Intek RheoVac 940 User Manual

TABLE OF CONTENTS

SECTION 1 — GENERAL INFORMATION ....................................... - 1 -

1.1 INTRODUCTION ................................................. - 1 -

1.2 PRINCIPLE OF OPERATION ....................................... - 2 -

1.3 TECHNICAL SPECIFICATIONS ..................................... - 2 -

1.4 PRECAUTIONS .................................................. - 2 -

SECTION 2 — INSTALLATION ................................................ - 4 -

2.1 INTRODUCTION ................................................. - 4 -

2.2 RheoVac MONITOR INSTALLATION/SITE SELECTION ................ - 4 -

2.2.1 Transducer Site Selection ..................................... - 4 -

2.2.2 Electronics Unit Site Selection ................................. - 4 -

2.3 MOUNTING HARDWARE INSTALLATION .......................... - 6 -

2.4 TRANSDUCER INSTALLATION .................................... - 6 -

2.5 ELECTRICAL CONNECTIONS ..................................... - 8 -

2.6 RheoVac MONITOR GROUNDING ................................. - 13 -

SECTION 3 — OPERATION .................................................. - 15 -

3.1 GENERAL INFORMATION ....................................... - 15 -

3.2 SYSTEM START-UP ............................................. - 15 -

3.3 OUTPUT SIGNALS .............................................. - 15 -

3.4 IBM-PC SOFTWARE ............................................. - 16 -

3.4.1 SOFTWARE INSTALLATION ............................... - 17 -

3.4.2 SOFTWARE OPERATION .................................. - 17 -

3.4.3 DATA PROCESSING ....................................... - 18 -

3.5 CUSTOM SOFTWARE ........................................... - 19 -

SECTION 4 — MAINTENANCE ............................................... - 21 -

4.1 GENERAL MAINTENANCE ....................................... - 21 -

4.2 CALIBRATION .................................................. - 21 -

4.3 SPARE PARTS .................................................. - 21 -

4.4 TROUBLE SHOOTING ........................................... - 21 -

SECTION 5 — CUSTOMER SERVICE ......................................... - 25 -

5.1 QUESTION ON EXISTING HARDWARE ............................ - 25 -

5.2 TROUBLE SHOOTING ........................................... - 25 -

5.3 FACTORY AND FIELD SERVICE .................................. - 25 -

5.4 QUESTIONS ON NEW EQUIPMENT ................................ - 25 -

SECTION 6 — CUSTOM INFORMATION ...................................... - 26 -

6.1 UNIT IDENTIFICATION .......................................... - 26 -

6.2 CONFIGURATION ............................................... - 26 -

6.3 SPECIAL INSTRUCTIONS ........................................ - 26 -

©Intek, Inc. 1999

Manual no. RVAC Rev. D

I:\OFFICE\WPMANUAL\RHEOVAC\RHEOVAC.RVD

WARRANTY

Intek, Inc. warrants each RheoVac product to be free from defects in
material and workmanship under normal use and service, Intek's
obligation under this warranty being limited to making good any part or
parts thereof which shall, within one (1) year after delivery of such
product to the original purchaser, be returned to Intek with transportation
charges prepaid and which Intek's examination shall disclose to its
satisfaction to have been thus defective; this warranty being expressly in
lieu of all other warranties, express or implied and all other obligation or
liabilities on Intek's part. The purchaser will assume all responsibility
and expense for removal, decontamination and reinstallation of
equipment.

Rheotherm instruments are manufactured under United States patent numbers
4,255,968, 4,942,763, 4,949,578, 5,485,754 and 5,752,411. Intek, Rheotherm,
Rheovec, Rheomax, RheoVac and RheoSmart are registered trademarks of Intek,
Inc.

Intek, Inc.

751 Intek Way

Westerville, Ohio 43082-9057

Phone [phone] – Fax [phone]

web site – www.intekflow.com

e-mail – [e-mail]

SECTION 1 — GENERAL INFORMATION

1.1 INTRODUCTION

For the first time, all necessary properties of the fluid in the condenser exhauster line are directly
measured to provide an accurate determination of air in-leakage. These properties are measured to
provide the power industry with the most advantageous and complete product for condenser system
diagnostics:

— the RheoVac

®

Air In-Leak Monitor System*

*USPNs 5,485,754; 5,752,411

The RheoVac air in-leak monitor system consists of multiple sensors configured in a single probe head
and an electronic signal conditioner and digital signal processor (DSP) unit. The sensing probe is
installed in the vacuum line between the condenser and the exhauster. The RheoVac monitor is superior
to all other methods in that it makes no assumptions about the dynamic condenser and vacuum line

®

environment. The sensor head employs the patented Rheotherm

technology to provide an accurate flow
measurement. Additionally, temperature, pressure and water vapor relative saturation measurements are
made using a high accuracy platinum resistance temperature detector (RTD), a strain gauge pressure
sensor and a specially configured and calibrated water vapor saturation sensor.

Figure 1 RheoVac Air In-Leak Monitor

- 1 -

1.2 PRINCIPLE OF OPERATION

The principal features of the RheoVac monitor are shown in Figure 1. At the heart of the RheoVac
monitor is the Rheotherm flow transducer which uses the same patented thermal sensing technique
employed in all precision flow instruments manufactured by Intek. Two temperature sensor probes are
used — one sensor is in thermal equilibrium with the flow medium and provides a temperature and flow
signal reference, while the second sensor is located near a constant power probe heater so that its
temperature is always above that of the fluid. The temperature of the heated sensor will vary with the
stream velocity of the fluid. Hence, the measured temperature differential between the reference sensor
and heated sensor is a function of flow rate, which is approximately proportional to the logarithm of
mass flow rate (USPN 4,255,968).

The Rheotherm flow sensor is calibrated to measure the total mass flow of the water vapor/air mixture.
From the other three measurements, the RheoVac electronics converts the total mass flow signal from
the transducer into two components, air mass flow rate and water vapor mass flow rate. This unique
measurement method is disclosed in two separate patents (USPN 5,485,754 & 5,752,411).

The RheoVac monitor is fully calibrated in the factory under dynamic fluid conditions identical to those
within the power plant vacuum line. No field adjustments are required.

1.3 TECHNICAL SPECIFICATIONS

Primary Calibration Accuracy:

±1% of reading

Repeatability:

±0.5% of reading

Operating Temperature:

Electronics: !20 to 120°F
Transducer: 40 to 160°F

Never subject transducer to
temperatures above 210°F

Operating Pressure:

0 to 10 inches Hg absolute

Process Connection:

Hot tap assembly
(1½” thread-o-let must be welded to

Wetted Surface:

300 Series SS and engineering plastic

Local Display:

air in-leakage (SCFM)

Input Power:

115 Vac, 50/60 Hz (±15V)
230 Vac, 50/60 Hz (±15V)

Signal Output:

4/20 mA (for 10 parameters)
RS 232/422

Storage Temperature:

!20 to 120°F

Storage Pressure:

15 psig (maximum)

pipe for hot tap installation)

1.4 PRECAUTIONS

• Read the entire manual before installing and operating the RheoVac monitor.

• Carefully select the best location for installation of the transducer probe. Adequate straight
run and freedom from standing water in the line are vital to achieving optimal performance
from the RheoVac monitor (See Figure 2).

• Use reasonable care in handling the transducer — the sensing components are delicate. Take
care not to bend the probes, damage the tips, or otherwise obstruct the sensing ports.

- 2 -

• Use proper input power — check the power select switch position on the electronics. Select
either 115 Vac or 230 Vac before applying power.

• Check the transducer maximum temperature and pressure ratings — never operate a
transducer at or subject it to temperatures or pressures beyond its specified limits.

. . WARNING - Never allow live high temperature steam to flow either direction in

the exhauster line where the probe is located.

• Keep moisture out of the enclosures — once all service connections are made, make sure the
enclosure lids are tightly closed and all gaskets are in place. Seal conduit lines at the
instrument.

SECTION 2 — INSTALLATION

Figure 2 RheoVac Probe Insertion Recommendation

- 3 -

2.1 INTRODUCTION

These instructions cover installation of the RheoVac monitor in its standard configuration. Additional
information pertaining to your unit is covered in SECTION 6 — CUSTOM INFORM A TION.
Carefully read these instructions prior to installing the equipment.

2.2 RheoVac MONITOR INSTALLATION/SITE SELECTION

2.2.1 Transducer Site Selection

# Select the installation site. The location should provide the transducer sensing area with

well-established smooth flow, uniform system temperature and pressure, and consistent non­liquid phase flow medium. Pipe sections ahead of probe, in which water can accumulate,
must be avoided. Refer to Figure 2 and select the most preferred location that fits your
vacuum line configuration. Do not install the probe beyond any “trap” sections as shown in
Figure 2, Configurations B and D. Special installation instructions unique to your unit,
where applicable, will be noted in SECTION 6.3 SPECIAL INSTRUCTIONS. Refer to
this section now to review any special instructions.

# Check installation clearance. The transducer probe is almost 3 feet long and the hot tap

assembly is about 13” long, so allow 4 feet of clearance for probe installation. Be sure there
are no obstructions around the vacuum line that will interfere with transducer insertion.
Figure 3 shows the proper insertion angle. THIS ORIENTATION IS IMPORTANT FOR
PROPER OPERATION.

# OBSERVE the selected site. It should be convenient for removal and replacing probe at any

time for service without building scaffolding or waiting for plant shutdown.

# Check operating conditions. The temperature and pressure limits of the unit should be

checked to ensure compatibility with your application.

2.2.2 Electronics Unit Site Selection

# Select the installation site. The electronics unit should be located in a dry area. The

electronics are not protected against condensed liquid water inside the enclosure.

# Check for input voltage access. The electronics unit should be located in an area with access

to a 115 Vac or 230 Vac single phase, 50-60 Hz input power source.

# Check cable distances. The distances from the transducer to the electronics unit and from

the electronics unit to the control room, or to the receiving equipment serial communications
port or to the analog input device, should not exceed the distances shown in Figure 4.

# Check electronics enclosure mounting area requirements. The RheoVac electronics

enclosure is NEMA 4, measuring 12"×10"×5". A detailed drawing of the mounting interface
is shown in Figure 5 (pg. 7).

# Check for accessibility to setup and use a portable computer (PC) at the site for trouble-

shooting. There should be a place to set up the PC and to open the electronics enclosure.

- 4 -

- 5 -

Transducer Installation Detail

2.3 MOUNTING HA RDWA RE INSTALLATION

Î Check hardware. Verify that the probe slides

through the hot tap assembly.

Ï Check installation configuration. Make sure

the probe is parallel to the floor. (see Figure 3).

Ð Check installation clearance. Verify there is a

probe insertion clearance of 4 feet from the
pipe wall.

Ñ Install the mounting hardware. Drill a 1½”

through hole and weld the thread-o-let onto
the condenser vacuum pipe (See Figure 3).
Thread the hot-tap assembly into the thread­o-let. Use thread tape or pipe dope to seal the
connection.

Ò It should be convenient to apply a force of

about 23 lb to remove or replace the probe
under plant operating conditions.

2.4 TRANSDUCER INSTA LLATION

Figure 4 Maximum Cable Lengths

Î Check proper installation direction. The transducer has a directional arrow on the tag and/or

etched into a metal part. Before installing the unit, note proper flow direction. This is
important to instrument operation.

Ï Check serial number. If more than one RheoVac unit has been purchased, make sure the

complete serial number of the transducer matches the complete serial number of the separate
electronics unit. The transducer and electronics are a matched set. Mismatched components
will result in erroneous readings.

Ð Verify stop clamp location (see Figure 6). A stop clamp is attached to the probe as an

indication of its insertion depth. It is important this stay in place so the sensors are in the
correct location and ensure the probes do not contact the opposite pipe wall. The clamp’s
location was determined based on your pipe diameter, as shown in SECTION 6.2, and is
marked with a groove on the probe’s shaft. Refer to this mark if the stop clamp is
inadvertently moved.

Ñ Inspect the transducer probe tips. Be sure wetted surfaces are clean before installing. If

cleaning is needed, use a damp cloth wetted with alcohol and wipe dry using a soft, lint-free
cloth. Do not immerse probe in liquid alcohol or any other liquids.

Ò Install the transducer. The instrument should be mounted through the pipe wall using the hot-

tap assembly. The transducer installs so that the two probes are side-by-side across the gas
stream. The transducer has a flow directional arrow on the transducer tag and/or marked into
the fitting. When installing under vacuum, do not allow the clamp to "slam" against the seal
nut upon opening the valve. Grasp the transducer shaft firmly before opening the ball valve.
Allow the transducer to slide through the valve by controlling the amount of grip on its shaft.
Special installation instructions, if any, will be noted in SECTION 6.

- 6 -

Figure 5 RheoVac Electronics Enclosure

- 7 -

2.5 ELECTRICAL CONNECTIONS

. . WARNING: Read the entire contents of this section

before powering up the unit. Improper hookup may result in
damage to this instrument or the interfacing equipment.

Î Verify/configure the input power. The input power

requirement is listed on the tag on the electronics enclosure.
Be sure the input power source to be used is properly selected
in the unit. Input power can be either 115 Vac or 230 Vac
single phase, 50-60 Hz. The power configuration may be
changed in the field. Using Figure 7, locate the power select
switch on the lower printed wiring board and slide the power
select switch to either the 115V or the 230V position. Do not

apply power to the instrument until all other connections
and optional selections have been made.

. CAUTION: The Table 1 output signals, both ! and +, are

isolated from the transducer and power ground. However,
the outputs are not isolated from each other; i.e. the 4-20 mA,
RS232/422, and status outputs are all common to each other.
All of the 4-20 mA receiver channels must have
independently isolated inputs.

Figure 6.
Transducer
Stop Clamp

Ï Check the serial communication setup. If a distance of greater than twenty feet is needed for

the serial communications, RS-422 should be used instead of RS-232 (See Figure 4). Inspect
the header pin shunt (Figure 8) at JP14 (upper board) for the proper communication type.
Consult Intek if the jumper is not configured correctly.

Figure 7 Input Power Select Switch

- 8 -

TABLE I. Ten 4-20 mA Wire Terminal Assignment

CONFIGURATION PIN ASSIGNMENT

OUTPUT VARIABLE

DESCRIPTION

ACTUAL VOLUME F LOW [ACFM] A B B A

TOTAL MASS FLOW [lbs/hr] C D D C

WATER VAPOR MASS FLOW [lbs/hr] E F F E

RheoVac PRESSURE ["Hg] G H H G

WATER VAPOR SPECIFIC VOLUME [cu. ft/lb] I J J I

WATER to AIR MASS RATIO K L L K

RELATIVE SATURATION [%] M N N M

PARTIAL PRESSURE, WATER ["Hg] O P P O

AIR IN-LEA K [SCFM] Q R R Q

RheoVac TEMPERATURE [°F] S T T S

NOT USED U U U U

Active 4-20 mA Passive 4-20 mA

! + ! +

Ð RheoVac units have ten 4-20 mA outputs. These outputs can be configured collectively for either

passive or active transmitter. The units are shipped from the factory with the output jumpers in
the active position; i.e. the transmitter provides the current source. Figure 8 shows the locations
of the 4-20 mA select jumper, JP13 of the lower board — active position is shown.

. CAUTION: changing the passive/active jumper changes the field wiring polarity and affects

all ten 4-20 mA channels. See Table I for wire terminal identifications.

Figure 8. Output Connections and Set-up

- 9 -

- 10 -

Monitor Wiring Detail (with 10 channel 4-20 mA output)

Ñ Figure 9 provides the RheoVac wiring

detail for the 10 channel 4-20 mA outputs.
Table I provides the appropriate
connection identification. As stated, the
output signals are not isolated from each
other and therefore the 4-20 mA receiver
channels must be independently isolated.
A typical current output circuit is shown in
Figure 10. The current control circuitry
works by controlling the (!) side return
current through Q1 which returns current
through the isolated, but circuit-common,
ground (L1). When the 4-20mA output is
configured as active, the (+) terminal is
connected to a common 35 to 40Vdc
supply (V
jumpered to the (+) output terminal and
“B” is jumpered to the (!) terminal. For
passive mode, the “A” is not connected,
the “B” is jumpered to the (+) terminal,
and the (!) terminal is connected to
isolated circuit ground (L1).

). The circuit “A” is

unreg

Figure 10 - 4-20mA Output Circuit

The remaining outputs - RS232/422 and status, are all (!) terminated to isolated circuit
ground. A single chassis or earth ground wire should be connected to the minus of any one
and only one of the receiving devices. This prevents high or noisy common-mode “floating”
potentials between the isolated transmitter and grounded transducer circuits. Do not connect
a ground wire to each output. Again, the 4-20mA, RS232/422 and status outputs are all
common to each other and should be connected to isolated input cards.

Ò The status output located on field wiring terminal, JP7, is a digital 0-15Vdc output. This output

will go low in the event of a fault or power loss. The remaining JP7 outputs are not normally used
with the RheoVac monitor and should be left unconnected. If a non-standard option has been
ordered there will be additional notes in the SECTION 6.3 SPECIAL INSTRUCTIONS.

Ó Mount the transmitter enclosure. Install conduit such that all seals are watertight and rigidly

secure. A separate external power switch is recommended to shut the equipment off during
outages. When the vacuum system is on-line, do not turn off power to the RheoVac monitor
unless you are preparing to take the probe out of the pipe.

Ô Choose a path for the transducer to transmitter cable conduit. Route the transducer interface

cable through the conduit (See Figure 9). The cable is labeled at both ends. DO NOT CUT
OR SPLICE THE CABLE, AS THIS WILL DESTROY THE LABELING AND MAY
AFFECT THE INSTRUMENT CALIBRATION. Pull the cable through the conduit starting
at either end; coil up the remaining length outside the transmitter or transducer enclosure, or
in a cable junction box.

- 11 -

Õ Pull wires through the conduit. Wire for power connection must be at least 24 gauge. After

pulling the wire, pot the conduit or wires near the enclosure if there is any possibility of
water from condensation or spray entering the enclosure through the conduit.

. CAUTION: The electronics are not protected against condensed liquid water inside the

enclosure. Be sure conduit interfaces are dry or sealed at the instrument to prevent
condensation that may be present in conduit lines from entering the enclosure.

Ö Make wiring connections. Power should be off at this time. Refer to Figure 9 for RheoVac

monitor wiring detail. Make power and transducer connections first on the lower circuit
board. Next connect the 4-20 mA signal wires at JP3 and the two status output wires at JP7.
There are no other terminals used on the upper board connector JP7.

. . WARNING: Verify the wiring. The equipment can be permanently damaged if not wired as

instructed in this manual.

Wire Color Label Wire Color Label Wire Color Label

Drain Wire (Black) A Red H Black/Brown Stripe O

Brown B Yellow I Green Stripe P

Orange C Purple J Black Stripe Q

Blue D Gray K Red Stripe R

White E Brown Stripe L Yellow Stripe S

Green F Orange Stripe M Purple Stripe T

Black G Blue Stripe N Gray Stripe U

× Install serial communication interface (see Figure 11, Pg. 14). Connections are made to the

serial communication receptacle with a cable with six-position RJ-11 plugs (phone type
jacks) supplied as an accessory. When using the RS-232 output, plug the RJ-11 connector
of the supplied cable into the RheoVac unit’s RS-232 receptacle. Plug the other end of the
RJ-11 cable into the provided RJ-11 to DB-9 adapter. The DB-9 adapter should then be
plugged into any standard IBM-PC compatible RS-232 port. Table II and Figure 11 provide
information on the connections.

Usually an RS-422 signal is converted to RS-232 before it is connected to a PC. The
converters do not have a standardized pin assignment, so use of the RS-422 output is less
straight-forward. The DB-9 pin out shown in Table II applies to an interface module,
QCOM-2, made by QSI Corporation. Other modules may have different wiring. Contact the
factory if you need assistance in using the RS-422 output.

Please note, the transmitter supports only one communications type at a time.

Close the lid of the enclosure. Make sure it is tight enough to make a good seal against the
gasket and ensure all other enclosure openings are completely watertight.

- 12 -

TABLE II. RJ-1 1 t o DB-9 Module Adapt er

RS-232 CONFIGURATION RS-422 CONFIGURATION

RJ-11 Pin Out DB-9 Pin Out RJ-11 Pin Out DB-9 Pin Out

1 Tx (transmit) 1 N/C 1 Tx+ (transmit+) 1 Rx! (receive!)

2 N/C 2 Tx (transmit) 2 Tx! (transmit!) 2 Rx+ (receive+)

3 Rx (receive) 3 Rx (receive) 3 Rx+ (receive+) 3 Tx+ (transmit+)

4 N/C 4 N/C 4 Rx! (receive!) 4 N/C

5 Power (+5V) 5 Ground 5 Power (+5V) 5 Ground

6 Ground 6 Pulled high 6 Ground 6 Tx! (transmit!)

7 N/C 7 TBD

8 Pulled high 8 TBD

9 N/C 9 TBD

2.6 RheoVac SYSTEM GROUNDING

The RheoVac electrical system includes the RheoVac monitor and your data collecting inputs. In
general, it is good practice to use a single point grounding scheme to terminate the system output circuit
to a stable reference potential. Improper grounding may cause significant data noise, or in extreme cases,
damage your equipment. To simplify this task, determine which outputs you will be using and refer to
the following section for specific grounding instructions.

• RS232/422 Serial Output Only - Many PCs have non-isolated serial ports. You must
determine if your serial port is isolated. With your PC (or DCS, etc.) powered and plugged
into a grounded outlet measure both the Vdc and Vac between the local circuit’s earth ground
and pin 5 of the PC’s RS232 DB-9 connector. If the voltage is not zero the circuit needs to
be grounded. Connect a locally earth-grounded wire to the RheoVac instrument’s “OUT1”
(!) terminal of JP7 located next to the RS232/422 jack (see Figure 9). If the voltage reads
zero, no additional grounding should be attached. Additionally, we have seen noise
problems with certain laptop computers when they are connected to their external power
supplies. Some of them are not fully isolated and have signal noise levels as high as 12Vac
on the serial port GND pin. In this case, the circuit should also be grounded by connecting
a wire to the RheoVac’s “OUT1” (!) terminal.

• 4-20mA Output Only - If only a single output channel is used, it may be connected directly
to a non-isolated input channel without any additional grounding. Any additional output
connections require isolated inputs. If all inputs are isolated, regardless of how many are
used, a single channel should be grounded locally near the input card(s). In this case, connect
a locally earth-grounded wire to one of the 4-20mA (! ) terminals.

• Multiple Outputs - Review the special wiring configurations above. Connecting all of the
used outputs to isolated input devices results in one common isolated circuit. This common
circuit needs to be grounded at a single point. Choose one of the ground points listed above.

- 13 -

- 14 -

Serial Communications Interface

SECTION 3 — OPERATION

3.1 GENERAL INFORMATION

The RheoVac monitor is 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. This is a rare occurrence which should not happen if the transducer is properly
installed, according to instructions in SECTION 2 — INSTALLATION.

3.2 SYSTEM START-UP

The RheoVac monitor has been designed for fast warm up following turn-on of power. When power is
first turned on, no differential temperature will exist between the heated and reference probe sensors.
The transmitter is programmed to apply heat to the sensor for a set period of time or until a factory set
value is reached. Then the heater will return to normal. During this initialization period, the display will
have the message '*INTEK, INC.*' on the top line and '*[phone]*', the phone number of Intek,
on the bottom. This message will then change to '*RheoVac*' and the unit's serial number. The bottom
display line will then change to 'initializing'. During this period the status output will be low (alarm
condition) and the analog outputs should be ignored. Further, no data is being transmitted over the serial
ports. The flow value will be monitored internally for stability, which will occur before the display is
set to the normal reading state. After the start-up sequence, program execution is sent to the main
instruction loop. It takes several seconds to execute the initialization sequence.

Upon a "cold" initial start-up of the RheoVac monitor, the transducer may take several minutes to give
accurate air in-leak flow measurements. During this time the probe is transitioning to thermal
equilibrium conditions under vacuum.

3.3 OUTPUT SIGNALS

Standard on all RheoVac instruments are one 2 x 20 alpha numeric LED backlit display, ten 4-20 mA
analog outputs, one 0-15V digital status port, and one serial communication port. Each process variable
is a linear, fully temperature and pressure compensated value on any of these readable outputs. All 4-20
mA output signals are scaled such that 4 mA represents 0% of the rated full scale value and 20 mA
represents 100% of the rated full scale value. The standard full scale values and definitions of all
process variables are listed in Table III.

Note: When the pressure rises above the calibrated range of 10" Hg absolute, all of the flow outputs will
indicate zero. In some instruments the display will read "General Fault Mode 6" at higher pressures,
such as one atmosphere. This is not a problem and the unit will read correctly under vacuum conditions.
Therefore, no flow rates will be reported when the generator is off-line or during hogging until the
pressure falls below 10" Hg absolute. All other variables will continue to be output normally.

- 15 -

Table III. Process Variable Definitions and 4-20 mA Range

PROCESS VARIABLE

4-20 mA

FULL

SCALE

VALUE

PROCESS VARIABLE DEFINITION

ACTUAL VOLUME FLOW

[ACFM]

TOTAL MASS FLOW

[lbs/hr]

WATER VAPOR MASS FLOW

[lbs/hr]

RheoVac PRESSURE

[" Hg]

WATER VAPOR SPECIFIC

VOLUME [cu. ft/lb]

WATER to AIR MASS RATIO 20

RELATIVE SATURATION

[%]

PARTIAL PRESSURE, WATER

["Hg]

AIR IN-LEAK

[SCFM]

RheoVac TEMPERATURE

[°F]

10000

10000

5000

8000

30

100

10

100

210

The actual volumetric flow rate of gases leaving the condenser. It is a
measure of exhauster capacity. Decreased capacity means pump
degradation.

The total mass flow rate of the flowing gas. Note: this value is not a
measure of air in-leak. It is a measure of steam jet ejector capacity.

The water vapor component of the flowing gas being removed from the
condenser.

Absolute pressure at the RheoVac probe head. Should be equal to or less
than turbine back pressure.

The inverse density of the water vapor present in the line.

Ratio of water vapor flow rate to dry air flow rate. Defines “vacuum
quality.”

The percent concentration of wa ter vapor in the extraction line relative to
saturation.

The partial pressure of water vapor in the vacuum line.

Actual measure of air volume flow rate passing the RheoVac sensor head,
normalized to standard conditions (70°F, 29.9" HgA).

Temperature of the flow media at the RheoVac probe head.

3.4 IBM-PC SOFTWARE

IBM-PC Windows 95 compatible software has been provided. This software performs four primary
functions. It allows the user to:

• access data stored inside the RheoVac monitor over the last 24 hours

• chart all ten process variables from the RheoVac serial output (transmitted by means of
RS-232 or RS-422)

• archive the data into a general spreadsheet format

• change the line size stored inside the instrument for mass and volume flow calculations.

The best way to archive RheoVac data is with a dedicated PC or DCS serial channel. However, RheoVac

software allows data from the last 24 hours to be downloaded to a PC file. This data is stored internally
in the RheoVac instrument. The data format is TAB delimited and is easily imported to spread sheet
programs. Column headers are included in the file and are defined in Table IV. There are two additional
columns which are not shown in the table. These two columns pertain to factory calibration and
diagnostics. They are for factory use only. For continuous archiving, a computer capable of running
Windows 95 software is required. The 24-hour instrument internal record is mainly a backup for
troubleshooting or for daily data collection when continuous control room recording is not available.

3.4.1 SOFTWA RE INSTALLATION

- 16 -

System Requirements (minimum recommended):

Windows 95, 98, or NT, 32M RAM
Pentium 100MHz, SVGA 800 x 600
One (1) RS-232 serial port w/DB-9 connector

Install the software by inserting disk 1 into an IBM-PC compatible disk drive, select that drive, and click
on the “Setup” icon. A folder, C:\RHEOVAC, will be created and seven files will be copied to this
folder. The two executable files are: “uninst.exe” and “RVMain95.exe”. The others are drivers and
configuration files and must remain in the RheoVac folder. An Excel macro file is also included for
Excel users. It quickly formats downloaded or archived data into fields with the appropriate precision
and width.

Execute the “uninst.exe” program only
If you want to move the application to a new drive or path, move only the folder contents to the new
location.

To execute the “RVMain95.exe” application the instrument must be installed with all communication
connections in place. Double click on the RVMain95 icon in the RHEOVAC folder. After several
seconds a menu will appear. The first time the application is launched, you are likely to be prompted
to check the system’s clock setting. A real-time clock has been included on-board the RheoVac monitor.
Therefore, the instrument has to be synchronized to your computer’s clock. This is done automatically
each time the software application is launched. Each download will contain a time stamp given by the
RheoVac monitor. Make sure your host computer’s clock is accurate before passing the clock setting
to the instrument. A communication error message may also occur initially. When this error occurs
initially, it usually means the software configuration file needs to learn which serial communication port
is connected to the instrument. Select the correct port when prompted, then hit the “RETRY” button.
If the error does not then go away, refer to the troubleshooting section of this manual.

3.4.2 SOFTWA RE OPERATION

Execute the “RVMain95.exe” by double clicking on the RVMain95 icon in the RHEOVAC folder. Use
this menu to choose from 24hr Data Download, Air In-Leak Monitor, or Change Line Size.

if you want to remove the entire application from your hard drive.

To select the choices from the Main Menu, left click on the button to the left of the desired option. For
help feature, right click on any button or control and pick “Description...” from the pick list.

- 17 -

RheoVac 24hr Data Download - Selecting this choice initiates a download from the data stored
in the RheoVac instrument. This operation takes a few minutes to complete. After the data has
been transferred, you will be prompted to select a filename to store the data. The default filename
is the instrument’s serial number with an “.eep” file extension.

RheoVac Air In-Leak Monitor - Use this choice to plot selected data on single or dual charts.
This application can also be used to acquire data continuously into your computer system. The
screen shown on page 20 appears when this choice is selected. Select the rate that the RheoVac
data will be written to disk. This number represents the time between data points saved to disk.
The stored process values will be the average value of all incoming data since the last archive.
After setting the archive rate, hit the “ARCHIVE TO FILE” button. This begins data collection to
your hard drive. Any previously saved data in the selected file will be retained as new data is
appended to the end of the older data. Each file record contains a time stamp and all ten process
variables regardless of the chart configuration or group select status. The file is built in an ASCII
spreadsheet tab-delimited format and can be easily imported to spreadsheet programs such as Excel.

Archiving continues to build data into the active archive file. You should maintain the file size by
temporarily stopping the archive and renaming the data file based on your data management needs.
Intek recommends either daily or weekly data maintenance schedules.

We encourage you to send to the factory an initial week or so of data (zipped format is preferred)
via e-mail at [e-mail]. This provides a baseline for the particular condenser
and will help us support you should future system problems arise. Our experienced support

engineers can access the “before” and “after” effects of an upset and work with you to identify and
understand the problem.

For further assistance on any feature, select help by right clicking on any button or control in the
application window and select “Description...” from the list.

Change Line Size - Use this option to update the instrument's stored line size variable for proper
volume and mass flow calculations. You should only need this option if the probe is installed in
a pipe size that is different from the value set in the instrument at the factory. Enter the new line
value, then click on “Send.”

3.4.3 DA TA PROCESSING

TABLE IV. Colum n Heading s f or Dat a Dow nloads and A rchived Dat a

O

Time

Stamp

(Time of

day)

0 1 2 3 4 5 6 7 8 9 10

Actual

Volume

Flow

(ACFM)

Total

Mass Flow

(lbs/hr)

Water
Vapor

Flow

(lbs/hr)

RheoVac

Pressure

("Hg abs)

Water

Vapor Sp.

Vol.

(Cu. ft/lb)

Water to

Air Mass

Ratio

(lb/lb)

Relative

Saturation

(%)

H

2

Partial

Pressure

("Hg abs)

Air Flow

In-Leak
(SCFM)

Probe

Temp . (°F)

Data may be retrieved from disk into any ASCII viewer or spreadsheet program. To do this, data
archiving may need to be terminated unless you open the file as read-only. Data is stored with an
appropriate number of significant digits. However, spreadsheet programs such as Excel may need you
to do additional formatting to display each field to the precision you need (e.g., Excel displays the time

- 18 -

stamp by default in a “M/DD/YY HH:MM” format). You may prefer to reformat these cells to
“M/DD/YY HH:MM:SSp/m” to display time to the nearest second in am/pm format. Once in your
desired format, you may construct trend graphs using your spreadsheet or other analysis program. An
Excel macro file is included to automatically format the raw downloaded or archived data.

3.5 CUSTOM SOFTWA RE

Custom software may be developed by the user to receive and archive RheoVac data into a computer
system. The electronics has a serial data protocol of 9600 baud, no parity check, eight data bits and one
stop bit (i.e., 9600,N,8,1). Each transmitted group of data is sent in a standard ASCII coded format
representing each process variable value, instrument identification and status information.

The data stream consists of 13 fields, followed by a carriage return <RETURN>. The first ten fields,
nine bytes each, are the process values. Following the process variables are the RheoVac serial number,
nine bytes, the process identification tag number, 15 bytes, and the RheoVac system status, seven bytes.
The data stream is then ended by a single <RETURN> byte (ASCII code 13). The total number of bytes
transmitted in each data stream is 122 bytes including the trailing <RETURN>. This data group is sent
about once every three seconds. Table V shows the field names and number of bytes in one data stream.

TABLE V. Serial Output Data Stream

Actual

Volume

Flow

(ACFM)

9

bytes

Water

Total

Vapor

Mass
Flow

(lbs/hr)

bytes9bytes

Flow

(lbs/hr)

9

RheoVac

Pressure

("Hg abs)

9

bytes

Water
Vapor

Sp. V ol.

(Cu.
ft/lb)

9

bytes

Water to
Air Mass

Ra tio

(lb/lb)

9

bytes

Relative

Saturation

(%)

9

bytes

H2O

Partial

Pressure

("Hg abs)

9

bytes

ID
Tag
No.

Status

(°F)

Instr.

Serial

Number

Air Flow

In-Leak

(SCFM)

bytes9bytes9bytes15 bytes7bytes1byte

Probe

Temp.

9

Term.
<CR>

Each of the first ten process values are sent in the fixed decimal format of XXXX.XXXX with leading
and trailing zeros inserted to maintain the nine character length. The next three fields are ASCII text
strings followed by the <RETURN>. Example: The nine bytes for an air in-leak of 10.0 SCFM would
be: 0010.0000, or 48,48,49,48,46,48,48,48,48 ASCII.

- 19 -

Figure 12 RheoVac Air In-leak Monitor IBM PC Display Menu for Plotting & Charting Data

- 20 -

SECTION 4 — MAINTENANCE

4.1 GENERA L MAINTENA NCE

Precautions should be taken to insure proper performance of all sensors. Since the quantification
technique involves signal measurements, care should be exercised to prevent build-up of dirt and/or
corrosive layers on the various terminal strip connections. Periodic checks with necessary cleaning
should be performed to insure clean terminals. The joints of the sensor leads should occasionally be
inspected for corrosion or presence of moisture.

4.2 CALIBRATION

The RheoVac air in-leak instrument is calibrated at the factory in a calibration system which replicates
the condenser and vacuum line environment. The system is designed to calibrate the temperature,
pressure, water vapor relative saturation and flow sensor under the gaseous fluid conditions found within
the power plant vacuum line.

In general, calibrations should be valid over a two to five year period. Should the unit require re-ranging
or recalibration, note the serial number of the RheoVac instrument and contact the factory concerning
recalibration cost and turn around times. Refer to SECTION 5 — CUSTOM ER SERV ICE of this
manual for additional information.

4.3 SPA RE PARTS

There are no normally recommended spare parts to stock. Should a spare be needed, a complete unit
should be ordered and stocked.

Spare fuses should be available for replacement of blown fuses. Appropriate fuses to stock are:

C Slow blow 250mA Wickmann fuse, part number 3720250041 or equivalent, for the

microprocessor printed wiring board (top board);

C Slow blow 160mA Wickmann fuse, part number 3740160041 or equivalent, for the flow

meter's heater on the microprocessor printed wiring board (top board);

C Fast acting 2A Wickmann fuse, part number 3731200041 or equivalent, for the sensor

interface printed wiring board (bottom board.)

4.4 TROUBLE SHOOTING

Table VI 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, take
field check readings as identified in Table VII before contacting factory.

- 21 -

TABLE VI. Trouble Shooting Guide

OBSERVATION PROBABLE CAUSE ACTION

'GENERAL FAULT'

'MODE 0'

‘GENERAL FAULT'

'MODE 1'

'GENERAL FAULT'

'MODE 2'

'GENERAL FAULT'

'MODE 3'

'GENERAL FAULT'

'MODE 4'

'GENERAL FAULT'

'MODE 5'

1. Shorted cable connection

2. Damaged flow sensor

1. Improper cable hookup

2. Failed A/D circuit. Short between
sensor terminals C and D of JP4 or
electronics terminals 3 and 4 of JP2

3. Damaged flow sensor

1. Cable contact corroded

2. Damaged flow sensor

1. Cable cut or not connected at all 1. Check cable for contact and continuity

1. Blown heater fuse at F1

2. Damaged flow sensor

1. Sensor's heater connection is open at
terminal H of JP4

2. Damaged flow sensor

1. Check for short in cable due to moisture
or corrosion

2. * Contact factory

1. Verify cable hookup is correct

2. Check cable connections for proper
contacts or moisture & corrosion

3. * Contact factory

1. Check both ends of cable for moisture
or corrosion

2. * Contact factory

1. Check wiring and replace fuse

2. * Contact factory

1. Check sensor heater for an open
connection

2. * Contact factory

1. Sensor at atmospheric pressure (fault
mode will disappear by the time

'GENERAL FAULT'

'MODE 6'

‘GENERAL FAULT'

'MODE 7'

Flow output saturates
high, will not
respond to flow
changes

Flow output saturates
low will not respond
to flow changes

* Record voltages in Table VII (last column) before contacting the factory. Use a high input impedance digital voltmeter for these
readings. All readings are to be taken from terminals A through U on JP4 (Dwg 94114-3, p. 10).

vacuum pressures are reached).

2. Pressure sensor not connected at
terminal L of JP4

3. Damaged pressure sensor

1. Temperature is above the specified
maximum (210°F)

2. Possible sensor damage

1. Flow rate is not within range of
calibration

2. Loose or damaged transducer cable

3. Blown heater fuse

4. Bad electronic component

1. System pressure is above 10" Hg

2. Flow rate out of range of instrument

3. Loose or damaged transducer cable

4. Bad electronic component

1. Restore operating vacuum condition or
ignore indication

2. Check pressure sensor for an open
connection

3. * Contact factory

1. Record temperature and remove sensor
from flow stream

2. * Contact factory

1. Contact factory about re-ranging

instrument

2. Fix cable / connection

3. Replace fuse

4. * Contact factory

1. Contact factory if operation above

10" Hg is required

2. Contact factory to re-range instrument

3. Fix cable connection

4. * Contact factory

- 22 -

When using the RheoVac software on a PC, the software may give you a “Communication Error.” Use
the following table to determine the source of this message and appropriate action.

TABLE VI. Trouble Shooting Guide (software communication errors)

OBSERVATION PROBABLE CAUSE ACTION

Appears the first time

the application was

executed

Appears

intermittently after

application has been

running normally

Completely stops

working after

application was been

running normally

Canno t be made to

work at a ll with
Com3 or Com4

Works fine w ith

RS-232 but does not

work with RS-422

1. Instrument not connected to the
software defaulted serial port

2. Communication connections not made
or instrument is not powered

1. Electrical noise interfering with
communications

2. Too many applications running in
windows

3. Another application is conflicting with
this comm port or IRQ

1. Instrument has stopped communicating

2. Loose or damaged communication
connection

1. Works fine on Com1 or Com2 but does

not work on other port due to other
hardware conflicts such as a modem

1. Converter module not wired or cabled
correctly

2. Instrument jumper not set to RS-422 or
jack not plugged into RS-422

1. Change serial comm port setting and hit
“Retry”

2. Check connections and instrument
power

1. Change to RS-422 communications, re­route or shield cable

2. Close other applications until problem
self corrects

3. Change to a different comm port

1. Check instrument power or look at
instrument display for fault status

2. Check cable adapter at back of PC or at
any other splices or at instrument

1. Using windows Control Panel - System
utility, check for IRQ or I/O hardware
conflict - ADVANCED USERS ONLY

1. Review communications interface
section of manual. Supplied adapter is
for RS-232 only. Convertor connectors
may have different pinouts.

2. Move jumper or jack

If the RheoVac instrument is operating without fault mode indications but output readings are
questionable, please send to Intek by telefax or e-mail the following plant data

: turbine back pressure,
hot well temperature, load, and inlet and outlet circulation water temperatures, along with a 24 hour data
down load from the RheoVac Monitor. (See SECTION 3.4.2)

- 23 -

TABLE VII. Field Check Readings

JP4WIRE

LABEL†

TRANSDUCER CABLE / WIRE

SIGNAL DEFINITION

EXPECTED

VOLTAGE [Vdc]

+ !

B A Flow sensor common voltage sense < 1.0V

C A Flow sensor current return 0.000V

D F Flow sensor heated RTD voltage sense Range: 5 to 40mV

E B Flow sensor heated RTD current source Range: .2 to .4V

F B Flow sensor reference RTD voltage sense Range: .2 to .4V

G B Flow sensor reference RTD current source Range: .2 to .4V

H B Flow sensor heater <10V

I Q Relative saturation sensor voltage source Range: 10 to 14V

J K Relative saturation sensor RTD differential voltage sense (+) Range: 1.0 to 1.4V

K Q Relative saturation sensor RTD offset voltage sense Range: 0 to !2V

L M Pressure sensor differential voltage sense (+) Range: 0 to 100mV

M K Pressure sensor offset voltage sense Range: 1.5 to 2.5V

*

RECORDED

VOLTAGE [Vdc]

N Q Relative saturation sensor voltage (+) Range: .5 to 5.5V

O K Pressure sensor current source Range: 3.5 to 4.5V

P K Relative saturation RTD current source Range: 1.0 to 1.4V

R Q Relative saturation heater supply Range: !2 to !4V

S Q Relative saturation heater return Range: !.7 to +.05V

T K Pressure sensor port heater supply Range: !18 to !24V

U Q Pressure sensor port heater return < .1V

*Complete this table and fax it to the factory (See SECTION 5 — CUSTOM ER SERVICE).
†Connect + lead of volt meter to + column; Connect ! lead of volt meter to ! column.

- 24 -

SECTION 5 — CUSTOM ER SERVICE

Intek's corporate philosophy is to help solve our customer's difficult flow measurement problems. When
you purchase a RheoVac monitor you also receive Intek's outstanding customer service. For sales or
product service, call your local representative or Intek directly at [phone] 8AM to 5PM EST/EDT
weekdays or fax us anytime at [phone]. E-mail inquiries should be sent to [e-mail]
or [e-mail]. Our customer service staff will provide assistance promptly.

5.1 QUESTION ON EXISTING HARDWARE

To allow us to help you more quickly, please have the serial number of the equipment available before
you call.

5.2 TROUBLE SHOOTING

If you have reviewed SECTION 4.4 TROUBLE SHOOTING and have questions, please call our
experienced engineers for assistance. In many cases we can solve a problem over the phone by analysis
of the data taken on TROUBLE SHOOTING, Table VII. Please record as much of the data as possible
prior to calling.

5.3 FACTORY A ND FIELD SERVICE

If you request field service, Intek has experienced engineers available to meet your needs. The RheoVac
monitor is complex and most repairs or recalibratio ns will re quire returni ng the instrument to t he factory.
If a problem cannot be solved over the phone, with your help, we will determine if factory service or
field service will be the best solution.

To request factory service, a Return Material Authorization (RMA) or purchase order is required. Our
customer service staff will assist you with the required information to return instruments for service.

5.4 QUESTIONS ON NEW EQUIPMENT

For a new RheoVac Monitor application or any liquid or gas flow measurement need, contact the Intek
technical sales department at the above phone/fax numbers. Our staff will be pleased to answer all
questions and provide quotations.

- 25 -

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.

Pipe Connection: : Hot tap with 1½" MNPT connection

9 Other

Input Power: : 115 Vac, 50/60 Hz

Q 230 Vac, 50/60 Hz (switch)

Calibrated Ranges: Air In-Leak: 0 to 100 SCFM (4-20 mA)

Outputs Ordered:

Analog: : 10 outputs, Standard (See Table I)

Digital: Q RS-232 Q RS-422

Calibrated for customer line size of

6.3 SPECIAL INSTRUCTIONS

inches, schedule

- 26 -