pressure,
impact pressure, and instrument air are directed through the manifold by the valves.
During normal sampling mode none of the valves are actuated; impact pressure and static pressure are
directed to the high and low sides of the differential pressure transducer, respectively. During a
blowback sequence or interference check, SV1 and SV2 send high pressure instrument air up the sample
line, while SV3 and SV4 isolate the differential pressure transmitter from the high pressure instrument
air.
The calibration check consists of a zero and span check. First, the DP transmitter high and low sides are
exposed to ambient pressure using SV3 and SV4. This provides a zero check. For the span check SV5,
SV6, and SV7 are activated. This allows low pressure instrument air to start pressurizing the DP
transmitter as well as the DP span set point switch. Once the DP span set point switch senses the correct
upscale pressure has been reached, it trips and shuts off SV6. This provides a stable upscale calibration
check. See the Plumbing & Instrumentation Diagram and the Timing Diagram in Appendix B for further
detail.

January, 2018 Page 10
Fig. 1-4 Solenoid Valve Manifold
1.1.5 Absolute Pressure Transmitter
Absolute stack pressure is needed to calculated velocity and standard volumetric flow. The DP
transmitter cannot continually measure stack pressure on its own. For this reason, the Deltaflow comes
standard with a 0-30 psia (61.1 inHg, 1551 mmHg) pressure transmitter. The transmitter is plumbed to
the static pressure line, and wired to input 3 of the analog module.
Fig. 1-5 Absolute Pressure Transmitter
1.1.6 Temperature Transmitter
Stack temperature is needed to calculated stack velocity and standard volumetric flow. The probe is
equipped with a type K thermocouple to accurately measure stack temperature. The thermocouple
signal is carried down to the instrument panel via thermocouple messenger cable in the sample line
where it is terminated on a DIN rail mounted transmitter. This device converts the thermocouple signal
to a 4-20mA signal that is wired to input 2 of the analog module.
The 4-20mA output range, and input type (RTD, TC, etc.) of the transmitter is adjustable using ProSense
XT-SOFT software and a USB adapter cable (TML P/N 55000048-2).

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Fig. 1-6 Stack Temperature Transmitter
1.1.7 Precision Differential Pressure Switch
In order to provide a repeatable upscale differential pressure for daily calibration checks, a precision DP
switch is tied into the high side of the DP transmitter plumbing. During the beginning of a span check
this DP switch will shut off SV6 when it senses the correct pressure has been achieved on the high side
of the DP transmitter. This provides a repeatable and stable differential pressure to check the pneumatic
and electrical drift of the DP transmitter. The DP switch set point is adjustable via a screw at the left end
of the switch spring housing. These switches come in various ranges, see Appendix B: Spare Parts for a
complete list of all the available ranges.
Fig. 1-7 Precision Differential Pressure Switch

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1.1.8 Sample Filters
The differential pressure transmitter used in the Deltaflow is meant to only come in contact with clean
non- corrosive air. The Deltaflow purges the sample lines at a minimum of every 6 hours to ensure they
stay filled with clean instrument air. As added protection, each side of the DP transmitter has sample
filters that contain 13X molecular sieve, soda lime, and indicating Drierite®.
Fig. 1-7 Sample Filter
1.1.9 Power Supplies
Two power supplies are used. A 120W 24VDC power supply powers all the onboard Deltaflow
electronics, valves, and switches. A 10W 12 VDC power supply is used as loop power for the analog
outputs. Both power supplies’ inputs are rated 100-240VAC, 50/60Hz and are automatically adapting.
Both power supplies have “DC Voltage OK” indicating LEDs to aid in troubleshooting. The 24 VDC power
supply has a DC voltage output adjustment potentiometer.
1.1.10 Precision Regulator
In order to minimize the drift of the upscale differential pressure used during the daily cal checks, a
precision regulator is used that drops the instrument air supplied by the user from 50 psi down to 1.5
psi. This low pressure instrument air is bled into the high side plumbing of the DP transmitter by SV6 at
the beginning the of the daily upscale cal check.
Fig 1-8 Precision Regulator

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1.2 Probe
The Deltaflow Pitot tube probe assembly consists of an S type Pitot tube, a K type thermocouple, and a
4” mounting flange. All wetted components are constructed of Stainless steel. The Pitot tube comes in
various lengths, and the insertion depth is adjustable for easy installation. Once the desired insertion
depth is determined the Pitot tube is secured in place using a large compression fitting. The impact and
static sample lines are easily terminated on the probe using 3/8” compression fittings. The K type
thermocouple comes in various lengths and has a fixed insertion depth. The thermocouple wires from
the sample line are easily terminate in the head of the thermocouple assembly.
Figure 1-8 Deltaflow Probe
1.3 Sample Line
The Deltaflow sample line consists of a two 3/8” PFA Teflon sample lines, a K type thermocouple
messenger cable, a small amount of insulation, and a PVC jacket. The maximum recommended length
for the standard sample line is 430 feet. Line longer that this will require custom design. Custom sample
lines can be ordered with options such as stainless steel tubes, heaters, larger wires, or extra wires.
Fig. 1-9 Sample Line Cut Away

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2Theory of Operation
The DeltaFlow 180 is a Pitot tube based gas flow and temperature monitoring system. Like all Pitot tube
flow measurements, the Deltaflow uses equations derived from the Bernoulli Principle. The Bernoulli
Principle states that for certain flow conditions the total energy of a streamline is constant between two
points even if pressure, velocity or elevation changes. A change in one of these parameters will results
in an equal and opposite change in the others. Utilizing this concept, a Pitot tube converts all the kinetic
energy (velocity energy) of a flow streamline to potential energy (pressure energy). To achieve this, a
gas streamline travels into the impact opening of the Pitot tube for a short distance for before it
stagnates in the tube, creating an elevated pressure at point B, see Figure 2-1. This is referred to as the
impact pressure. Static pressure is the stack or duct pressure not resulting from any velocity energy
conversion. The pressure at points A, C, and D are all equal, and can all be thought of as the static
pressure (also known as the absolute pressure, or just pressure). A differential pressure transducer is
connected to the Pitot tube to measure the difference between the impact pressure and static pressure
(this is referred to as the velocity head, delta P, DP, or ΔP).
Figure 2-1 Pitot Tube In Gas Stream
The governing equations used by the DeltaFlow for velocity is Equation 2.1 for calculations done in
Metric Units, and Equation 2.2 for calculations done in Imperial units. These equations are derived from
the Bernoulli Principle, and the Ideal Gas Law.
Eq 2.1 Metric: =11.17()() ()
()()
Eq 2.2 English: =85.49()() ()
()()

January, 2018 Page 15
Where:
Vs = stack gas velocity, m/sec (ft/sec).
Cp = Type S pitot tube coefficient, dimensionless, Default 0.84.
ΔP = Velocity head measured by the Pitot tube, Pa (in. H2O.)
Ts = Stack temperature, °C (°F).
Ps = Absolute stack pressure, mm Hg (in. Hg)
Ms = Molecular weight of stack gas, wet basis, g/g-mole (lb/lb-mole).
Molecular weight is calculated based on Equation 2.3
Eq 2.3 =44 %
+32 %
+18 %
+28 (%%%)
Where:
%W = Percent by volume of water vapor in the gas stream, %
%O2= Percent by volume of oxygen in the gas stream, %
%CO2= Percent by volume of carbon dioxide in the gas stream, %
After velocity has been calculated, volumetric flow rate can be calculated based on Equation 2.4.
Eq 2.4 = 3600
Where:
A = Cross-sectional area of stack, m2(ft2).
QAct= Volumetric stack gas flow rate, m3/hr (ft3/hr).
To adjust the stack volumetric flow to a standard temperature and pressure, use Equation 2.5.
Eq 2.5 =
Qstd = Volumetric stack gas flow rate corrected to standard conditions, scm/hr (scf/hr).
Pstd = Standard absolute pressure, default 760 mm Hg (29.92 in. Hg).
Tstd = Standard absolute temperature, default 20 °C (68 °F).

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3Installation
Below are general descriptions of several areas of consideration for installation of the Deltaflow 180
system. Please see the installation drawings provided in Appendix B for further detail.
3.1 Pre-Installation Planning and Preparation
The engineering that precedes installation of the Deltaflow is vital to successful operation of the
instrument and should be performed in consultation with responsible Teledyne Monitor Labs
representatives. Key factors that must be considered include:
Location of the probe, and instrument panel. Items such as vibration, heat range, stream turbulence,
installation and maintenance access, and protection from environmental and mechanical hazards must
be considered.
Sample line run (distance, routing, proximity to electrical equipment and heat sources).
Accessibility to a continuous supply of clean oil free instrument air at approximately 50 psig (345 kPa).
Each blowback sequence consumes about 3 standard cubic feet (0.085 standard cubic meters) of air.
The Deltaflow 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. This is
provided at the time of purchase or it can be downloaded off the Teledyne Monitor Labs website.
3.2 Site Selection
Without question, the single most important factor affecting overall performance of any continuous
monitoring device is that of site selection. If this decision is not made prudently, then monitor accuracy
and reliability will suffer.
3.2.1 Representative Sampling Location
Complex flow patterns in the vicinity of bends or obstructions may potentially cause the monitor's
sample point to be unrepresentative of the total flow velocity and volume. Teledyne Monitor Labs
recommends a minimum of 6 duct diameters of straight undisturbed duct length upstream of the
monitor and 2 downstream. However, due to the complexity of the fluid dynamics of these types of gas
streams and their dependence on individual site geometry, the burden of responsibility for testing to
determine the flow characteristics at the site location is solely that of the user.
3.2.2 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 exposed outside areas where maintenance personnel are subject to
extremes of wind, precipitation, or temperature, then monitor maintenance will suffer adversely in the
long term. Without proper maintenance, reliability decreases and the access problems extend monitor
outage during repair.

January, 2018 Page 17
3.2.3 Environmental Conditions at Instrument Panel Location
The other important factor involved in site selection is to consider the potential conditions of the area
where the Instrument Panel will be located. Ambient conditions at this location must not exceed the
temperature range specified in the Teledyne Monitor Labs specifications. This will void the Teledyne
Monitor Labs warranty. The presence of potentially corrosive or toxic gases in the ambient air in the
vicinity of the instrument panel may deteriorate the condition of electrical connections.
4Web Interface
The DeltaFlow web interface is required to configure the monitor. Depending on what the user specifies
at the time of order, the Deltaflow controller may ship with a static IP address or a dynamic IP address
that will require a DHCP server to assign it one. If it ships with a static IP address, specified by the user,
it will have a label on the controller with the IP address, subnet mask, and default gateway.
To connect to the web interface, enter the IP address/delta/ (example: 172.16.254.1/delta/) into the
address bar of any web browser. You will be prompted with the below prompt window. Click the
Connect with DF180 button. The web interface is configured at the Teledyne Monitor Labs Factory so
you do not need to click Create New Configuration the first time you access. You should only need to
create a new configuration if you find that the engineering units (British Imperial or Metric) of the
configuration are incorrect. When creating a new configuration, you will need to configure all the
screens in the Configure menu, see section 4.3.
If the Deltaflow shipped configured for DHCP the Teledyne Support Tool software will need to be used to
detect the DeltaFlow and what IP address it has been assigned on the network. This can be downloaded
from http://www.teledyne-ml.com/downloads.asp you will need to call Teledyne Monitor Labs
Technical Support (1-800-846-6062) for a username and password. When started, the program detects
all devices present on the network (see lower left hand corner in the image below).
Note: Administrator password may be required to install Teledyne Support Tool on a computer.
Note: To detect all DF180, C3i/o, and RPD2 devices Teledyne Support Tool uses UDP port 4444. Use
Administrative Tools->Windows Firewall->Inbound Rules to open this port.
Note: If you are not able to detect, you may need to be on the same subnet as the DF180, C3i/o, or
RPD2 you are attempting to detect. If possible the computer should be plugged into the same network
switch as the DF180, C3i/o, or RPD2.

January, 2018 Page 18
Click the Configure Device link to start the configuration process.
A dialog box with all detected devices will be displayed. Using the check box, select the device you want
to configure and click OK.

January, 2018 Page 19
Configure the device’s IP Address, Subnet Mask and select Time Zone.
Once configured, enter the IP address/delta/ (example: 172.16.254.1/delta/) into the address bar of any
web browser the web interface.
4.1 Data
The Data screen will be the first screen displayed once connected. This section will outline all the data
screens and their functionality.
4.1.1 Data: Values
The Values screen displays live data that is updated every five seconds. Each widget can be renamed by
clicking on it. A RED border around a widget means that data is invalid due to the value being out of
range or a failed QA check.

January, 2018 Page 20
If a parameter is invalid it will also cause any dependent calculated parameters to be invalid. For
example invalid Stack Temperature will cause Velocity and Volumetric Flow to be invalid. A YELLOW
border means the parameter is in the process of a QA check such as a calibration or interference check.
4.1.2 Data: Alarms
This screen keeps a log of the 99 most recent alarms that have occurred. Examples of alarms that will
show up here are QA check failures, communication failures, DP/temp/pressure out of range faults, and
value alarms. Value alarms are user defined Lo and Hi alarms and can be configured for almost any
parameter in the appropriate Configuration screen.
4.1.3 Data: Calibrations
This screen will show you the results of the most recent calibration check and interference check. The
performance specification is user defined and can be configured in the Configuration screen.
4.1.4 Data: Modbus Map
This screen outlines all the available Modbus addresses.
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