Teledyne Deltaflow DF180 User manual

DF180 GAS FLOW AND TEMPERATURE MONITOR
Operation and Maintenance Manual
Teledyne Monitor Labs
35 Inverness Drive East
Englewood, CO 80112
TML DOCUMENT 99702200
Revision A
www.teledyne-ml.com

January, 2018 Page 2
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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

January, 2018 Page 8
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).