Intek RheoVac DR 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 AND RECOMMENDATIONS ............................ - 3 -

SECTION 2 I NSTALLATION ................................................ - 4 -

2.1 INSTALLATION ..................................................... - 4 -

2.2 RheoVac DR SYSTEM INSTALLATION/SITE SELECTION ................. - 4 -

2.2.1 Probe Site Selection ............................................. - 4 -

2.2.2 Electronics Unit Site Selection .................................... - 6 -

2.3 PROBE INSTALLATION .............................................. - 6 -

2.4 ELECTRICAL CONNECTIONS ........................................ - 8 -

SECTION 3 OPERATI ON .................................................. - 12 -

3.1 GENERAL INFORMATION .......................................... - 12 -

3.2 SYSTEM START-UP ................................................ - 12 -

3.3 PORTABLE USB DATA STORAGE/Warranty Registration Instructions ....... - 12 -

3.4 DISPLAY .......................................................... - 12 -

3.5 COMMUNICATIONS ................................................ - 13 -

3.6 DATA PROCESSING ................................................ - 14 -

3.7 CUSTOM SOFTWARE .............................................. - 15 -

SECTION 4 MAINTENANCE ............................................... - 16 -

4.1 GENERAL MAINTENANCE .......................................... - 16 -

4.2 CALIBRATION ..................................................... - 16 -

4.3 SPARE PARTS ..................................................... - 16 -

4.4 TROUBLESHOOTING ............................................... - 17 -

4.5 HARDWARE AND SOFTWARE MODIFICATIONS AND UPGRADES ...... - 19 -

SECTION 5 CUSTOMER SERVICE ......................................... - 20 -

5.1 QUESTION ON EXISTING HARDWARE ............................... - 20 -

5.2 TROUBLESHOOTING ............................................... - 20 -

5.3 FACTORY AND FIELD SERVICE ..................................... - 20 -

5.4 NEW EQUIPMENT AND SERVICES ................................... - 20 -

SECTION 6 CUSTOM I NFORMATION ...................................... - 21 -

6.1 UNIT IDENTIFICATION ............................................. - 21 -

6.2 CONFIGURATION .................................................. - 21 -

6.3 SPECIAL INSTRUCTIONS ........................................... - 21 -

Appendix A - RheoVac Instrument User Interface Software
Appendix B - RheoVac DR Networking

I:\OFFICE\WPMANUAL\Rheovac\Manuals\RV DR Rev B.wpd

Manual no. RV DR Rev. B

Intek, Inc. 2011

WARRANTY

Intek, Inc. warrants each RheoVac DR 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.

RheoVac instruments are manufactured under United States patent numbers 4,255,968,
5,485,754, 5,752,411, 6,385,974 and 6,526,755. Inte k, Rheotherm and RheoVac 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 techsupp [e-mail]

[e-mail]

SECTION 1 — GENERAL INFORMATION

1.1 INTRODUCTION

For the first time, all necessary properties of the gases in the vacuum dryer exhaust line are directly
measured to provide an accurate determination of water vapor removal and dryer performance related
parameters. These properties are measured to provide the industry with the most advantageous and
complete product for vacuum dryer system diagnostics:

®

the RheoVac

A RheoVac DR system consists of sensor probes reporting to a central signal conditioner and processor
unit. The sensing probes, consisting of multiple sensors configured in two separate probes (the standard
configuration is a main FTP probe and a RS probe), is installed in the vacuum line, generally between
the dryer and the exhauster. The RheoVac DR system is superior to all other methods in that it makes
no assumptions about the dynamics of the dryer and vacuum line environment. The main FTP probe
sensor head employs the patented Rheotherm® technology to provide an accurate mass 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.

System*

*USPNs 4,255,648; 5,485,754; 5,752,411; 6,385,974; 6,526,755

Figure 1 RheoVac DR

- 1 -

1.2 PRINCIPLE OF OPERATION

The principal features of the RheoVac DR system are shown in Figure 1. At the heart of the RheoVac
DR system is the Rheotherm mass flow transducer, which uses the same patented thermal sensing
technique employed in all precision flow instruments manufactured by Intek. Two temperature sensors
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 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 - temperature, pressure and relative saturation - the RheoVac DR
electronics converts the total mass flow signal from the probe 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 DR system is fully calibrated in the factory under dynamic fluid conditions similar to those
within the dryer vacuum line. Typically, field adjustments are not required.

1.3 TECHNICAL SPECIFICATIONS

1.3.1 Sensor (Probe) Specifications

Primary Cali bration Accuracy:

±5% of total mass flow

Repeatability:

±0.5% of reading

Operating Temperature:

Electronics: 40 to 120ºF (5 to 49ºC)
Probe: 40 to 160ºF (5 to 71ºC)

Never subject probe to temperatures above 210ºF (99ºC)

Operating Pressure:

0.5 to 30 inches Hg absolute
15 psi maximum

Storage Temperature:

-20 to 210ºF (-29 to 99ºC)

Storage Pressure:

15 psig (maximum)

Process Connection:

NPT
Hot tap assembly (optional, 1½” thread-o-let must be welded to pipe for
hot tap installation)

Wetted Surface:

300 Series SS and engineered plastic

- 2 -

1.3.2 Main Electronics (Remote or PC) Signal & Data Access

Local Display:

Back-lit LCD
Selectable display of air mass flow and 6 additional instrument output parameters
Parameter scrolling
Metric/English units

Input Power:

100-250 Vac, 50/60 Hz

Signal Output or Data Access:

RS-232/RS-422/Serial Modbus, Ethernet, TCP/IP
Eight 4-20mA signals (optional)
Wireless (Optional)
OPC (Optional)

Temperature Environment:

Operating: 40 to 120

/F (5 to 49/C)

Storage: -20 to 210/F (-29 to 99/C)

1.4 PRECAUTIONS AND RECOMMENDATIONS

Read the entire manual before installing and operating the RheoVac DR system.

Carefully select the best location for installation of the probe(s). Access, clearances, freedom
from standing water, and straight-run should all be considered when selecting probe
locations.

Use reasonable care in handling the probes the sensing components are delica te. Do not
bend the probes, damage the tips, or obstruct the sensing ports. If shipping the unit, make
sure the probes are adequately protected from foreign objects and damage; save and reuse
factory provided custom probe protector and shipping boxes.

Use proper input power it must be between 100 and 250 Vac (nominal 120/240 Vac) at
50/60 Hz (60 Hz nominal).

Confirm the line and environmental temperature is always below the probe and electronics
ratings never operate a probe at or subject it to temperatures or pressures beyond its
specified limits. (See SECTION 1.3)

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

the line where a probe is located.

Keep moisture out of the enclosures once all service connec tions are made, make sure the
enclosure lids are tightly closed and all gaskets are in place. Seal all conduit lines.

The RJ45 is the recommended network connection for all data traffic (as opposed to serial
and 4-20 mA communication).

Intek recommends a service contract to ensure probes are within calibration specifications
and electronics are maintained with appropriate updates. Instrument probes should be
returned to the factory for inspection and calibration service every two years.

- 3 -

SECTION 2 — INSTALLATION

2.1 INSTALLATION

These instructions are generalguidelines for the installation of RheoVac DR instruments in their standard
configuration. Additional information pertaining to your unit is covered in SECTION 6 CUSTOM
INFORMATION. Carefully read these instructions prior to installing the equipment. Also, see
preceding SECTION 1.4 PRECAUTIONS AND RECOMMENDATIONS.

2.2 RheoVac DR SYSTEM INSTALLATION/SITE SELECTION

The RheoVac DR can be configured with one or two probes, with the two probe being the standard
configuration. In the standard two-probe configuration, the main probe (FTP) is the larger probe, and
the relative saturation (RS) sensor is located in a second probe, separate from the remaining primary
sensors in the FTP probe. The RS probe is typically installed in the same line at a location slightly
downstream of the FTP probe.

2.2.1 Probe Site Selection

The location for the probe pair should be selected so as to provide the probe sensing area
with well-established smooth flow, uniform system temperature and pressure, and consistent
non-liquid phase flow medium. Pipe sections ahead of a probe, in which water can
accumulate, must be avoided. Refer to Figure 2 and select the most preferred location for
the probe pair. Do not install the probes 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 special instructions.

Check installation clearance. The installation location should allow sufficient clearance for
ease of probe removal (for servicing), including the required clearance space for the hot tap,
where used. Be sure there are no obstructions around the vacuum line that will interfere with
probe insertion. Figure 3 shows the proper insertion angle. THIS ORIENTATION IS
IMPORTANT FOR PROPER OPERATION, particularly if liquid water is expected to wet
the wall surfaces of the probe(s).

Observe the selected sites; check for ease of access. They should be convenient for the
removal and replacing probes at any time for service; without requiring ladders, building
scaffolding or waiting for plant shutdown.

Check operating conditions. The temperature and pressure limits (see TECHNICAL
SPECIFICATIONS; SECTION 1.3) of the unit should be checked to ensure compatibility
with your application.

- 4 -

Figure 2 RheoVac DR Probe Insertion Recommendation

Figure 3 Probe Installation Detail

- 5 -

2.2.2 Electronics Unit Site Selection

The RheoVac DR system may have up to three electronics enclosures; a main processor box, an
optional distribution box, and an optional transmitter box. These enclosures should be installed
in a convenient indoor location and should be kept away from direct sources of heat. The
maximum temperature rating of electronics is 120°F; ensure that this temperature will not be
exceeded inside the enclosure. Once the wiring connections are made, close and latch down the
box lid to protect the contents from damage and debris. The enclosures should be located in a
dry area and should be kept clamped shut during normal operation. Do not allow water to get
into the enclosures. If installed outdoors, build a roof over all enclosures to prevent potential
water infiltration, or direct sunlight to overheat contents.

A. Processor Enclosure: This 12x10 NEMA 4 enclosure houses the display and central

processing unit. Input power (100-250 Vac, 50/60 Hz) is connected inside this enclosure.
This enclosure should be installed in a convenient location and should be kept away from
direct sources of high heat, such as uninsulated steam lines.

B. Distribution Box (optional): This 8x6 NEMA 4 enclosure is typically located near the probe

that is closest to the processor enclosure unit. It is connected to the main processor with an
RS-485 bus DeviceNet™ cable, which can be hundreds of feet long. The probe and
transmitter RS-485 cable connections are also made within this box. The probe and

transmitter cable lengths should be 15 ft. or less.

C. Transmitter Box (optional): This 10x8 NEMA 4 enclosure contains terminals for accessing

the optional eight 4-20mA signals. It can be located in or near the control room so that the
4-20 wires do not have to be run from the plant floor. An RS-485 DeviceNet cable connects
the distribution box to the transmitter box. (There are restrictions on how this can be done,
so check manual SECTION 6, or contact the factory.)

2.3 PROBE INSTALLATION

!!WARNING!! The FTP probe and the RS probe(s) contain components and materials that
have a temperature rating limit of 210°F. If line and fluid temperatures are anticipated to exceed
this limit, the probe(s) must be removed from the vacuum pipe before and must not be reinstalled
until the problem condition has passed. Failure to do this can result in severe damage to the
sensor probe(s), especially when steam enters the vacuum pipe due to vacuum pump operating
anomalies. If Steam Jet Air Ejectors are used, always
pump start up and do not reinstall the RS probe until stable operating conditions are achieved.

A. NPT/Hottap Installation

1. Check hardware. Verify that the probe slides easily through the NPT fitting or hottap
assembly and pipe penetration hole.

2. Verify there are the necessary minimum probe insertion clearance four (4) feet- between
pipe surface and any obstruction.

3. For NPT fitting installation, ensure that the threaded mating fittings (not provided) for
mounting the sensing probe(s) are installed at the proper locations in the process line.
Typically, 1" threaded couplings are needed for the FTP and the RS probes.

remove the RS probe from the line before

- 6 -

4. If using a hottap: install the mounting hardware; drill a 1½” through-hole, center the
thread-o-let over the hole and weld it onto the dryer vacuum pipe; thread the hottap
assembly into the thread-o-let. Use thread tape or pipe dope to seal the connection.
Alternate: weld thread-o-let to pipe wall, then drill a 1½" hole in pipe wall using a hottap
drill.

5. Make sure the probes are parallel to the floor (see Figure 3). Be sure location is
accessible for probe removal and maintenance.

B. Installing/Removing the Probe

1. Check proper installation direction and probe orientation. The FTP probe has a
directional arrow on the junction box. Before installing the unit, note proper flow
direction. This is important to instrument operation.

2. Check serial number (S/N). If more than one RheoVac DR system has been purchased,
make sure the first five digits of the serial numbers of the probe(s) match the first five
digits of the serial number of the main processor unit. The electronics and probe pairs
are a matched set. Mismatched components will not work correctly. The dash number
on the probe S/N is the probe number shown on the display. Record the probe pair
number and installation location for future reference.

3. Verify stop clamp location (see Figure 4). A stop clamp is attached to each FTP probe
as an indication of its insertion depth. It is important that the stop clamp is securely in
place to position the sensors in the correct location and to ensure that the probes do not
contact the opposite pipe wall. Contact with the pipe wall
could damage the probe. The clamp’s location is determined
based on your submitted pipe diameter, as shown in
SECTION 6.2, and is marked with a groove on each probe
shaft. Refer to this mark if a stop clamp is inadvertently
moved. When installed in the line, the sensors in the probe
should be positioned in the middle of the pipe.

4. Prior to inserting probe, loosen the compression nut on the
thermocouple connector of the hot tap or the NPT fitting and
clean the inner surface of the thermocouple connector to
ensure it is free of particles that may cause probe damage.

5. Be sure to power up your RheoVac DR instrument system
and probe pair for at least 30 minutes before inserting probes
into the vent line. DO NOT leave probes in vent line
without power.

6. Install probes. The probes should be mounted through the
pipe wall using the hottap assembly or NPT fitting.
a. The FTP probe installs so that the two sensor tips are

side-by-side across the gas stream. Each probe has a
flow directional arrow on the junction box. Make sure
the probe orientation is correct.

b. The RS probe does not have an orientation requirement.

The RS probe has a 4 foot (1.2 m) cable with a plug-in
connector (with attached dust cap) for connecting to the
FTP probe. Unscrew the dust caps on the RS cable and
the FTP probe junction box, plug the cable connector in
securely first, before inserting the RS probe in the line.

- 7 -

Figure 4 Probe Stop

Clamp

7. When installing under vacuum, do not allow the clamp to “slam” against the seal nut

upon opening the valve. Grasp each probe firmly, with hand against the seal nut,
before opening the ball valve. Allow the probe shaft to slide slowly through the
valve by controlling the amount of grip on the probe shaft. Do not let it slam against
the seal nut. Once fully inserted, tighten the seal nut. Special installation
instructions, if any, will be noted in SECTION 6.

8. It may be necessary to apply a force of about 23 lb (102 Newtons) to remove or

replace the probe under operating conditions. Firmly grip the probe shaft when
removing a probe from the line.

2.4 ELECTRICAL CONNECTIONS

IMPORTANT Inspect and VERIFY these electrical connections carefully. Improper
connection could damage electronic components and sensor function. If additional holes need
to be drilled in the processor enclosure, remove the electronics subassembly (mounted on a
mounting plate) and temporarily store inside an ESD bag in a safe, clean place. Do not drill with
electronics boards inside the enclosure.

A. Main Processor Unit (see Figure 5)

1. Sensor Power and Communication Line

: Connect the distribution box to this main
processor box using the RS-485 communications/power cable. Follow indicated
connector color code. [communications: white (A), blue (B) and shield (SH); power:
24Vdc, red (+), and black (

2. Main Power

: Connect main power terminals to a dedicated 100-250Vac, single phase,

!)]

15-amp circuit. An external disconnect switch should be used for disconnecting power
to the system during outages. Power
connection wires should be at least 18
gauge and comply with accepted wiring
codes. SW1 on the power input PWA
(printed wiring board #01011-5) is used
for cycling power to reset.

3. Network Connection (Recommended)

:
The Ethernet connection at CN3 on the
CPU interface PWA (printed wiring
board #08017-1) is an RJ-45 style jack.
A 10-foot Ethernet Cat5 crossover cable
is supplied with the unit for laptop
connections. Intek recommends using
this connection for all data transmissions
and RheoVac communications because:
a. More measured data is accessible

through the network connection.

b. Software and calibration file updates

can be done remotely.

- 8 -

Figure 5 Electrical Connections and Set-up

4. Serial Communication: Connector JP3 on the
CPU interface PWA (printed wiring board
#08017-1) is the RS-232 serial communication
interface. This interface should only be used for
distances of 20 feet or less, such as to a laptop
computer. A 20-foot serial cable with a DB-9
connector is available from Intekupon request (see
Figure 6 and Table I). An RS-422 serial
communication interface is present for long data
communications when configured without 4-20
mA outputs. Note: Intek recommends using the

network connection for all data transmissions and
RheoVac communications.

Figure 6 Serial Communication Interface

TABLE I. RJ-11 to DB Module Adapter

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 7 TBD

8 Pulled high 8 8 TBD

9 N/C 9 9

B. Distribution Box (optional) (see Figure 7)

1. Connect the RS-485 wires (blue, white and shield) and 24Vdc power (red and black)

from the main processor unit.

2. Install ½” liquid-tight conduit between the

distribution enclosure and the probes unless
½” rigid conduit is used for long distance
runs. Use a minimum of 6 feet of liquid­tight at the probes.

3. The probe connector comes with an adapter

which allows the attachment of the ½”
flexible conduit connector.

4. Connect the probes to the distribution

enclosure using the manufacturer supplied
four conductor shielded cable to any of the
screw terminals labeled JP3 to JP6. Probe
cable connections are shown in Figure 7.

5. Optional - Connect the transmitter box to the

distribution box using the supplied RS-485
cable.

Figure 7 Distribution Box

- 9 -