Pyrometer Manual

TM
PYROMETRIX
AP-106
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
P.O. Box 469 © 2014 Enertechnix Incorporated Phone: 360-753-8831

Maple Valley, WA 98038 Fax: 360-753-8847
Innovative Technologies for Maximum Efficiency
Proprietary Note
The information in this manual, including technical data and copies of drawings,
embodies information proprietary to Enertechnix Incorporated. This manual is provided
to the user of equipment purchased from Enertechnix Incorporated for use only in
operating or maintenance of such equipment. Such information in this manual is not to
be used, disclosed, copied, reproduced in whole or part for any use other than that
indicated above, or for any other purpose detrimental to the interests of Enertechnix
Incorporated. Patents owned by Enertechnix Incorporated have been issued or are
pending on at least some of the information in this manual, and unauthorized use of this
subject matter of such patents is a violation of such patents and is prohibited.
Copyright Notice
 Copyright 2014 Enertechnix Incorporated. Copyright in this manual and associated
documents and drawings belong to Enertechnix Incorporated. All Rights reserved. No
reproduction of all or part of this manual shall be made without prior written consent of
Enertechnix Incorporated.
© 2014 Enertechnix Inc. File Name: ECN073 – PyroMetrix AP106 Manual 140203.pdf ii
Record of Revisions
Revised reference material, written text and drawings will be furnished as required to
update the information contained within this manual. When revisions to the content of
this manual are submitted, utilize the Record of Revisions form provided to record all
revisions. Specific instructions will be provided in the Revision Packet for recording and
inserting all changes affecting this manual.
Revision Date
Description of Changes Initials
Number Issued
 Jan 2007 Original Issue 
7-16-2010 July 2010 Lubricator Information Updated 
Dec 2011 Updated Section 8 to Reflect Change to SPCW REH
1-25-2012 Dec 2011 Updated Section 9 to Reflect Change to SPCW REH
April 2012 Sections 12 (TempView Software Guide) Removed HAH
Section 9 (Fault Isolation & Troubleshooting) Removed and

April 2012 HAH
Made into Separate Manual
April 2012 Updated Sections 1 to 7 plus Introduction HAH
April 2012 Sections 10 and 11 Renumbered to Sections 9 and 10 HAH
5-08-2012 April 2012 Updated Renumbered Sections 9 and 10 HAH
Remove Pressure Switch; Add Oiler Information, New Air

2-03-2014 Feb 2014 HAH
Filter, and Safety Pages; General Update to All Sections
iii
SECTION INDEX
Section Title
Section 1.0 Safety
Section 2.0 General System Description
Section 3.0 ASG Recommended Installation
Section 4.0 System Sub-Component Installation
Section 5.0 Pneumatics, Lubricator & Low/High Pressure
Section 6.0 Electrical Connections
Section 7.0 Measurement Verification
Section 8.0 System Power ON/OFF
Section 9.0 Periodic Maintenance and Repair
Section 10.0 Replacement Parts and Repair Kits
Section 11.0 Appendix A: AP106 Troubleshooting Manual
Section 12.0 Appendix B: PyroMetrix Software User Guide
Section 13.0 Appendix C: Installation Drawings
iv
List of Figures
Figure 1 PyroMetrix System Concept ............................................................ ix

Figure 2-1 Basic PyroMetrix System Block Diagram ......................................... 2-2
Figure 2-2 PyroMetrix System ........................................................................... 2-3
Figure 3-1 ASG Installation Diagram ................................................................. 3-4
Figure 3-2 ASG Installation Details ................................................................... 3-5
Figure 3-3 Completed ASG Installation (prior version) ...................................... 3-7
Figure 4-1 Mark III Air Amplifier Mounting ......................................................... 4-2
Figure 4-2 Hose Plate Assembly Mounting ....................................................... 4-3
Figure 4-3 Photo of Hose Plate ......................................................................... 4-4
Figure 4-4 Proximity Diagram ............................................................................ 4-4
Figure 4-5 Hose Plate Assembly ....................................................................... 4-5
Figure 4-6 Membrane Slot Detail....................................................................... 4-6
Figure 4-7 Membrane Tube Boiler, Negative Pressure
Installation with Seal Box………………………………………………..4-7
Installation with Gussets.………………………………………………..4-8
Installation with Mounting Plate.………………………………………..4-9
Figure 4-10 Mounting Plate Detail……………………………………………………4-9
Figure 4-11 Membrane Tube Boiler, Positive Pressure Installation….…………...4-10
Figure 4-12 ASR Layout……………………………………………………………….4-11
Figure 4-13 AST Layout & Details……………………………………………………4-13
Figure 4-14 SPCW Enclosure………………………………………………………...4-15
Figure 5-1 Basic Pneumatic Block Diagram ...................................................... 5-2
Figure 5-2 Plant Air to Air Preparation System to Air Amplifier ......................... 5-3
Figure 5-3 Air Preparation System .................................................................... 5-4
Figure 5-4 Installed Air System (prior version) .................................................. 5-4
Figure 5-5 Air Amplifier Connection Detail ........................................................ 5-5
Figure 5-6 Hose Plate Assembly to ASG ......................................................... 5-6
Figure 5-7 ASG to AST………………………………………………………….……5-7
Figure 5-8 Plant Air to ASR Purge Regulator……………………………………...5-8
Figure 6-1 SPCW Enclosure & Panels .............................................................. 6-3
Figure 6-2 SPCW Panel & Component Layout ................................................. 6-4
Figure 6-3 SPCW Panel Connections ............................................................... 6-5
v
Figure 6-4 SPCW Panel Connection Detail ....................................................... 6-6

Figure 6-5 SPCW Panel Connection Detail ....................................................... 6-7
Figure 6-6 ASR and AST Connection Details to SPCW .................................... 6-8
Figure 6-7 ASR Wiring ...................................................................................... 6-10
Figure 6-8 AST Wiring………………………………………………………………..6-11
Figure 7-1 Measurements ................................................................................. 7-4
Figure 7-2 Boiler Measurements ....................................................................... 7-5
Figure 7-3 Boiler Layout……………………………………………………………...7-7
Figure 9-1 Differential Pressure Gauge ............................................................. 9-2
Figure 9-2 ASR Microphone Replacement ........................................................ 9-3
Figure 9-3 AST Microphone Replacement…………………………………………9-4
Figure 9-4 Remove ASG from Service .............................................................. 9-6
Figure 9-5 ASG Cutaway .................................................................................. 9-8
Figure 9-7 ASG Disassembly (Front) ................................................................ 9-10
Figure 9-8 Seal Removal................................................................................... 9-11
Figure 9-9 Seal Replacement ............................................................................ 9-15
Figure 9-10 Front Component Assembly ............................................................. 9-19
Figure 9-12 Mark III Air Amplifier ......................................................................... 9-28
Figure 9-13 Air Preparation System .................................................................... 9-30
Figure 9-14 Solenoid Valve on Hose Plate Assembly ......................................... 9-31
Figure 10-1 PyroMetrix System ........................................................................... 10-2
Figure 10-2 Acoustic Signal Generator Seal Kit .................................................. 10-3
Figure 10-3 Acoustic Signal Trigger Enclosure with Interior Views ..................... 10-4
Figure 10-4 Acoustic Signal Recceiver with Internal Views ................................. 10-5
Figure 10-5 ASR External Components .............................................................. 10-6
Figure 10-6 Mark III Air Amplifier ......................................................................... 10-7
Figure 10-7 Mark III Check Valve Kit ................................................................... 10-8
Figure 10-8 Mark III Shaft Seal Kit ...................................................................... 10-9
Figure 10-9 Mark III Cylinder Seal Kit.................................................................. 10-10
Figure 10-10 Air Preparation System Components ............................................... 10-11
Figure 10-11 Hose Plate Assembly Components .................................................. 10-12
Figure 10-12 SPCW Enclosure showing Interior Views......................................... 10-13
Figure 10-13 Hoses ............................................................................................... 10-15
vi
Figure 12-1 The Front Panel ............................................................................... 12-4

Figure 12-2 Load Signal ...................................................................................... 12-5
Figure 12-3 Edit Setup Files ................................................................................ 12-5
Figure 12-4 Save Signal ...................................................................................... 12-6
Figure 12-5 Manual Fire ...................................................................................... 12-7
Figure 12-6 Process Signal ................................................................................. 12-8
Figure 12-7 Load Signal ...................................................................................... 12-9
Figure 12-8 Save Signal ...................................................................................... 12-10
Figure 12-9 Trend View ....................................................................................... 12-11
Figure 12-10 AST Signal with Zoom Views ........................................................... 12-12
Figure 12-11 ASR Signal....................................................................................... 12-13
Figure 12-12 Filtered ASR Signal .......................................................................... 12-14
Figure 12-13 Spectrogram .................................................................................... 12-15
Figure 12-14 Setup Configuration ......................................................................... 12-16
Figure 12-15 Graphic Leak Channel Display ......................................................... 12-17
Figure 12-16 Path Table Tab ................................................................................ 12-18
Figure 12-17 Block Tab ......................................................................................... 12-18
Figure 12-18 2D Table with Contours.................................................................... 12-19
Figure 12-19 ISO Tab............................................................................................ 12-19
Figure 12-20 Path Tab .......................................................................................... 12-20
Figure 12-21 Edit Setup Files ................................................................................ 12-21
Figure 12-22 Block Display ................................................................................... 12-24
Figure 12-23 LeakLog.csv ..................................................................................... 12-25
Figure 12-24 ValidLog.csv..................................................................................... 12-26
vii
List of Tables
Table 2-1 Equipment Specifications ................................................................. 2-8
Table 2-2 Customer Requirements .................................................................. 2-10
Table 7-1 Barrel, Hose & Tube Measurements (offline) ................................... 7-2
Table 9-1 Routine Care Schedule .................................................................... 9-2
Table 9-2 Air Amplifier Trouble Shooting ......................................................... 9-29
Table 10-1 Typical AST Replacement Parts ...................................................... 10-4
Table 10-2 Typical ASR Internal Replacement Parts ......................................... 10-5
Table 10-3 Typical ASR External Replacement Parts………………………….....10-6
Table 10-4 Mark III Air Amplifier Repair Kits……………………………………….10-7
Table 10-5 Air Preparation System Typical Replacement Parts…………………10-11
Table 10-6 Hose Plate Assembly Typical Replacement Parts…………………...10-12
Table 10-7 Typical SPCW Replacement Parts…………………………………….10-14
Table 10-8 Hose Assembly Part Numbers…………………………………………10-16
Table 10-9 Recommended Spare Parts…………………………………………….10-17
Table 11-1 Signal Processing Troubleshooting……………………………………11-14
Table 11-2 Diagnostic Programs…………………………………………………….11-15
viii
Boiler Cavity
Generator Receiver
2310°F
(1266°C) SPCW
Figure 1 – PyroMetrix System Concept
ix
Introduction
Purpose
This manual provides detailed instructions for the installation, operation, and servicing
of the Enertechnix PyroMetrix™ High Energy Acoustic Pyrometer System. You are
advised to become thoroughly familiar with the equipment and the contents of this
manual. Give careful attention to applicable warnings and cautions. Before performing
any servicing procedure, make sure all necessary safety equipment, test equipment,
repair materials, and special tools are on hand.
If you find an error, omission, or other technical discrepancy, please fill out a copy of the
Comment Form found at the back of this manual and send to Enertechnix Incorporated
at the address found in the Exclusive Distributor section of this manual.
User Qualifications
The information contained in this manual is intended for use by persons qualified to
properly install, operate, and repair Enertechnix Incorporated PyroMetrix™ High Energy
Acoustic Pyrometers.
Safety Advisory
This manual describes physical and chemical processes that require the use of
chemicals or other commercially available materials that require precautionary attention.
The user of this manual should obtain material safety data sheets from the
manufacturers or suppliers of the materials to be used. The user must become
completely familiar with and follow all recommendations, warnings, and cautions for the
safe use, handling, and disposal of the materials. The following describes the use of
WARNINGS, CAUTIONS, and NOTES within this manual:
WARNING
WARNINGS CALL ATTENTION TO THE USE OF MATERIALS,
PROCESSES, METHODS, PROCEDURES, OR LIMITS, WHICH MUST
BE FOLLOWED PRECISELY TO AVOID INJURY TO PERSONS.
x
CAUTION
Cautions call attention to methods and procedures that must be
followed to avoid damage to equipment.
NOTE
Notes call attention to methods that make the job easier.
Material List
The material listed in the table below is required for processes within this manual.
WARNINGS and/or CAUTIONS will precede the use of the materials listed.
Material Recommendation Used in…

Installation, Routine
Teflon® Tape Commercially Available
Maintenance, Repair
Teflon® Grease Permatex Repair
Degreasing Agent Commercially Available Repair
Cleaning Solvent
(Compatible with steel) Commercially Available Repair
(Compatible with aluminum)
Anti-seize Compound Permatex Repair
Marine Grease Lubriplate Repair
Thread Sealant Loctite 567 Repair
xi
Abbreviations and Acronyms
The following is a list of abbreviations and acronyms used in this manual.
AAC Amps Alternating Current
A/D Analog to Digital
AC Alternating Current
AMP Ampere
AP106 Acoustic Pyrometer AP106 System
ASG Acoustic Signal Generator
ASR Acoustic Signal Receiver
AST Acoustic Signal Trigger
AWG American Wire Gauge
bar PSIG multiplied by a factor of .0689
BNC British Naval Connector or Bayonet Nut Connector
°C Centigrade
CFM Cubic Feet per Minute
D/A Digital to Analog
dB Decibel
DCS Distributed Control System
DIN Deutsche Industrinorm - German Standard
gal Gallon
xii
°F Fahrenheit
GND Ground
in. Inch
in-lbs Inch Pounds
JIC Joint Industrial Council
kg Kilograms
L Liter
L/s Liter/second
lbs. Pounds
mA Milliampere
mHz Megahertz
MPC Multiple Processing Control
mm Millimeter
N/A Not Applicable
NPTF National Pipe Thread Female
Nm Newton Meter
NPT National Pipe Thread
O.D. Outside Diameter
psi Pounds Per Square Inch
PSIG Pounds Per Square Inch Gage
qt Quart
xiii
REF. Reference
RMS Root Mean Squared
SCFM Standard Cubic feet Per Minute
SPCW Signal Processing Computer with Windows software
SST Stainless Steel
TOF Executable File TOF.exe
UNS Unified National Standard
V Volt
VAC Volts Alternating Current
VDC Volts Direct Current
SSR Solid State Relay
xiv
1.0 SAFETY
Topic Page
1.1 Safety Definitions ............................................................................................ 1-2
1.2 General Safety Rules ....................................................................................... 1-3
1.3 General Plant Safety Rules ............................................................................. 1-4
1.4 Enertechnix Equipment Safety ....................................................................... 1-5
1.5 Lockout Tagout Procedures for Enertechnix Equipment ............................ 1-6

1.1 Safety Definitions
Statements in this manual preceded or adjacent to the following words and graphics are
of special significance:
WARNING
WARNING indicates a potentially hazardous situation which if NOT avoided, could

result in death or serious injury.
CAUTION
CAUTION indicates a potential situation which if not avoided, could result in equipment
or property damage.
Safety 1-2
1.2 General Safety Rules
1. Personal Protection Equipment (PPE) must be worn as prescribed for each job, such
as: safety glasses for eye protection (ANSI Z87.1), earplugs or earmuffs for hearing
protection, hard hats at all times within the confines of an industrial area where there
is the potential for falling materials or tools, gloves when handling materials, and steel
toe footwear as necessary for protection against foot injuries.
2. Before servicing, repairing, or adjusting any powered tool or piece of equipment,

disconnect it, lock out the sources of energy (electrical, pneumatic and/or hydraulic),
tag it out, and then try it out to confirm that it is off.
3. Never work without a harness when elevation is more than 4 feet high. Personnel
using a safety harness need to be trained in the proper use of a safety harness.
4. Lift correctly – with legs, not the back, and do not twist. If the load is too heavy
(greater than 70 pounds or 32 Kg) GET HELP.
5. Do not use power tools and equipment until you have been properly instructed in the
safe work methods and become authorized to use them.
6. Be sure that all guards are in place. Do not removed, displace, damage or destroy
any safety device or safeguard furnished or provided for use on the job, nor interfere
with the use thereof.
7. Never oil, lubricate or fuel equipment while it is energized.
8. Use caution when using compressed air. Do not use a compressor or compressed
air to blow dust or dirt from your cloths, hair, face or hands.
9. Use the ‘four and one’ rule when using a ladder. One foot of base for every four feet
of height. Keep ladder base free of debris, hoses, wires, materials etc. No wood or
aluminum ladders can be used.
10. Know where firefighting equipment is located and be trained in how to use it.
11. Use only extension cords of the three-prong type. Use ground fault circuit
interrupters at all times and when using tools in wet atmosphere (e.g. outdoors) or
with any temporary power supply. Check the electrical grounding system daily.
12. Know what emergency procedures have been established for your job site (location
of emergency phone, emergency contact numbers, first aid kit, stretcher location, fire
extinguisher locations, evacuation plan, etc.).
13. Report any work-related incident (near miss), injury or illness, no matter how minor,
to your supervisor or manager.
1-3 Safety
1.3 General Plant Safety Rules
• Follow the plant’s safety rules at all times.
• Follow plant Lockout Tagout procedures for conducting any installation or

maintenance on equipment.
• Never operate plant mobile equipment without proper authorization.
• Wear Personal Protective Equipment (PPE):
1. Head protection in the form of a hardhat will be worn on job sites when there
are potentials of falling objects, hair entanglement, burning, or electrical
hazards.
2. Eye protection with side shields (ANSI Z81.1) will be worn when there are
potentials of hazards from compressed air, flying objects, particles, sparks,
chemicals, arcing, glare or dust.
3. Protective steel toe footwear shall be worn to protect from falling objects,
chemicals, or stepping on sharp objects. Athletic or canvas-type shoes shall
not be worn. In many plants, Metatarsal Boots are required.
4. Protective gloves and/or clothing shall be worn when required to protect

against a fire hazard. Fire resistant clothing (FRC) is required.
5. Hearing protection shall be worn in areas with high acoustic levels.
Safety 1-4
1.4 Enertechnix Equipment Safety
WARNING
BURN HAZARDS:
1. Avoid touching any hot lens tubes. Wear leather gloves to prevent burns.
2. While opening inspection or port doors on a furnace or boiler, always wear PPE
(hard hat, safety glasses, ear plugs, safety shoes and gloves), and use the lens
tube heat shield provided by Enertechnix. Keep your face off to the side of the
opening or behind the heat shield to avoid high temperatures and/or any
unexpected positive pressure bursts of heat. Wearing a face shield is
recommended.
WARNING
SHOCK HAZARD:
1. Disconnect power to any electrical field boxes, junction boxes and/or electrical
enclosures, or Universal Enclosure prior to conducting any work, repair or
maintenance on them in order to prevent electrical shocks.
WARNING
PINCH POINT HAZARD:
1. The AutoRetract has a pinch point hazard when in motion. Keep the safety
guard in place at all times to prevent pinch injuries.
WARNING
COMPRESSED AIR HAZARDS:
1. Shut compressed air off and bleed pressure in lines before working on any
pneumatics to prevent injuries from unsecured lines and/or pressurized air.
2. Don’t look down the lens tube when the Purge Air is on to prevent injuries from
pressurized air and/or particulate matter. Wear safety glasses to prevent eye
injuries.
WARNING
POTENTIAL INJURY TO MAINTENANCE WORKER:
1. Do not use Acoustic Pyrometer (AP) while workers are inside cold boiler or
furnace that is under maintenance.
2. Do not stand in front of AP barrel while Acoustic Signal Generator (ASG) is
pressurized.
WARNING
EQUIPMENT INSPECTION & LABELS:
1. Equipment needs to be inspected before each use.
2. Equipment labels should be wiped off monthly and replaced if they become
unreadable. Failure to do so could result in equipment damage or injury.
1-5 Safety
1.5 Lock Out Procedures for Enertechnix Equipment
These lockout instructions are to be incorporated into each facility’s Lock-Out
Tag-Out Procedures. Lock-out of energy sources should be done prior to any
maintenance or repair on Enertechnix equipment.
For Electrical Sources of Energy:
1. If there is a Signal Processing Computer (SPCW), first turn off the computer.
2. Inside the control box for each piece of equipment (SPCW, Acoustic Signal
Receiver [ASR], Acoustic Signal Trigger [AST], Combo Box, AutoRetract
Controller, AutoRetract Port Rodder Controller, OptiTrak Controller, and/or
PyroRemote Controller), flip the main circuit breaker (which has LOTO capability)
into the Off position.
3. Locate the plant circuit breakers powering the Enertechnix equipment, shut them
off, and lock them out according to the plant’s Lock-Out Tag-Out procedures.
Safety 1-6
For Pneumatic Sources of Energy:
1. Rotate the safety-discharge lock-out ball valve into the Off position (90° to pipe
direction) that is located on the air filter system. This allows the system air
pressure to bleed off safely.
2. For the Acoustic Pyrometer 106 (AP106), the stored air in the Acoustic Signal
Generator(s) [ASG(s)] must also be bled off by adjusting the metering valve on
the Solenoid Valve/Hose Plate to the open position. (Close this valve before
restarting.)
3. Place a lock through the hole in the safety-discharge lock-out ball valve in
accordance with the plant’s Lock-out Tag-Out procedures.
1-7 Safety
2.0 GENERAL SYSTEM DESCRIPTION
Topic Page
2.1 Equipment Description ................................................................................... 2-3
2.2 System Component Description .................................................................... 2-4
2.3 Equipment Specifications ............................................................................... 2-8
2.4 Customer Requirements ............................................................................... 2-10

85 PSIG Min. Air
85 PSIG Min. Air Air (Instrument Quality)
(Instrument Quality) Prep 1” Pipe (~20 SCFM intermittent
½” Pipe (~20 SCFM intermittent approx. 5 minutes)
approx. 5 sec/ 30 minutes)
Receiver ASG Trigger

(1-12 devices) 120/240 VAC (1-4 Total)
ASR AST
Control Line
In Flexible
Conduit
Processor
PyroMetrix
SPCW Software
1 Total
2 Twisted Pair (Belden 88102) 3 Twisted Pair (Belden 88103)
120/240 VAC 120/240 VAC

120/240 VAC 4 -20 mA (1-16
total) Outputs to
DCS
Figure 2-1 – Basic PyroMetrixTM System Block Diagram
REFERENCE ONLY / FINAL CONFIGURATION MAY VARY
General System Description 2-2

2.1 Equipment Description
The PyroMetrixTM Acoustic Pyrometer measures the gas temperature using

sound signals. In addition it can be configured for use as a Leak Detection
System.
As illustrated in Figure 2-2, the PyroMetrixTM High Energy Acoustic Pyrometer

consists of:
- Air Prep / Mark III Amplifier - Acoustic Signal Trigger (AST)

- Acoustic Signal Generator (ASG) - Signal Processing Computer (SPCW)
- Acoustic Signal Receiver (ASR) - Connecting Hose Assemblies
- Connecting Data Transmission Cables
Figure 2-2 – PyroMetrixTM System
2-3 General System Description

2.2 System Component Description
PyroMetrixTM Acoustic Pyrometer Basic System
The PyroMetrixTM temperature measurement system provides,

continuous, reliable, and accurate information regarding internal
temperatures of combustion processes. The PyroMetrixTM system
utilizes the fundamental principle that the velocity of sound through a
medium is proportional to the temperature of the medium.
Therefore, by accurately knowing when a sound is generated, when
it is received at a remote location, and the distance between the
source and the receiver, the average temperature between the two
points can be determined.
2.2.1 Acoustic Signal Generator
The Acoustic Signal Generator (ASG) system consists of the primary

signal generator, transmission barrel, charge control valve assembly,
trigger assembly, and an air amplifier with regulator. These
components are assembled and physically mounted according to
unique, site specific, requirements. The final ASG provides a high-
energy burst of sound capable of clear detection and processing
within a range of 100 feet in an open furnace.
At the heart of the PyroMetrixTM system is the Acoustic Signal

Generator. This device, using standard plant service air, creates a
high-energy, sharp leading-edge sound wave with an intensity of
over 170 dB. This sharp leading edge, using traditional algorithms, is
easily distinguishable from ambient boiler noise. Because of the
intensity of the sound wave, multiple receivers up to 100 feet away in
an open furnace can detect and process the signal. Also, because
the signal propagation does not rely on interaction with the
combustion particulate, the accuracy of the system is independent of
fuel type or source.
The ASG creates a high energy (>170 dB) acoustic pressure wave
with a very short, well-defined rise time. This clearly defined edge
allows the system components to detect and determine the starting
time of the wave at the AST within 50 microseconds.
The ASG system includes mounting hardware for the ASG. Included
are brackets, recoil constraint springs, and attachment brackets for
the transmission barrel. The material supplied is suitable for
permanent support of the 170 pound ASG hardware.

2.2.2 Transmission Barrel
The transmission barrel directs the high-energy sound impulse from

the generator, through the penetration and into the boiler. It is
constructed of 2 1/2”, mild steel piping with a Stainless Steel end for
boiler penetration.
2.2.3 Mechanical Control Components
The Air Preparation System, Acoustic Signal Trigger (AST), and

Solenoid Control Valve combine to provide local control of the Sound
Generator. The Air Preparation System pre-charges the ASG to
approximately 400 psi. The SPCW sends a logic level signal to the
AST, which in turn sends an AC control signal to the solenoid control
valve, which then discharges (fires) the ASG, producing the sound
pulse.
Following discharge, the charging process repeats and holds the

amplified air charge until the controller re-triggers the system. Sound
impulse interval timing is determined by the user and generally
ranges from one pulse per 5 minutes to one pulse per 15 minutes.
2.2.4 Acoustic Signal Trigger
The Acoustic Signal Trigger (AST) accepts the logic level firing signal
from the SPCW and sends AC control power to the solenoid control
valve to fire the ASG. The AST also includes a microphone assembly
to detect when the sound pulse leaves the ASG. It is housed in a
standard 10” x 12” (NEMA 4) enclosure and mounts near the ASG.
2.2.5 Acoustic Signal Receiver
The Acoustic Signal Receiver (ASR) provides a listening mechanism

for detection of the generated sound wave and a communications
mechanism for verification of signal recognition.
The ASR is housed in a standard 10” x 12” (NEMA 4) enclosure and

mounts, through the boiler skin, to the back side of the waterwall
tubes. Penetration through the wall membrane is accomplished via
0.4” holes providing both mounting support and room for insertion of
a 3/8” stainless steel receiving tube. This tube may be up to 20 feet
in length but shorter, direct penetration installation is desirable.
Typical tube lengths are less than 36 inches.
The PyroMetrixTM system can support up to a combination of up to 4

ASGs and 12 ASRs. ASRs are capable of receiving and verifying

sound from ASGs as far as 100’ distance (open furnace), provided
that there is an unobstructed line of sight between the ASG and the
ASR. Each ASR is capable of detecting a valid acoustic signal and
providing verification of receipt with 50 microseconds of actual sound
incidence.
NOTE: The ASRs are connected to the SPCW controller via

shielded, twisted pair connection.
2.2.6 Signal Processing Computer
The Signal Processing Computer (SPCW) controls the system

operation. The SPCW is housed in a standard enclosure and is
capable of operating in typical industrial conditions to temperature up
to 110 F. (NOTE: Higher ambient Temperatures require vortex
cooler)
NOTE: It is recommended to install the SPCW in an air conditioned

room.
The electronics system resides on an industrial grade processor with

a flat screen display for local configuration, reporting, and
modification of operating parameters. Data displayed on the flat
screen includes temperatures and signals, which can be used to
verify the performance of the system.
The electronics system provides sufficient process inputs/outputs for

simultaneous control of up to 48 ASG/ASR pairs. Up to 32 separate
4-20 mA signals are provided for reporting of temperatures along
specific paths, zones or leak detection channels. Zones are custom
defined areas across a plane of a boiler. Each zone consists of
multiple paths for collective assessment of temperature. Leak
channel alarm outputs and operation-inhibit inputs are also provided
via the OPC interface.
The system may also provide a MODBUS over TCP (Ethernet)

interface to connect to a DCS or the TempView TM boiler display
software.
The SPCW's purpose is to initiate the sound pulse, monitor and

determine the exact moment that the sound pulse is launched into
the boiler, monitor and determine the exact moment that the sound
pulse is received at various remote ASR sites, and then to calculate
the average path temperatures within the boiler using an advanced
signal detection and processing methodology.

2.2.7 PyroMetrixTM System Operation
Prior to firing, the ASG must be pressurized with compressed air to

about 400 psi. This is accomplished by operating the Mark III air
amplifier, for up to 4 minutes to boost the 90 psi (5 scfm) plant air
supply to the 400 psi used by the ASG. When the SPCW determines
that it is time to fire the ASG, it sends a signal to the AST, which
operates the solenoid control valve, which fires the ASG. When the
ASG fires, it releases the air charge very rapidly, which creates a
sound wave with a very sharp rising edge. The actual duration of this
sound wave is unimportant but it is in the order of tenths of
milliseconds. This sharp edged sound wave travels through the
boiler and reaches the ASR(s) in 10 to 30 milliseconds, depending
on boiler dimensions and boiler temperature. The SPCW has a data
acquisition window when it "listens" for the sound wave at the AST
and then at the ASR. After this window, the SPCW processes the
data and then provides a boiler temperature reading on the LCD
screen, 4-20 mA current loop (or optional MODBUS protocol). This
processing takes between 5 and 30 seconds to complete, depending
on the number of paths and/or zones.
The SPCW is configured to fire the ASG at a predefined interval.

This interval is usually set between 5 and 15 minutes. When the
interval expires and it is time to fire the ASG, the SPCW "listens" to
the ASRs in the boiler and waits for the background sound level to
drop below a predefined level before actually firing the ASG. This
prevents the PyroMetrixTM System from getting false temperature
readings during high background noise levels such as during soot
blowing.
The SPCW can detect waterwall tube leaks by monitoring the

background noise level. A 4-20 mA signal can be programmed to
output background noise level (4-18 mA) or alarm (20 mA).

2.3 Equipment Specifications
Table 2-1 lists the equipment specifications for the PyroMetrixTM Acoustic
Pyrometer.
Component Characteristic Specification
Power Requirement 120/240 VAC, 15A, 50/60 Hz.
System Internal Voltages 12 VDC, 24 VDC

(1 boiler with
2 planes) 4 - 20 mA (ground isolators may be
Output
used)
Compressed Air 90 psi (6.2 bar), 5 SCFM (2.4 L/s)
Power Consumption 100/240 VAC, <4A, 50/60 Hz.
Internal Voltages 12 VDC, 24 VDC

SPCW
(Signal Output 4 - 20 mA Isolated
Processing
Computer Temperature 0 - 43°C (32-110°F)
with
Windows Relative Humidity 10% - 85%, Non-Condensing
software)
Min-Max Inlet Pressure
60 – 80 psi (4.1 - 5.5 bar)
(for Cabinet Cooler)
Min-Max Usage (for
4 – 8 SCFM (1.9 – 3.8 L/s)
Cabinet Cooler)
250 - 500 PSI (17.2 – 34.5 bar) from
Compressed Air
Air Preparation System
Temperature 0 – 80°C (32 – 175°F)
Water Wash OK for Enclosure; 0% -

ASG Relative Humidity 90%, Non-Condensing for
(Acoustic Electronics inside Enclosure
Signal
Min-Max Inlet Pressure
Generator) 60 – 120 psi (4.1 – 8.2 bar)
(at once per 5 minutes)
Average Air 2.7 – 4.2 CFM (1.3 – 2.0 L/s) at 90
Consumption psi (6.2 bar)
Min-Max Usage per 50 – 80 SCFM (23.6 – 37.8 L/s)
Firing Depending on Operating Pressure

Power Consumption 110/240 VAC, < 1A, 50/60 Hz.

AST
(Acoustic
Temperature -10 – 80°C (14 – 175°F)
Signal
Trigger)
Relative Humidity 0% - 90%, Non-Condensing
Power Consumption 120/240 VAC, < 1A, 50/60 Hz.
ASR Temperature -10 – 85°C (14 – 185°F)

(Acoustic
Signal Relative Humidity 0% - 90%, Non-Condensing
Receiver) Min-Max Inlet Pressure
35 – 120 psi (2.4 – 8.3 bar)
(for each ASR)
Min-Max Usage (for
< 1 SCFM (0.5 L/s)
each ASR)
Air Filtration 0.01 Micron Particulate Coalescing
85 psi (5.9 bar), 5SCFM (2.6 L/s) @

Compressed Air
< 15% Duty Cycle
Air 2 gal (7.6 L) Quart Lubricator &

Microfog Lubricator
Preparation 5W30 Motor Oil
System ~500 mL (0.5 qt) per Month (for
Oil Consumption
(Regulator/ Lubricator and Mark III Air Amplifier)
Filters/Oiler)
Temperature 0 – 80°C (32 – 175°F)
Relative Humidity Water Wash OK
Min-Max Inlet Pressure 60 – 120 psi (4.1 – 8.3 bar)
Temperature -10 – 85°C (14 – 185F)

Microphones
Relative Humidity 0% - 90%, Non-Condensing
ASCO
Control Temperature 0 – 52°C (32 – 125°F)
Valve (on
Hose Plate Relative Humidity 0% - 95%, Non-Condensing
Assembly)
Table 2-1 – Equipment Specifications

2.4 Customer Requirements
Table 2-2 lists the materials to be supplied by the customer.

1 Power Feed per
Electric Power SPCW System 120/240 VAC
(1 system per boiler)
90 psi (6.2 bar), 5 SCFM (2.4
Compressed Air 1” Pipe to Air Filter
L/s)
3 Individually
3 Twisted Pair
Shielded/Twisted Belden 88103 (or equivalent)
Shielded Cable
Pairs
2 Individually
2 Twisted Pair
Shielded/Twisted Belden 88102 (or equivalent)
Shielded Cable
Pairs
Table 2-2 – Customer Requirements

3.0 ASG RECOMMENDED INSTALLATION
Topic Page
3.1 Planning ........................................................................................................... 3-2
3.2 Boiler Preparation (ASG) ................................................................................ 3-3
3.3 ASG Mounting and Installation ...................................................................... 3-4

3.1 Planning
The following should be reviewed by personnel prior to installation.
Confirm type of monitoring system to be installed:

■ Single path temperature system
■ Multi-path temperature system
■ Zone temperature system
Verify:
■ Clear line of site available between ASGs and ASRs to be installed
■ Line of sight will not exceed 100 feet (30.48 meters) A to B in open
furnace (< 70’ in narrow passages)
■ An atmosphere controlled room to house the SPCW System cabinet
■ Verify there is adequate clearance around obstructions
Personnel understand boiler type to be modified:
■ Tangent tube
■ Membrane tube
For mounting, availability of existing:
■ Access panels
■ Unused soot blower
Plan for:
■ Cutting access holes in boiler casing
■ Making boiler tube bends
■ Delivering plant air to system
■ Separate cable trays or conduit for data transmission lines
■ Individual electrical circuits for each electrical device installed
■ Compensating for boiler expansion of 6 to 8 inches (152 to 203 mm)
Fabrication of:
■ Buckstay bracket
■ Other suitable mounting
Availability of:
■ Cutting/drilling tools
■ Welding equipment
ASG Recommended Installation 3-2

3.2 Boiler Preparation (ASG)
This section provides instructions for preparing the boiler for ASG vertical
mounting. After selecting a location for mounting the ASG, an access port
needs to be made.
WARNING
FOLLOW YOUR PLANT SAFETY PRECAUTIONS AND GUIDELINES
FOR WORKING WITH THE BOILER.
3.2.1 With boiler offline, cut a 3.5 in. diameter (90 mm) hole in the lower
boiler casing.
3.2.2 Perform boiler tube bend procedure as necessary to allow the ASG
tube of 3.0 in. diameter (76 mm), to pass through to the centerline of
the water tube walls.
NOTE
The end of the 3.0 in. diameter (76 mm) ASG tube may be crushed
down to an oval to aid in installation. The 3.0 in. diameter (76 mm) may
be crushed to a minimum of 2.0 in. (50.80 mm). Contact Enertechnix
in this case.
3-3 ASG Recommended Installation

3.3 ASG Mounting and Installation
This section provides assembly instructions for the ASG. The ASG is shipped
partially disassembled, and when completely assembled it will weigh
170 lbs (77 kg). The following procedure contains numbers in parentheses ( ),
which refer to item numbers in Figures 3-1 and 3-2 below.
Figure 3-1 – ASG Installation Diagram

Figure 3-2 – ASG Installation Details
WARNING
FOLLOW YOUR PLANTS SAFETY PRECAUTIONS AND GUIDELINES
FOR WORKING WITH HEAVY COMPONENTS.
WARNING
ANTI-SEIZE COMPOUND IS FLAMMABLE AND TOXIC, DO NOT USE
NEAR OPEN FLAMES OR SPARKS. USE IN A WELL-VENTILATED
AREA.
WARNING
FOLLOW PLANT SAFETY PRECAUTIONS AND GUIDELINES FOR
WELDING PROCEDURES.

3.3.1 Install seal box (1) as shown in Detail A of Figure 3-2.
3.3.2 Weld stainless steel barrel end (2) to seal box (1). The end of the
stainless steel barrel must end at the water-wall center line of the
boiler.
3.3.3 Weld flange #1 (3) onto the other end of the stainless steel barrel.
3.3.4 Apply anti-seize compound to the threads of 4 flange bolts and

connect one end of the stainless steel flex hose (4), with a gasket, to
flange #1 (3) using the flange bolts, lock washers and nuts (5).
3.3.5 Position barrel assembly (6) and mounting bar (7) such that they
meet up with the other flange end of the stainless steel flex hose (4).
3.3.6 Slide onto the mounting bar a spring stop, spring, second spring and
second spring stop (8, 9) in the orientation as shown in Figure 3-1.
3.3.7 Weld location of mounting bar (7) to available boiler structure via the
end brackets (10).
3.3.8 Hang barrel assembly (6) from mounting bar (7) using the spring
hanger (11).

attach the barrel assembly (6) with a gasket to the flange end of the
stainless steel flex hose (4) using the flange bolts, lock washers and
nuts (5).
3.3.10 Cut barrel assembly (6) to length.
3.3.11 Hang ASG between the spring and spring stop pairs (8, 9) using 2
pins and 2 rollers (12, 13).
3.3.12 Place flange #2 (14) onto the end of the cut barrel assembly (6), roll
the ASG assembly (15) up to this flange, orient its holes so that they
match the ASG flange holes, and then weld it in place.
3.3.13 As an alternative method for aligning the flange holes (if flange #2
gets welded on prior to matching the ASG flange holes), the front
end of the ASG assembly (15) can be loosened and adjusted. First,
loosen the front barrel jam nuts (16) and front barrel nut retaining
bolts (17). Next, rotate the ASG barrel in order to align the ASG
flange holes to those of flange #2 (14). Lastly, retighten the barrel
nut retaining bolts (17) to a torque specification of 20 ft-lbs, then
retighten the jam nuts (16).

attach the ASG flange with a gasket to flange #2 (14) using the
flange bolts, lock washers and nuts (5).
3.3.15 With the location of the ASG assembly fixed, compress the springs
(8) on either side of the ASG mounting tabs (18) by 1/4 to 1/2" using
the spring stops (9). Drill a hole in the mounting bar through the bolt
hole opening in each spring stop, and then secure each spring stop
with a bolt, lock washer and nut (19).
Figure 3-3 – Completed ASG Installation (prior version)

4.0 SYSTEM SUB-COMPONENT INSTALLATION
Topic Page
4.1 Mark III Air Amplifier Mounting....................................................................... 4-2
4.2 Hose Plate Assembly Mounting ..................................................................... 4-3
4.3 Boiler Preparation (ASR)................................................................................. 4-5
4.4 ASR Mounting ................................................................................................ 4-11
4.5 AST Mounting ................................................................................................ 4-13
4.6 SPCW Enclosure Mounting .......................................................................... 4-14

4.1 Mark III Air Amplifier Mounting
The Mark III Air-Amplifier is designed to be mounted vertically and has two ½”
diameters through holes located in the base plate for fasteners.
WARNING
WORKING WITH HEAVY COMPONENTS. THE HOIST USED SHOULD
BE CAPABLE OF CARRYING OVER 200 LBS. (91 KG).
Mark III Air

Amplifier with
Cover Removed
Figure 4-1 – Mark III Air Amplifier Mounting
System Sub-Component Installation 4-2

4.2 Hose Plate Assembly Mounting
This section provides mounting instructions for the hose plate assembly. See
Figures 4-2 to 4-4 below.
Figure 4-2 – Hose Plate Assembly Mounting
4-3 System Sub-Component Installation

Figure 4-3 – Photo of Hose Plate
Figure 4-4 – Proximity Diagram

4.2.1 Identify an existing structure to which the hose plate assembly can be
mounted to. The assembly needs to be within close proximity of the
ASG per distance requirements shown in Figure 3-4 above. Position
hose plate assembly to the left or right of the existing support structure.
4.2.2 Measure and mark the assembly mounting hole locations onto existing
support structure.
4.2.3 Drill two 9/16” diameter holes through support.
4.2.4 Fasten support block of the assembly to the existing structure with
mounting bolts and lock washers as shown in Figure 3-2.
4.2.5 Set metering valve to the CLOSED position.
Figure 4-5 – Hose Plate Assembly
4.3 Boiler Preparation (ASR)
This section provides instructions for preparing the boiler for ASR mounting. The
following instructions refer to diagrams in Figures 3-6 to 3-11 below. After
selecting a location for mounting the ASR, an access port needs to be made.

NOTE
The following procedure assumes an existing opening in the boiler is not present.
WARNING
FOLLOW PLANT SAFETY PRECAUTIONS AND GUIDELINES FOR WORKING
WITH THE BOILER.
4.3.1 With boiler offline, cut a 2 inch diameter (51 mm) hole in the
boiler casing.
4.3.2 Drill two 0.5 inch diameter (13 mm) holes vertically on 0.5 inch centers in
the water wall membrane. File edges to create slot. See Membrane
Slot Detail in Figure 3-6 below.
Figure 4-6 – Membrane Slot Detail
WARNING
FOLLOW PLANT SAFETY PRECAUTIONS AND GUIDELINES
FOR WELDING PROCEDURES.

4.3.3 Attach 1 inch mounting pipe centered over slot in the membrane. Use
either a seal box, gussets, or a mounting plate (see Figures 4-7 to 4-11
below) to support the 1 inch mount pipe. Welds must be sufficient to
support over 100 lbs. (45 kg) of weight at this location.
Figure 4-7 – Membrane Tube Boiler, Negative Pressure Installation with Seal Box

Figure 4-8 – Membrane Tube Boiler, Negative Pressure Installation with Gussets

Figure 4-9 – Membrane Tube Boiler, Negative Pressure Installation with Mounting Plate
Figure 4-10 – Mounting Plate Detail

Figure 4-11 – Membrane Tube Boiler, Positive Pressure Installation

4.4 ASR Mounting
This section provides assembly and mounting instructions for the ASR. The
following procedure refers to Figures 3-7 to 3-11 above and 3-12 below.
Figure 4-12 – ASR Layout
NOTE
The ASR cabinet is completely assembled; no additional assembly is
required inside the cabinet.
WARNING
ANTI-SEIZE COMPOUND IS FLAMMABLE AND TOXIC, DO NOT
USE NEAR OPEN FLAMES OR SPARKS. USE IN A WELL-
VENTILATED AREA.

4.4.1 Apply anti-seize to the threads of the pipe set items and then attach
the pipe set and ASR to the 1 inch mount pipe.
4.4.2 Remove microphone from the ASR. With a tape measure, measure
from the slot in the water wall membrane to the end of the
microphone pipe mount. Then subtract approximately 0.5 inch (12
mm) for the distance beyond the compression fitting in the
microphone.
CAUTION
ASR listening tube is supplied as a four-foot
(1219 mm) section and must be cut to proper
length. The ASR listening tube must extend from
compression fitting in the microphone to the center
of the water wall membrane within a 1/4 inch.
4.4.3 Using a tube cutter, cut the ASR listening tube to the proper length.
Record its final this into the table provided in Section 7.0
Measurement length to 0.25 in. (6 mm) and record Verification.
4.4.4 Install the listening tube into the compression fitting and tighten.
Positioned correctly, it should end within 0.25 inch of the slot in the
membrane wall.
CAUTION
Be careful not to damage, bend or crimp ASR
listening tube.
4.4.5 Screw microphone back onto pipe mount in ASR.

4.5 AST Mounting
This section provides mounting instructions for the AST. The following
procedure refers to Figure 3-12 below.
NOTE
The AST cabinet is completely assembled; no additional assembly is required
inside the cabinet.
Figure 4-13 – AST Layout & Details

4.5.1 Select a location to mount the AST cabinet. Mount AST cabinet no more
than five feet from ASG connector (refer to Figure 3-4 Proximity
Diagram).
4.5.2 Position AST to railing, column, or other suitable support.
4.5.3 Mark AST mounting position by tracing the four 0.31 inch diameter
(8 mm) holes. Temporarily move AST aside.
4.5.4 Drill four 0.31 inch diameter (8 mm) holes through support.
4.5.5 Reposition AST aligning holes in AST to holes in support.
4.5.6 Bolt AST to support utilizing appropriately sized bolts, washers,

and nuts.
4.6 SPCW Enclosure Mounting
This section provides assembly and mounting instructions for the SPCW
enclosure. The following procedure refers to Figure 3-14.
NOTE
The majority of cabinet hardware was installed at the factory. Detailed
electrical connections are covered in Section 5.0 Electrical Connections.
CAUTION
The cabinet houses a microcomputer, please handle with care.

4.6.1 Install unistruts onto an available wall space in a convenient climate-
controlled room. Using the included hardware, mount the SPCW
enclosure onto the unistruts. It should be installed at a convenient
height for ease of access.
Figure 4-14 – SPCW Enclosure

5.0 PNEUMATICS, LUBRICATOR & LOW/HIGH PRESSURE
Topic Page
5.1 General ............................................................................................................. 5-2
5.2 Plant Air to Filter/Regulator/Lubricator ......................................................... 5-3
5.3 Air Preparation System to Air Amplifier ........................................................ 5-4
5.4 Air Amplifier to Solenoid Valve Block ........................................................... 5-5
5.5 Solenoid Valve to ASG .................................................................................... 5-6
5.6 ASG to AST ...................................................................................................... 5-6
5.7 Plant Air to ASR Purge Air Regulator ............................................................ 5-8

0.25 in. hose 0.19 in. hose
AST Boiler
Air Amp 0.25 in.

Filter hose
2 in.
0.5 in. hose Temperature
hose Path
ASG ASR
Plant
Air
Micro-Fog
Lubricator Solenoid
Block
Exhaust Air
e ASG Plant Air
Barrel
Purge
Solenoid Regulator
Figure 5-1 – Basic Pneumatic Block Diagram
5.1 General
This section provides instructions for making system pneumatic connections. The
following procedure contains numbers in parentheses ( ), which refer to item
numbers found in figures in this section. You will need to repeat some
procedures based on the number of listening paths installed.
CAUTION
• Do not deliver air to system until after all pneumatic and

electrical connections have been completed.
• Do not operate system without oil in lubricator.
Pneumatics, Lubricator & Low/High Pressure 5-2

5.2 Plant Air to Filter/Regulator/Lubricator
5.2.1 Set air regulator (1) to zero psi by adjusting pressure regulator control fully
counterclockwise.
5.2.2 Fill Lubricator with 5W-30 Motor Oil while unpressurized.
5.2.3 With zero air pressure in plant system, wrap fitting threads with Teflon
tape and connect plant air supply to the 0.5 in. (13 mm) NPTF inlet of air
regulator.
5.2.4 Adjust lubricator Allen screw for maximum drip rate.
Figure 5-2 – Plant Air to Air Preparation System to Air Amplifier
5-3 Pneumatics, Lubricator & Low/High Pressure

5.3 Air Preparation System to Air Amplifier
Figure 5-3 – Air Preparation System
Figure 5-4 – Installed Air System (prior version)

5.4 Air Amplifier to Solenoid Valve Block
5.4.1 Connect ½” Low Pressure Hose PN 030336 (3) from Air Filter to Air
Amplifier ½” JIC fitting.
5.4.2 Connect ¼” High Pressure Hose PN 030334 (4) from JIC fitting (5) outlet
on air amplifier to Hose Plate (6).
Figure 5-5 – Air Amplifier Connection Detail

5.5 Solenoid Valve to ASG
5.5.1 Remove bolts and flanges from solenoid valve block (1).
5.5.2 Remove bolts and flanges from ASG (2).
5.5.3 Apply anti-seize to threads of bolts.
5.5.4 Attach 90° elbow flange head of hose (3) to solenoid valve block (1) and
fasten with flanges, washers, bolts, and safety bolts with new lock wire.
5.5.5 Attach straight flange head of hose (3) to ASG and fasten with flanges,
washers, bolts, and safety bolts with lock wire.
1
3
Flanges, Bolts, Washers,

and Lock Wire
Flanges, Bolts, Washers, 2

and Lock Wire
Figure 5-6 – Hose Plate Assembly to ASG
5.6 ASG to AST
CAUTION
• Do not alter AST trigger hose (1). Length should be 72 in.

(1829 mm).
• Minimum bend radius for AST trigger hose (1) is 0.75 in.
(19 mm).

5.6.1 Attach AST trigger hose (1) to 3/16” JIC fitting at bottom AST cabinet (2),
and to 3/16” JIC fitting on Barrel (3). Attach Air Purge Hose 030335 (7)
from Air Filter to AST.
Figure 5-7 – ASG to AST

5.7 Plant Air to ASR Purge Air Regulator
5.7.1 Set air regulator (1) to zero PSI. Adjust fully counterclockwise. See Figure
5-8.
5.7.2 With zero air pressure in the plant system, wrap fitting threads with
Teflon tape and connect plant air supply to the 0.5 in. (13 mm) NPTF inlet
of the ASR (2).
Figure 5-8 – Plant Air to ASR Purge Regulator

6.0 ELECTRICAL CONNECTIONS
Topic Page
6.1 SPCW Cabinet.................................................................................................. 6-2
6.2 SPCW Connections ......................................................................................... 6-4
6.3 ASR Enclosure Connections ........................................................................ 6-10
6.4 AST Enclosure Connections ........................................................................ 6-11

6.1 SPCW Cabinet
This section provides instructions for the general electrical arrangement of the
SPCW Cabinet, ASR Enclosure and AST Enclosure. You will need to also refer
to the appropriate engineering drawings for exact cable wiring diagrams.
WARNING
WORKING WITH ELECTRICAL POWER.
CAUTION
Do not engage circuit breakers supplying electrical power to
system components until after all electrical connections have
been completed.
The SPCW cabinet/enclosure and its associated internal panels and components
are shown in Figures 6-1 and 6-2 below.
Electrical Connections 6-2

Figure 6-1 – SPCW Enclosure & Panels
6-3 Electrical Connections

Figure 6-2 – SPCW Panel & Component Layout
6.2 SPCW Connections
6.2.1 SPCW Factory Wiring
Figures 6-3 to 6-6 below illustrate the SPCW Panel connections and
individual wiring details. These connections should be checked to
verify that none have come loose during shipping.

Figure 6-3 – SPCW Panel Connections

(Figure 6.5)
Figure 6.4 – SPCW Panel Connection Detail

(Figure 6.4)
Figure 6-5 – SPCW Panel Connection Detail

Figure 6-6 – AST and ASR Connection Details to SPCW

6.2.2 Conduit Knockouts
SPCW Cabinets require knockout punches for electrical conduit

runs. Utilize an appropriately sized round knockout punch driver for
the size cable glands you will be installing.
• For SPCW, ASR and AST cabinets, install conduit from the
bottom of the cabinet.
6.2.3 SPCW Power
Connect a 120/240 VAC (15 AMP) rated power line to the SPCW
Cabinet as illustrated in Figures 5-2 and 5-4. Be sure that the SPCW
System is on an individual circuit, and that properly sized conduit is
used to protect the power line.
6.2.4 SPCW System Signals
Locate the proper terminal block locations as illustrated in Figure 5-3.

See Figures 5-5 and 5-6 for typical wiring diagrams. Refer to the
mechanical drawings at the end of this manual for specific details.
NOTES
1. All twisted pair cores include a drain wire, which must be
connected to the appropriate ground shield terminal for each
pair. Failure to do so will lead to system errors. See Figures 5-3
to 5-6 for typical wiring diagrams.
2. Each SPCW system panel provides 4-20 mA output channels
for use in the customers DCS system. These are powered, data
channels. See Figure 6-5 for output wiring terminations.
3.
CAUTION
Before installing output channels to the DCS system, remove
shorting resistor between terminals 1 and 2 of the appropriate
terminal block group. When output channels are not in use,
shortening resistors must be installed. Failure to do so will result in
errors in operation.
4. For channel-to-channel isolation, 4-20 mA isolation modules may

be used.

6.3 ASR Enclosure Connections
6.3.1 ASR Internal Wiring Connections
Figure 6-7 illustrates the ASR receiver enclosure wiring connections.
Figure 6-7 – ASR Wiring

6.4 AST Enclosure Connections
AST Internal Wiring Connections in Figure 6-8 illustrates the AST trigger
enclosure wiring connections.
Figure 6-8 – AST Wiring

7.0 MEASUREMENT VERIFICATION
Topic Page
7.1 General ............................................................................................................. 7-3
7.2 Measurements ................................................................................................. 7-4
7.3 Boiler Dimensions ........................................................................................... 7-5

Length Measurement Length Measurement
Component (Millimeter) Initials
(Inch)
ASG Barrel #
ASG Barrel #
ASG Barrel #
ASG Barrel #
AST Trigger Hose #

AST Trigger Hose #
AST Trigger Hose #
AST Trigger Hose #
ASR Listening Tube #

Table 7-1 – Barrel, Hose & Tube Measurements (offline)
Measurement Verification 7-2

7.1 General
This section provides for critical measurements to be taken, and recorded for
later entry into the systems software program.
Previous sections in this manual have referenced entering data into the table
provided in this section (Table 6-1); if measurements were not taken and
entered during those procedural steps, follow the instructions in this section for
taking the measurements and recording them.
NOTE
Copy Table 7-1 as needed to record additional tube measurement.
CAUTION
It is critical that length measurements be accurate. Measurements
deviating by a small amount from the actual lengths will result in
considerable errors during system operation.
Measurements must be accurate within ± 0.25 in. (6 mm) of actual
lengths for proper system operation.
7-3 Measurement Verification

7.2 Measurements
This section refers to Figure 6-1 below.
7.2.1 Measure length of all ASG barrels, from the 3/16” JIC fitting to the
end of SST barrel end, and record data in Table 6-1. This is
Measurement 1 in Figure 7-1.
7.2.2 Measure length of all AST trigger hoses and record the data in Table
7-1. This is Measurement 2 in Figure 7-1.
7.2.3 Measure length of all ASR listening tubes per instructions in Section
3.4, page 3-12 and record data in Table 7-1. This is Measurement 3
in Figure 7-1.
Figure 7-1 – Measurements

7.3 Boiler Dimensions
With the boiler offline, and working from inside the boiler, perform the following.
7.3.1 Establish an X, Y coordinate system inside the boiler. See the

example in Figures 7-2 and 7-3.
NOTE
Figure 7-2 illustrates complex temperature paths in a zone
configuration. Your application may be a single, multiple, or
staggered arrangement.
Figure 7-2 – Boiler Measurements

7.3.2 Utilizing Figure 7-2, sketch and record the following.
NOTE
Copy Figure 7-2 as needed for additional boiler installations.
7.3.2.1 Boiler length.
7.3.2.2 Boiler width.
7.3.2.3 Location dimension for ASGs in the X axis.
7.3.2.4 Location dimension for ASGs in the Y axis.
7.3.2.5 Location dimensions for ASGs in the Z axis (elevation).
7.3.2.6 Location dimensions for ASRs in the X axis.
7.3.2.7 Location dimensions for ASRs in the Y axis.
7.3.2.8 Location dimensions for ASRs in the Z axis (elevation).
CAUTION
Accurately determining boiler dimensions,
locations of ASGs, and locations of ASRs is
critical to system operation.
CAUTION
The following procedure is to be
accomplished by Enertechnix personnel.
7.3.2.9 Enter all dimensional data taken in steps 7.3.2.1 through

7.3.2.4 into the Enertechnix spreadsheet, which will calculate
the path lengths for the systems setup.ini file.
NOTE
Enertechnix personnel will enter the data into the
Enertechnix spreadsheet, make boiler online (full load)
measurements and adjustments, and input data
into the systems setup.ini file.

Figure 7-3 – Boiler Layout

8.0 SYSTEM POWER ON/OFF
Topic Page
8.1 General ............................................................................................................. 8-2
8.2 Power ON ......................................................................................................... 8-2
8.3 Power OFF........................................................................................................ 8-3

8.1 General
This section describes powering ON and powering OFF the PyroMetrix

System. Review the following checklist before proceeding with system
power up.
■ All mechanical mounts are secure

■ All pneumatic connections are complete and tight
■ Lubricator is filled with 5w-30 motor oil
■ All electrical connections have been properly installed
■ Update of the setup.ini file is complete and accurate
■ Outputs to DCS are connected (may require 4-20 mA isolation
modules).
8.2 Power ON
8.2.1 Air Supply
WARNING
WHEN WORKING WITH COMPRESSED AIR, WEAR EYE
AND FACE PROTECTION. TAKE PRECAUTIONS TO AVOID
INJURY TO OTHER PERSONNEL IN THE AREA.
8.2.1.1 Deliver clean, dry, oil free air to the systems main air
regulator. Minimum 85 psi at 5 scfm (5.86 bar).
8.2.1.2 Adjust metering valve on solenoid valve/hose plate to the

closed position.
8.2.1.3 Adjust main air regulator between 80 and 100 psi (5.51 to
6.89 bar).
NOTE
Final pressure needs to get entered into the
setup file.
8.2.1.4 Adjust air amplifier regulator using pressure gauge on AST

such that the signal to noise ratio is at least 2 to 1 (range
between 250 and 500 psi [17.23 to 34.47 bar]). The seals
last longer using lower pressure.
8.2.1.5 Adjust ASR purge regulators to 50 psi (3.44 bar).
8.2.1.6 Set ASR purge timers for 5 seconds on every 5 minutes.
System Power ON/OFF 8-2

8.2.1.7 Set microphone flow meter to ~5 SCFH.
8.2.2 Electrical Supply
8.2.2.1 Engage circuit breakers delivering 120/240 VAC power to

SPCW Enclosure.
8.2.2.2 Engage circuit breakers delivering 120/240 VAC power to

ASTs and ASRs.
8.2.3 Microcomputers
8.2.3.1 Inside SPCW enclosure, toggle all microcomputer

power switches to ON.
8.2.3.2 Engage circuit breaker for SPCW electronics.
8.2.3.3 The Time of Flight (TOF) program will begin to run. See
Section 8.0 PyroMetrix Software User Guide for detailed
software operating instructions.
8.3 Power OFF
The PyroMetrix System should be powered off in three steps:
8.3.1 Disengage circuit breaker for SPCW electronics. This will prevent
ASGs from firing electronically.
8.3.2 Adjust the main air regulator to zero psi or shut off air supply valve.
8.3.3 After powering OFF the system, bleed the stored air from ASGs by
adjusting the metering valve on hose plate assembly to the open
position. (Close after pressure is released)
NOTE
Bleeding the stored air from the ASG keeps the internal piston
closed, keeping unit free of ash, and unable to fire accidentally!
WARNING
WHEN WORKING WITH COMPRESSED AIR, WEAR EYE AND
FACE PROTECTION. TAKE PRECAUTIONS TO AVOID INJURY
TO OTHER PERSONNEL IN THE AREA.
8-3 System Power ON/OFF

9.0 PERIODIC MAINTENANCE AND REPAIR
Topic Page
9.1 General ............................................................................................................. 9-2
9.2 Routine Care Schedule ................................................................................... 9-2
9.3 Microphone Replacement ............................................................................... 9-3
9.4 Removing ASG from Service .......................................................................... 9-6
9.5 Disassembly of ASG ....................................................................................... 9-8
9.6 Seal Removal per Seal Kit ............................................................................ 9-12
9.7 Cleaning ......................................................................................................... 9-14
9.8 Seal Replacement .......................................................................................... 9-16
9.9 ASG Assembly ............................................................................................... 9-19
9.10 Returning ASG to Service ............................................................................. 9-21
9.11 Air System Maintenance ............................................................................... 9-21

9.0 PERIODIC MAINTENANCE AND REPAIR
Topic Page
9.1 General ............................................................................................................. 9-2
9.2 Routine Care Schedule ................................................................................... 9-2
9.3 Microphone Replacement ............................................................................... 9-3
9.4 Removing ASG from Service .......................................................................... 9-6
9.5 Disassembly of ASG ....................................................................................... 9-8
9.6 Seal Removal per Seal Kit ............................................................................ 9-12
9.7 Cleaning ......................................................................................................... 9-14
9.8 Seal Replacement .......................................................................................... 9-16
9.9 ASG Assembly ............................................................................................... 9-19
9.10 Returning ASG to Service ............................................................................. 9-21
9.11 Air System Maintenance ............................................................................... 9-21

9.1 General
This section provides for the care of your PyroMetrixTM system. Please follow
the recommended replacement schedules and repair instructions for your
PyroMetrixTM system.
If a problem persists and cannot be resolved by use of this section, please

contact Enertechnix for assistance.
CAUTION: Do not operate system without oil; seal life is greatly reduced.
9.2 Routine Care Schedule
Pneumatic System Scheduled Task

Check sight glass ~once/year and refill as
Lubricator Oil (5W-30 Motor Oil)
needed
Replace if Differential Pressure (D.P.) Gauge
Air Filter Element
is yellow or red (see Figure 9-1)
Air Amplifier Rebuild Every 12 months
Rebuild Every 12 Months

ASG Unit
(every 100,000 discharge cycles)
Control Valve Rebuild Every 12 Months
Regulator Inspect every 12 Months
Computer System Scheduled Task

Not applicable unless changes to boiler or
Validlog.txt
ASG are made.
Manually fire all paths every 6 months.
ASG System
(Menu items #6 and #9).
Table 9-1 – Routine Care Schedule
Figure 9-1 – Differential Pressure Gauge
Periodic Maintenance and Repair 9-2

9.3 Microphone Replacement
The following instructions contain item numbers in parentheses ( ), which refer

to item numbers in Figures 9-2 and 9-3.
9.3.1 Removal
9.3.1.1 Turn OFF 12 VDC power to the microphones in the SPCW

cabinet. Pull fuse or breaker.
9.3.1.2 Open ASR/AST cabinet door.
9.3.1.3 For ASR/AST cabinets, remove elbow (4) from microphone (3).
9.3.1.4 Remove 12-volt connector (2).
9.3.1.5 Remove BNC connector (1).
9.3.1.6 Unscrew microphone from pipe mount (7).
9.3.1.7 For ASR cabinets, using a wrench, remove listening tube from
compression fitting (5). Be careful not to damage the listening
tube. Using socket wrench, remove compression fitting (5).
Replace microphone and reassemble.
9.3.1.8 For AST cabinets, remove 1/8” pipe plug (8) from base of
microphone. Replace microphone and reassemble.
Figure 9-2 – ASR Microphone Replacement
9-3 Periodic Maintenance and Repair

Figure 9-3 – AST Microphone Replacement

9.3.2 Installation
The following instructions refer to item numbers in Figures 9-2 and

9-3.
WARNING
ANTI-SEIZE COMPOUND IS FLAMMABLE AND TOXIC, DO NOT
USE NEAR OPEN FLAMES OR SPARKS. USE IN A WELL-
VENTILATED AREA.
9.3.2.1 Apply Teflon tape compound to the threads of pipe mount (7).
9.3.2.2 For ASR cabinets, using a socket wrench, install compression

fitting (5) and listening tube (6) into base of microphone (3). Be
careful not to over tighten or damage listening tube.
9.3.2.3 For AST cabinets, reinstall 1/8” pipe plug (8).
9.3.2.4 Install microphone on pipe mount (7). For ASR cabinets, be

sure listening tube is properly positioned through the boiler
casing.
9.3.2.5 Reinstall BNC connector (1).
9.3.2.6 Reinstall 12-volt connector (2).
9.3.2.7 For AST & ASR cabinets, reinstall elbow (4).
9.3.2.8 Close and secure ASR/AST cabinet door.
9.3.2.9 Reapply power to system to bring system back online.

9.4 Removing ASG from Service
9.4.1 Remove ASG from service
The following instructions contain item numbers in parentheses ( ),

which refer to item numbers in Figure 9-4 below.
Figure 9-4 – Remove ASG from Service
WARNING
FOLLOW PLANT SAFETY PRECAUTIONS AND GUIDELINES
FOR WORKING WITH HEAVY COMPONENTS.

9.4.1.1 Turn OFF power and air supply to system.
9.4.1.2 Open metering valve on solenoid/valve plate to bleed off stored

air.
WARNING
DO NOT PROCEED UNTIL AIR FLOW FROM THE BLEED
VALVE HAS STOPPED. INJURY COULD RESULT FROM
THE RELEASE OF HIGH PRESSURE AIR.
9.4.1.3 Remove safety wire, bolts, flanges, and straight flange head
end of hydraulic hose (21) from back of ASG.
9.4.1.4 Remove bolts, washers and nuts from flange #2 (14).
9.4.1.5 Remove hardware from ASG spring stops (8, 9) and pins (12).
WARNING
ASG WEIGHT IS 160 LBS (73 KG). GET HELP TO LIFT.
9.4.1.6 Remove ASG and transport to workshop.
9.4.1.7 Change O-rings & seals (use Seal Kit).

9.5 Disassembly of ASG
9.5.1 Rear components

which refer to item numbers in Figure 9-5.
9.5.1.1 With the rear hanger (1) still fastened to the ASG via barrel nut
retaining bolts and jam nuts (3), use it as a tool to loosen the
rear outer nut (2) by rotating it counterclockwise. Remove
assembly (4).
Figure 9-5 – ASG Cutaway

9.5.2 Piston removal
NOTE
This assembly is tack welded. Do not disassemble unless O-

ring (8) is leaking. Use soap bubbles to test for leaks.

9.5.2.1 Remove the front flange (1).
9.5.2.2 Remove the throat (2).
9.5.2.3 Remove the pressure can (3).
9.5.2.4 Then pull out the piston (4).
9.5.2.5 Clean and replace seals (use Seal Kit A30754).

9.5.3 Rear subassembly

9.5.3.1 Disassemble rear subassembly consisting of inlet nut (5), small

barrel (6), and rear insert (7) by unscrewing and separating the
components.
9.5.3.2 Using an O-ring pick, remove and discard O-ring (8).
9.5.4 Front Components

9.5.4.1 With the front hanger (6) still fastened to the ASG, use it as a
tool to loosen the front outer nut (7) by rotating it
counterclockwise. Remove assembly.
9.5.4.2 Remove outlet weldment (5).
9.5.4.3 Remove throat (4).
9.5.4.4 Using an O-ring pick, remove O-ring (3) from throat (4),
and discard.
9.5.4.5 Pull center seal can (2) from large barrel (1).
1 2 3 4 5 6
Figure 9-7 – ASG Disassembly (Front)

ASG Piston
Alignment Mark
4
5 10
6
7
3
8
2
9
1
15
12
14
13
11
Figure 9-8 – Seal Removal

9.6 Seal Removal per Seal Kit
9.6.1 Front seals

9.6.1.1 Remove cotter pin (10).
9.6.1.2 Using a box wrench, remove castle nut (9).
9.6.1.3 Remove piston washer (8).
9.6.1.4 Remove delrin piston assembly (5). Delrin piston assembly (5)
consists of:
■ O-ring (6) seated in groove of delrin piston, with Piston ring
(7) over top of O-ring (6). Components can be removed by
using an O-ring pick.
9.6.1.5 Using an O-ring pick, remove shaft O-ring (4).
9.6.2 Center seals

9.6.2.1 Using an O-ring pick, remove step-cut wear ring (11).
CAUTION
Inspect center O-ring (12) carefully. Only replace
center O-ring (12) if damage has occurred.
CAUTION
The following procedure should be accomplished by a
qualified machinist to preserve integrity of components.

9.6.2.2 Draw an alignment mark across components with a making pen
as illustrated in Figure 9-8.
CAUTION
Setscrew (15) has been peened at the factory. Peening must
be carefully removed before setscrew (15) can be extracted.
CAUTION
If setscrew (15) must be drilled out, use a 0.20 in. (5.16 mm)
drill bit. Drilling out setscrew (15) can result in damage to
threads. If threads become damaged it will be necessary to
tap to the next size.
9.6.2.3 Unscrew and remove setscrew (15).
9.6.2.4 Using a spanner wrench unscrew and remove piston locking

ring (14).
9.6.2.5 Using an O-ring pick, remove center piston O-ring (12).
9.6.2.6 Using a spanner wrench, remove center piston O-ring retainer

(13).
9.6.3 Rear seals

9.6.3.1 Using an O-ring pick, remove piston ring (1).

■ Piston ring (1) is seated over top of O-ring (2).
9.6.3.2 Using an O-ring pick, remove O-ring 2.
9.6.3.3 Using an O-ring pick, remove wear ring (3).

9.7 Cleaning
WARNING
CLEANING SOLVENTS ARE FLAMMABLE AND TOXIC, DO NOT USE
NEAR OPEN FLAMES OR SPARKS. USE IN A WELL-VENTILATED AREA.
9.7.1 Steel components
Clean all steel components with a solvent that is compatible with

steel. Remove all ash deposits or other contaminants that may have
entered the ASG components.
9.7.1.1 Inspect all sealing surfaces for nicks or burrs. Note that the
cylinder surfaces are chrome plated.
9.7.1.2 Significant scratches or nicks will require component

replacement. Do not attempt to polish or grind.
9.7.2 Aluminum components (Piston)

WARNING
THE ASG PISTON IS MADE OF ALUMINUM. USE ONLY
SOLVENTS COMPATIBLE WITH ALUMINUM.
9.7.2.1 Thoroughly clean piston surface and seal grooves with a solvent
that is compatible with aluminum.
9.7.2.2 Inspect piston for damage.
CAUTION
Minor repair to piston including, polishing down
burrs or nicks is permissible. Damage beyond that
indicated requires replacement of piston.
NOTE
Do not wash off alignment mark.

ASG Piston
Alignment Mark
4
5 10
6
7
3
8
2
9
1
15
12
14
13
11
Figure 9-9 – Seal Replacement

9.8 Seal Replacement
9.8.1 Center seals

9.8.1.1 Apply Teflon grease to new center piston O-ring (12).
9.8.1.2 Install new center piston O-ring (12) over piston shaft and seat
into groove.
9.8.1.3 Install center piston O-ring retainer (13) over piston shaft and
tighten with spanner wrench to previous alignment mark.
9.8.1.4 Install piston locking ring (14) over piston shaft and tighten with
spanner wrench to previous alignment mark.
9.8.1.5 Using the alignment mark made in step 9.6.2.2, align setscrew
hole in piston locking ring with tapped hole in piston.
9.8.1.6 Install new setscrew (15) setting head below surface of piston
locking ring (14).
9.8.1.7 Peen setscrew to freeze it.
9.8.1.8 Install new wear ring (11) into .509 in. (13 mm) wide groove.
9.8.2 Rear seals

9.8.2.1 Install new wear ring (3) into .385 in. (10 mm) wide groove.
9.8.2.2 Apply Teflon grease to new O-ring (2).
9.8.2.3 Install new O-ring (2) into .130 in. (3 mm) groove.
■ O-ring is used as a backup ring.
WARNING
BOILING WATER CAN CAUSE SEVERE BURNS.
WEAR PROTECTIVE GLASSES AND GLOVES WHEN
WORKING WITH HOT WATER.

9.8.2.4 Heat new piston ring (1) in boiling water 212°F (100° C) for 5
minutes.
9.8.2.5 Install piston ring (1) over top of O-ring (2).
9.8.2.6 Seat piston ring into .130 in. (3 mm) groove.
9.8.2.7 Using oil or grease on Rear Subassembly, carefully press piston

into cylinder (9.5.3) to seat new piston ring. Allow to cool for
several minutes before removing.
9.8.3 Front seals

9.8.3.1 Apply Teflon grease to new O-ring (4).
9.8.3.2 Install new O-ring (4) into 0.19 in. (5 mm) wide groove.
WARNING
BOILING WATER CAN CAUSE SEVERE BURNS.
WEAR PROTECTIVE GLASSES AND GLOVES
WHEN WORKING WITH HOT WATER.
9.8.3.3 Heat new piston ring (7) in boiling water 212°F (100° C) for 5
minutes.
9.8.3.4 Apply Teflon grease to new O-Ring (6).
9.8.3.5 Install new O-ring (6) onto groove of delrin piston (5).
■ O-ring is used as a backup ring

9.8.3.6 Install new piston ring (7) over top of O-ring (6).
9.8.3.7 Using oil or grease, carefully press delrin piston assembly into
throat (9.5.2.2) to seat new piston ring. Allow to cool for several
minutes before removing.
9.8.3.8 Install delrin piston assembly on piston shaft.
9.8.3.9 Install new front piston washer (8).
9.8.3.10 Install castle nut (9).
9.8.3.11 Using a box wrench, tighten castle nut until cotter pin hole is
visible.
9.8.3.12 Install new cotter pin (10) and bend ends back.

9.9 ASG Assembly
9.9.1 Front components

1 2 3 4 5 6
Figure 9-10 – Front Component Assembly
9.9.1.1 Apply marine grease to outer surface of center seal can (2) to
prevent rust.
9.9.1.2 Push center seal can (2) into large barrel (1) until seated.
9.9.1.3 Apply Teflon grease to new O-ring (3) and install in 0.19 in. (5
mm) wide groove in throat (4).
9.9.1.4 Install throat (4) into center seal can (2) until seated.
WARNING
ANTI-SEIZE COMPOUND IS FLAMMABLE AND
TOXIC, DO NOT USE NEAR OPEN FLAMES OR
SPARKS. USE IN A WELL-VENTILATED AREA.
9.9.1.5 Apply anti-seize to threads of large barrel (1), and front outer
nut (7).
9.9.1.6 Install outlet weldment (5) to throat (4).
9.9.1.7 Capture installed components with front outer nut (7).
9.9.1.8 Using front hanger (6) as a tool, tighten front outer nut (7).

9.9.2 Piston installation

9.9.2.1 Insert piston (6) into large barrel (3).
9.9.2.2 Applying steady pressure, push piston (6) in until delrin piston
(5) is fully seated into throat (4).
9.9.2.3 Applying steady pressure, push subassembly (7) over end of

piston (6) until fully seated against large barrel (3).
WARNING
ANTI-SEIZE COMPOUND IS FLAMMABLE AND
TOXIC, DO NOT USE NEAR OPEN FLAMES OR
SPARKS. USE IN A WELL-VENTILATED AREA.
9.9.2.4 Apply anti-seize to threads of large barrel (3) and threads of

rear outer nut (1).
9.9.2.5 Using rear hanger (2) as a tool, install rear outer nut (1) to large
barrel (3). Tighten rear outer nut (1).

9.10 Returning ASG to Service
To return the ASG to service, please follow the installation instructions in

Section 3.0 ASG Recommended Installation.
9.11 Air System Maintenance
WARNING
WHEN WORKING WITH THE AIR SYSTEM, TURN OFF COMPRESSORS
AND BLEED OFF STORED AIR BEFORE ATTEMPTING ANY SERVICE TO
THE SYSTEM OR COMPONENTS.
9.11.1 Hoses
Even with proper installation, hose life may be significantly reduced

without a continuing maintenance program. Frequency of
maintenance inspections should be determined by the severity of the
application and risk potential.
A maintenance program, at a minimum, must include visual

inspections for the following:
■ Fitting slippage
■ Damaged, cut or abraded covers
■ Hard, stiff, cracked or charred hose
■ Cracked, damaged or corroded fittings
■ Kinked, twisted, crushed or flattened hose
■ Blistered, soft or degraded hose
Any of the above conditions requires immediate shut down of system

and repair or replacement of the hose assembly as required.

9.11.2 Routine Maintenance
The following scheduled preventative maintenance checks should be done

monthly to insure continuous trouble free operation.
10.12.1.1 Air Preparation System – Check oil level and quality in

lubricator.
10.12.1.2 Check air lines for water and drain if necessary.
9.11.3 Service Maintenance
The Mark III air-amplifier is designed to operate continuously at an output

pressure between 250 psig and 500 psig for a period of approximately 6
months before scheduled maintenance is required.
CAUTION
Operating the air amplifier without oil will significantly reduce the life
of the air amplifier and ASG seals.
Operating the air amplifier at pressures above 300psi may reduce the life
of the high pressure seals requiring an increase in scheduled
maintenance. When seal replacement is necessary refer to the photos and
instructions below.
MARK III Shaft Assembly with High Pressure Piston installed

4-Way Control Valve showing Hose Clamp on Pilot Section

• Remove shaft assembly from MARK III air amplifier.
• Remove nuts from both ends and slide off pistons, o-rings and spacers.
• HIGH PRESSURE PISTON SEAL REPLACEMENT
Layout High Pressure Piston Parts Install O-ring using Lubrication
Press Piston Ring over O-ring Install Piston seal section and nut

• LOW PRESSURE PISTON SEAL REPLACEMENT
(NOTE: It is not necessary to disassemble bronze/aluminum/magnet assemblies)
Bronze/Magnet Assembly Install Piston seal section
Install o-ring between piston halves Install Piston Seal and Wear Band sections

Install Bronze/Magnet and tighten nut to complete assembly
NOTE: To reinstall piston assembly in MARK III be sure to use a light coat of oil on
seals. Always use lubrication on o-rings and seals for installation of new parts to prevent
scratching or cutting when inserting into cylinders and over threads.

• MARK III SEAL KITS
Component
Enertechnix Part
Part Numbers
Number Required Quantity Service Manual Description
A31048 Shaft Assembly Seal Kit
O-ring, Back-up, High Pressure Piston, Viton V-
031046 1 75/129
031250 1 SL Bearing, Low Pressure, 5"
O-ring, Back-up, Low Pressure Piston, Viton, V-
031202 1 75/157
031267 1 SL Bearing, High Pressure, 2"
031282 1 Low Pressure Piston Ring, 5", PTFE
031290 1 High Pressure Piston Ring, 2”, PTFE
031317 1 Low Pressure Piston to Shaft seal O-ring, Viton 2-016
031318 1 High pressure Piston to Shaft seal O-ring, Viton 2-014
031307 1 Nut, Stover, ½-20 NF
031306 1 Nut, Stover, 5/8-18 NF
A31050 Check Valve Assembly

Check valve, SS303, 10 PSI cracking pressure, Viton
033350 2 Seals
031294 4 O-ring V-014, Viton, for Check Valve Retainer
031297 2 Ring, Internal Locking, SST
A31051 Cylinder Seal Kit

High pressure cylinder to high pressure end cap, O-
031302 2 Ring, 2-031, Viton
031314 1 High pressure connector O-ring, Viton-906
Low pressure cylinder to low pressure end caps, O-
031291 2 ring, 2-048, Viton

Figure 9-12 – Mark III Air Amplifier

Check supply air.
No air supply to pump.
Pump will not cycle. No Check Lubricator Oil
pressure at output. Pump air regulator set
Increase air setting.
too low.
Disconnect and reconnect air supply to re-
set air spool valve (1) to end position.
Four-way air Manually push spool (1) to far end using

Pump will not cycle probe through access hole. If spool remains
reciprocating valve
with regulated pressure trapped or requires excessive force,
spool (1) is trapped in
at output. disassemble the air valve assembly and
center position.
inspect for contamination or mechanical
binding. Repair or replace as necessary.
Lubricate seals with waterproof grease.
Pump makes one cycle Faulty 4-way air valve. Repair or replace.
and stops. (Broken, leaks or is
contaminated)
External leak at pump or Verify and correct.
downstream high-
pressure circuit.
Pump cycles continuously
Check valve is trapped Clean or replace.
when deadheaded.
open or contaminated.
Internal leak in pump. Check all dynamic and static seals, check
valves and gaskets.
Table 9-2 – Air Amplifier Troubleshooting

9.11.4 Air Preparation System
The following instruction refers to Figure 9-13.
The air preparation system consists of an air regulator, air filter,

coalescing filter and lubricator. These should be inspected every six
months. The filters should be replaced during inspection.
CAUTION: DO NOT OPERATE SYSTEM WITHOUT OIL. Adjust oil

drops using see-through dome for one drop per air amp stroke.
General maintenance should include inspection, cleaning, and

lubricating O-rings with waterproof grease. Plastic elements can be
cleaned in warm water. Internal components can be cleaned by
blowing them out with low-pressure compressed air.
If unit leaks air, or internal components appear worn, the

components should be replaced. The unit can be disassembled for
servicing without removing it from line.
Figure 9-13 – Air Preparation System

9.11.5 Solenoid Valve
The following instruction refers to Figure 9-14 below.
The solenoid valve should be cleaned periodically. The time

between cleanings will vary depending on operating conditions.
If voltage to the coil is correct and valve operation is sluggish, or
there is excessive noise or leakage, this will indicate that cleaning
is required.
General maintenance should include inspection, cleaning, and

lubricating O-rings with waterproof grease. The internal
passageways should be cleaned by blowing them out with low-
pressure compressed air.
If unit leaks air, or internal components appear worn, the

components should be replaced. The unit can be disassembled
for servicing without removing it from line. Depressurize before
disassembly.
The following rebuild kit is also available:
■ 033353 Norgren Solenoid Rebuild Kit
Solenoid Valve
Figure 9-14 – Solenoid Valve on Hose Plate Assembly

10.0 REPLACEMENT PARTS AND REPAIR KITS
Topic Page
10.1 General……………………………………………………………………………..10-2
10.2 Acoustic Signal Generator……………………………………………………...10-3
10.3 Acoustic Signal Trigger………………………………………………………….10-4
10.4 Acoustic Signal Receiver (Internal Components)…………………………..10-5
10.5 Acoustic Signal Receiver (External Components)………………………….10-6
10.6 Mark III Air Amplifier……………………………………………………………...10-7
10.7 Air Preparation System…………………………………………………………10-11
10.8 Hose Plate Assembly……………………………………………………………10-12
10.9 SPCW Cabinet…………………………………………………………………....10-13
10.10 Hose Assemblies……………………………………………………………......10-15
10.11 Recommended Spare Parts…………………………………………………...10-17

10.1 General
Key replacement parts and/or repair kits are provided for each major
component of the PyroMetrix system:
■ Acoustic Signal Generator (ASG)

■ Acoustic Signal Trigger (AST)
■ Acoustic Signal Receiver (ASR)
■ Mark III Air Amplifier
■ Hose Plate Assembly
■ Signal Processing Computer (SPCW)
■ Hose Assemblies
Replacement parts for sub-assemblies of these major components appear in

the same section as the major component.
Figure 10-1 – PyroMetrixTM System
Replacement Parts and Repair Kits 10-2

10.2 Acoustic Signal Generator
Figure 10-2 – Acoustic Signal Generator Seal Kit
10-3 Replacement Parts and Repair Kits

10.3 Acoustic Signal Trigger
Figure 10-3 – Acoustic Signal Trigger Enclosure with Interior Views
Item Part Number Description

1 A30108 Microphone Assembly
2 030256 Connector, BNC Cable Assembly
3 030205 DC Power Cable Assembly
4 030911 Fuse, 1 Amp, Slow Blow
5 030202 Solid State Relay
Table 10-1 – Typical AST Replacement Parts

10.4 Acoustic Signal Receiver (Internal Components)
Figure 10-4 – Acoustic Signal Receiver Enclosure with Interior Views

1 A30108 Microphone Assembly
2 030256 Connector, BNC Cable Assembly
3 030205 DC Power Cable Assembly
4 030666 2-Pole Circuit Breaker
5 002396 Timer
Table 10-2 – Typical ASR Internal Replacement Parts

10.5 Acoustic Signal Receiver (External Components)
Figure 10-5 – ASR External Components

1 031327 ASR Purge Solenoid Valve
Table 10-3 – Typical ASR External Replacement Part

10.6 Mark III Air Amplifier
160 PSI
REGULATOR
Figure 10-6 – Mark III Air Amplifier

1 A31050 Mark III Check Valve Kit
2 A31048 Mark III Shaft Seal Kit
3 A31051 Mark III Cylinder Seal Kit
Table 10-4 – Mark III Air Amplifier Repair Kits

Figure 10-7 –Mark III Check Valve Kit

Figure 10-8 –Mark III Shaft Seal Kit

Figure 10-9 –Mark III Cylinder Seal Kit

10.7 Air Preparation System
Figure 10-10 – Air Preparation System Components

1 002823 Air Filter Element (5 um, inside)
2 002824 Coalescing Filter Element (inside)
Table 10-5 – Air Preparation System Typical Replacement Parts

10.8 Hose Plate Assembly
Muffler
1, 2
`
Hose Plate
3, 4
Figure 10-11 – Hose Plate Assembly Components

1 Depends on Norgren Solenoid Valve
Voltage and
2 033353 Norgren Solenoid Rebuild Kit
3 033478 0-600 psi Pressure Gauge
4 033487 Mini Ball Valve, 1/8” NPT
5 031325 Fine Metering Valve
Table 10-6 – Hose Plate Assembly Typical Replacement Parts

10.9 SPCW Cabinet
Figure 10-12 – SPCW Enclosure showing Interior Views

1 030666 6 Amp Circuit Breaker
2 030911 1 Amp Fuse
Table 10-7 – Typical SPCW Replacement Parts

10.10 Hose Assemblies
Figure 10-13 – Hoses

1 033612 2 ½” x 16 ½” Flanged SST Flex Hose
2 030505 1 ¼” x 45” High Pressure ASG Hose
3 030338 3/16” x 6’ Braided SST AST Trigger Hose
4 030334 ¼” x 6’ Braided SST High Pressure Hose
5 030336 ½” x 6’ Low Pressure Rubber Hose
6 A31054 ¼” x 10’ Low Pressure Air Purge Hose
Table 10-8 – Hose Assembly Part Numbers

10.11 Recommended Spare Parts
(See Section 9.2 for Recommended Maintenance Intervals)
Part Recommended #
Component Description
Number Spares
ASG A30754 ASG Rebuild Kit 1
A30108 Microphone Assembly 1
ASR
031327 ASR Purge Solenoid Valve 1
Hose Plate Depends on

Assembly Voltage & High Pressure Solenoid Valve 0
Frequency
High Pressure Solenoid Valve 1
033353
Rebuild Kit
030374 Muffler 0
Air Amplifier A31051 Air Amplifier Cylinder Seal Kit 1
A31048 Air Amplifier Shaft Seal Kit 1
A31050 Air Amplifier Check Valve Kit 1
Air Filters 033702 Air Filter (0.01 um) Filter Element 1

AST 030202 AST Solids State Relay 0
SPCW 030911 Fuse, 1A, Slow Blow 1
Table 10-9– Recommended Spare Parts

11.0 APPENDIX A
PYROMETRIX ACOUSTIC PYROMETER 106 SYSTEM FAULT

ISOLATION AND TROUBLESHOOTING MANUAL
Topic Page
11.1 General ........................................................................................................... 11-2
11.2 Hardware Troubleshooting ........................................................................... 11-2
11.3 Troubleshooting Charts ................................................................................ 11-5
11.4 General Signal Processing Troubleshooting ............................................ 11-12
11.5 Software Diagnostics .................................................................................. 11-15

11.1 General
This section provides troubleshooting and fault isolation procedures for the
PyroMetrix System. If a problem persists and cannot be resolved by use of this
section, please contact the agent in your region for assistance.
11.2 Hardware Troubleshooting

Hardware Problem Solution
Generator will not charge fully. Mark Cycle system through several acquisitions. Check
III Air Amplifier pumps continuously. trigger signal (AST) for sharp leading edge AS
SHOWN BELOW. (A weak Trigger Signal can be
caused by firing ASG at low pressures.
Check Supply Air and Filter Regulator for inlet

pressure 50 to 80 psi. The Mark III Air Amplifier will
multiply the inlet air by approximately 6.25. Check Air
Filter for Element Differential Pressure Indicator.
Replace element if indicator is yellow or red. Check
Mark III gauge for proper inlet pressure.
Check for leaks in system from the high pressure air

supply to the ASG using ASG Tool and Procedure
for locating High Pressure Leaks.
Appendix A 11-2
DIAGNOSTIC TOOLS for DETECTING HIGH PRESSURE AIR LEAKS
IN ACOUSTIC PYROMETER SYSTEM
If a high-pressure air leak occurs, the ASG signal will become weak and the temperatures
reported by the computer will lose accuracy. To locate the source of a high-pressure air
leak in the Acoustic Pyrometer system while it is mounted at boiler side, isolate the four
following components in sequence until the leak is found.
• Mark III Air Amplifier A30120

• ASG A30106
• ASCO control valve 030503
• Hoses 030334 and 030505
1. A 1/4” JIC cap or plug included in this kit can be used to isolate the Mark III Air
Amplifier from the rest of the system. When plugged at the air amplifier outlet or
high-pressure hose, a working air amplifier will develop high pressure (If a high
pressure gauge is attached) and stop pumping at the set point (regulator) pressure
(250 ~ 500 psi). If it continues to pump and fails to reach pressure, then the leak is
in the air amplifier, hose or fittings. Check Spool Valve o-rings, Return Spring, Pilot
Air and Fittings. Use Soapy Water to detect external leaks. Otherwise proceed to
ASG.
2. A tool for isolating the ASG from the rest of the system is included in this shipment.
(Depressurize ASG before inserting ASG tool) Loosen the four hose clamping
bolts on the rear of the ASG where the 1 1/4” ASG Hose PN 030505 is attached.
The ASG tool can be inserted and the bolts retightened causing a seal but
preventing the air from entering the ASG. Re-pressurize system. If High Pressure
Leak stops then it must be inside the ASG. Otherwise the leak is confined to the
Hose Plate Assembly (including High Pressure Valve.)
3. The Norgren control valve can leak air through the muffler or fail to open properly
if clogged or defective. If the ASG is isolated from the rest of the system (using
ASG tool) and the air amplifier continues to pump, then the leak is in the control
valve, fittings or hoses. Clean valve or use Norgren Rebuild Kit PN 033353. If the
air amplifier reaches set point pressure and stops with the ASG tool in place after
the other components have been determined not to be the cause of the leak, then
the leak is in the ASG.
4. Hose Leaks can be found by spraying soapy solution on suspected areas.
11-3 Appendix A
Hardware Problem Solution
Generator firing erratically. (High The generator receives a signal from the computer
Pressure is good and no leaks.) (SPCW) to a Solid State Relay (SSR) in the AST
enclosure. The SSR open the control Valve by
causing a slight imbalance in the internal pressure
against the return spring. If the piston inside the
control valve is damaged or installed improperly the
operation may become erratic. Depressurize system
and remove top of valve on hose plate assembly.
Remove and inspect piston. Use Norgren Valve
Rebuild Kit PN 033353 to repair.
The Electrical Signal required to energize the Solid

State Relay (SSR) is approximately 3 Volts. Be sure
the signal from the SPCW to the SSR is close to 4
volts DC when activated.
Appendix A 11-4
11.3 Troubleshooting Charts
The trouble shooting chart references the connections shown below:
12 VDC Power 120/240 VAC

CPU 24 VDC Fuse Supply 24 VDC Power Circuit Breaker
Supply
12 VDC Fuse
Terminals
11-5 Appendix A
Symptom: No Power/LCD Display Blank
1a. Is there NO 1b. Check breakers

120/240 V into the SPCW Check power at source
cabinet?
YES
2a. Is there NO 2b. Reset breaker/replace NO 2c. With power off, check for
120/240 V to the SPCW fuse. Is power now continuity between 120/240V in
power connector? present? and the CPU power terminals. If
not check connections.
YES
3a. Is there NO 3b. With power off, check for

120/240 V to the LCD continuity between the 120/240V
power connector? in and the display power
terminals.
YES
4a. Is there 12 to 18 V 4b. Replace transformer

present on the output of NO for LCD display.
the transformer
connected to the LCD?
YES
5a. Check and secure

connections for the VGA
display cable on both the
LCD and CPU. Is the
display still failed?
YES
6a. Remove the LCD NO 6b. Replace LCD display.

display and connect to
another computer. Does
the display work?
YES
7d. Faulty I/O card (A/D
7a. Remove the CPU 7b. CPU component YES or D/A card), test cards
cover. Reseat the failure. Remove all cards individually are replace
processor card. Are both except processor and failed cards.
fans (power supply and YES retry. Does the CPU
CPU) are working? startup?
NO
NO 7c. Check Power supply 7e. Faulty processor card,

for +/- 12VDC & % VDC. replace.
If not, Replace Power
Supply
Appendix A 11-6
Symptom: Bad Temperatures Displayed On All Channels
1a. Display Path 1b.

temperatures on the NO See section “Bad Path
SPCW. Are all the path Temperature Displayed”
temperatures bad?
YES
2a. Verify the cable

connections for the D/A
card and A/D cards are
tight.
3a. Is there 12V between NO 3b. Is the 12V supply 3c. Replace fuses if
the +12V and COM receiving 110/240V NO blown. Check AC power
terminals on the (check the 12V supply connections.
Microphone I/O fuse)?
connector?
YES YES
4a. 4bc. Replace 12 VDC

See section “Bad Path Power Supply.
Temperature Displayed
11-7 Appendix A
Symptom: Bad Path Temperature Displayed On All Channels From One ASG
1a. 1b.
Manually fire the ASG. NO Check for high pressure
Did the ASG fire? leaks and Hardware
Problems in section 9.2.
YES
NO
2a. Display the ASG 2b.
signal using AST signal. Go to the ASG
Is there a valid signal Troubleshooting section
present? (see Software and section 9.2
section)
YES
NO
3a. Display the ASR 3b.
signal of the bad paths. Go to the ASR
Is there a valid signal Troubleshooting section.
present? (see Software
section).
Appendix A 11-8
Symptoms: Displayed Random or Erratic Temperatures
1a. 1b.
Check background noise levels Go to the ASR
on each receiver (without YES Troubleshooting
sootblowing). Readings are section.
normally no higher than 40.
Are signals in range?
NO
2a. 2b. 2c.

Are the noise levels consistently YES Turn off the air supply YES Replace or rebuild the
above 50 with all sootblowers to the purge solenoid. solenoid as necessary to
retracted (visually inspect). Does the noise level stop leaking or reduce
drop? Flow Control to
Microphone.
NO NO
3a. 1c. 2b. Check cable shielding

Inspect the signals and noise Check the 1” pipe NO and connections.
levels of a successful firing. union and microphone
Repeatedly fire the ASG until it for tightness. Does this
records bad temperatures. improve noise levels?
1b. YES 1c.

Does the ASG signal look Possible problem with the Air Amp or
bad? Trigger solenoid. Set system to supervisor
mode and watch operation. Go to ASG
troubleshooting section and section 9.2.
NO
1b. YES 1c.

Does the ASR signal look Possible interference
bad? from the purge
solenoid. Verify the
solenoid is set to 10
min. off, 5 secs. off
NO
1b.
If the background noise spiked when the measurement failed, then the likely
cause is improper threshold levels. Decrease the threshold levels (set on the
ASR configuration) until the system operates properly (do not reduce below
30). Alternatively try increasing the ASG pressure, but without exceeding 450
psi.
11-9 Appendix A
ASG Troubleshooting
1a. NO 1b. 1c.

Does the ASG hold Is the Air Amp pumping YES Verify the supply air is at
pressure between firings? slowing down so that it least 80 psi.
strokes less than once Try increasing the Air
per 5 sec.? Amp regulator set point.
YES NO 1e.
There is a leak in the trigger
1d. YES solenoid, hose or ASG. Isolate the
Cap the hose from the Air leak and repair or replace. See
Amp. Does the device section 9.2.
build and hold pressure?
NO 1f.
There is a problem with
the high pressure seals or
2a. 2b. Is the wiring between the inlet check valves. Go
Does the system hold the cabinet and the to section 9.2.
pressure but not fire? solenoid ok?
YES
NO YES
2c. 2d.
Is there power to both NO Replace fuses and verify
sides of the fuse box in connections as
the trigger cabinet? necessary.
YES
2f. Check wiring between
2e. Does the solid state NO ASG and SPCW.
relay fire on schedule?
YES 2g. Depressurize the

system and inspect the
3a. 3b. System air leak or trigger solenoid for
Does the Air Amp run check valves are leaking. damage. See Section 9.2.
constantly? Bubble test all fittings and
replace check valves. Go
YES To Section 9.2.
NO
4a. 4b. Any of the following:

Air Amp does not run at 1. The Air Amp support rods are misaligned. See Air
all? Amp rebuild procedures.
YES 2. Bad power connection to the Air Amp from the
trigger box, or blown fuse in the trigger box.
3. Insufficient air supply (at least 50 psi)
4. Low pressure cylinder “gummed up”. Disassemble
and clean.
5. Check oil level in Lubricator
Appendix A 11-10
ASR Troubleshooting
1a. NO 1b. Does the ASR have NO 1c.

Inspect the signal for this 12 V available on Check 12V power supply and fuses.
path ASR. terminals TB3 and TB4 Replace as necessary.
Is any signal present? (see Electrical
Connections section)? Continuity check the field wiring.
YES Verify that the ASG wires are landed on

the correct terminals. (refer to plant
specific drawings and ASG definitions in
the setup page.
2a. 2b. 2c. Ream out the listening

Check the ASR signal YES Is the microphone slot in the YES tube and retest.
response by tapping on it membrane slagged over? Check the fuse for the
while measuring the (Valve out and depressurize purge system and verify
signal on TB1&TB2 with a the purge solenoid before the purge system is
meter. Does it respond? inspecting). operating.
NO NO
3a. 3b.
Replace or swap out ASR Check the microphone element
microphone assembly. by removing the 3 cap screws
and removing the cover.
Remove any ash from the
element.
11-11 Appendix A
11.4 General Signal Processing Troubleshooting
Signal Processing Problem Solution
Also, see Acoustic Pyrometer Waveforms in Section 12, PyroMetrix Software User Guide when
referencing this table.
Good AST trigger signal (F6) with zoom Check trigger tube and fittings for looseness or
view following. blockage, Teflon tape, etc.
Isolate box from vibration and excessive ambient
noise.
Make sure ASG control valve is opening fully. (A puff
of air will be heard from the silencer). See Section 9.2.
Check trigger microphone for proper operation and
connection.
Set trigger level at .5 in setup page.
Poor AST Signal. Signal is too weak.
AST Hose is damaged, contaminated or

loose. AST Signal is not sharp enough.
Appendix A 11-12
Poor ASR Signal with zoom view Check for boiler leaks if high noise level persists.
following. Very high RMS (boiler or
Make sure listening tube extends to centerline of
other noise) without soot blowers (F11).
water wall tubes or 0.25 in. (7 mm) from web slot. See
Background noise too high.
Section 4.0, Figure 4-8 for ASR installation.
Make sure the ASR Purge Solenoid is not
continuously on or leaking.
ASR microphone purge air Flow Control should be set
at 5~15 scfh.
ASR Signal not strong enough (F7). Make sure signal has clear path without any physical
obstruction including port water-wall tubes.
Make sure ASG tube extends to centerline of
water-wall tubes. See Section 3.0 for proper ASG
installation.
Make sure listening tubes are not plugged with ash.
Check ASG operation and Pressure Setting on Mark
III Air Amp. Increase if necessary.
Make sure listening tubes extend to within 0.25” (7

mm) centerline of water-wall tubes. See Section 4.0
for component installation.
Example of good ASR Signal.
11-13 Appendix A
Incorrect temperatures due to other Check for other events such as leaks or sootblowers.
noise event. Examine spectrogram (F9) for events other than
signal.
Verify path length settings in configtof.csv file.
Check for red marker at beginning of signal indicating
a sharp transition in spectrogram (F8).
Save several signals

before contacting agent
in your region. Use F4 to
Save Signal.
Table 11-1 – Signal Processing Troubleshooting
Appendix A 11-14
11.5 Software Diagnostics
The PyroMetrixTM system contains two diagnostic programs to assist with

hardware configurations and trouble shooting.
Program To Run Test

Actions Options
Name Program Type Performed
Displays
A/D Microphone
Simple Test Simple Test Microphone 1-16 Channels
Tests
Inputs
Advantech
Advantech D/A 4-20 mA Sets Output
Device 1-32 Channels
Device Manager Outputs Current Loops
Manager
Table 11-2 – Diagnostic Programs
To check the operation of the Microphones (analog to digital) use the “Simple
Test” program. Simple Test is located by clicking the START button/All
Programs/UEI/Power DAQ/Utilities/Simple Test. Select “ANALOG IN” Tab.
11-15 Appendix A
Select Microphone channel (0-15).
Select the following:
MODE = “Single Ended”
TYPES = “Bipolar”
RANGES = “± 10V”
GAIN = “1”
TOTAL CHANNELS = “15”
ACTIVE CHANNEL = The microphone in test (All ASRs and ASTs)
Appendix A 11-16
If the Microphone can hear the boiler then a waveform of random noise will
appear on the graph. If the Microphone is in an AST it will not hear the boiler or
the boiler is nor running, noise can be induced by tapping on the outside of the
microphone can or by turning up the microphone purge air to 20 SCFH using
the Flow Control Valve. Increase GAIN to “8” for this test to see waveform as
shown below.
11-17 Appendix A
To check the 4-20 mA output channels use Advantech Device Manager.
Advantech Device Manager is started by clicking the START button/All
Programs/Advantech Automation/Device Manager/Advantech Device Manager.
Select “TEST” Button
Appendix A 11-18
Select “Analog Output” tab.
11-19 Appendix A
Adjust two channels at once to output a 4-20mA current.
Appendix A 11-20
12. APPENDIX B
PYROMETRIX SOFTWARE USER GUIDE

VERSION 253
Topic Page
1.0 PyroMetrix Software Purpose and Description………………………………..12-2
2.0 Start-Up………………………………………………………………………….…….12-2
3.0 The Front Panel Description………………………………………………………12-4
4.0 Program Controls……………………………………………………………………12-7
5.0 Data Logging Examples……………………………………………………….……12-25

PyroMetrix Software User Guide
1.0 PyroMetrix Software Purpose and Description
The purpose of the PyroMetrix Software is to provide an interface between the operator and the PyroMetrix
hardware that gets installed on an industrial boiler, or other similar application. Its primary function is to initiate
the firing of the Acoustic Sound Generator (ASG), acquire data associated with the firing, process the collected
data, and then return temperature information based on that data. The software generates temperature
information, either in milliamps or in volts. Either range, 4 to 20 mA or -5 to +10 Volts, directly correlates to the
interpreted temperature values that the software produces and displays in degrees Fahrenheit or Celsius. The
resulting temperatures allow the operator to properly monitor the conditions in the boiler that relate to its
ongoing operation, overall efficiency and general safety.
2.0 Start-Up
The system should have required files, drivers and executables already installed. When the computer boots, or
upon double-clicking the PyroMetrix icon, the software immediately starts-up and enters Supervisor Mode after
15 seconds provided the required files are located as indicated below. If this is the first time the software is
used, or no configuration files are detected in the ‘Setup Files’ folder (C:\LabTOF), the user will be prompted to
locate three separate configuration files:
1. Program Configuration File - This file must be setup in the format specified in the attached example
file (ConfigTOF.csv) or the software will not run correctly. This file contains system parameters such
as pathway dimensions, and ASR/ASG information. The pathway to this file is (C:\LabTOF\Setup
Files\ConfigTOF.csv. This file is interfaced through PyroMetrix.exe via ‘OPEN SETUP.csv (see Section
4.10).
C:\users\Enertechnix\Documents\LabVIEW Data\XYAnnotation.xlm contains position information for
the Path Temperature Display.
2. ConfigPathLocations.ini contain path layout positioning.
Appendix B 12-2
3. Zone Configuration Files - Contains pathway coefficients necessary for zone temperature
calculations. ZoneLocate.csv contains wall labeling, zone position, and temperature value visibility.
ZonesMatrix.csv holds the weighted layout of the zones in relation to the paths. The file pathways
respectively for these are C:\LabTOF\Setup Files\ZoneLocate.csv, and C:\LabTOF\Setup
Files\ZonesMatrix.csv.
If these files are already present in the program file folder, the files will be automatically loaded without
prompting the user.
12-3 Appendix B
3.0 The Front Panel Description
The Front Panel is the top-level portion of the user-interface. Its main features include a vertical column of
function buttons, two control settings, a front panel window with message screen beneath it, and a series of
path temperature indicators (see Figure 12-1).
Figure 12-1: The Front Panel
3.1 Function Button Column

Each button in this column, when turned on, activates a function. Most of these functions do not run
simultaneously alongside another function. The buttons are activated upon a single mouse click, or by
pressing a corresponding function key (the associated key is labeled on each button). When the button
is activated it will change color. A button’s active color is representative of its functionality:
• Yellow - Data acquisition or communication to external hardware is occurring.
Buttons: FIRE, ASR BACKGROUND, SUPERVISOR MODE
• Blue – This color is associated with signal processing or data display.
Buttons: PROCESS SIGNAL, ASG SIGNAL, ASR SIGNAL, FILTERED ASR SIGNAL, SPECTROGRAM, VIEW
TREND
• White – This color is associated with file loading, saving or editing.
Buttons: LOAD SIGNAL, SAVE SIGNAL, OPEN SETUP.CSV
Figures 2, 3 and 4 illustrate the Load Signal, Edit Setup Files (with Constants Descriptions) and Save
Signal buttons. Each button’s function is addressed in Section 4, Program Controls.
Appendix B 12-4
Figure 12-2: Load Signal
Figure 12-3: Edit Setup Files
12-5 Appendix B
Figure 12-4: Save Signal
3.2 Control Settings
3.2.1 Fire ASG
This designates which ASG will be fired upon activation of the Manual FIRE function (see
Section 4.1).
3.2.2 Proc. Path (Process Path)

This designates which pathway’s most recent signals will be processed while PROCESS
SIGNAL (Section 4.2), AST SIGNAL (Section 4.6), ASR SIGNAL (Section 4.7), FILTERED ASR
SIGNAL (Section 4.8), or ASR SPECTOGRAM (Section 4.9) is active.
3.3 Front Panel Window

This is the user interface that allows you to load and save acoustic signals, view signals, and edit setup
parameters.
3.4 Message Box

This displays information the user may find useful during system operation.
3.5 Path Temperature Indicators

This allows you to scroll through the most current path temperatures obtained through either
SUPERVISOR MODE operation or by use of the FIRE function. The left index for each indicator designates
the path number. The user can scroll through these indexes to view any desired path or zone
temperature. If no temperature has been calculated for a given pathway, and SUPERVISOR MODE is
active, a blank space will be displayed, marking that no usable value has been obtained for that pathway.
Appendix B 12-6
Note that a blank space is used throughout the software to represent either invalid temperatures (see
Section 3.2) or this special pre-calculation case.
4.0 Program Controls

This section provides a description of all the function buttons and settings with displays, logs, and 4-20 mA
outputs. These are outlined below.
4.1 Manual FIRE Mode (F1)

This mode is used to manually acquire AST and ASR signals for user specified pathways. Before pressing
the FIRE button, which activates this function, the user should select the ASG that he or she wants to fire
using the front panel ASG control. Once the desired ASG is selected, the user can press the FIRE button
to obtain signals corresponding to the pathways associated with the selected ASG. Once the ASG
successfully fires and data is acquired, the button will automatically re-pressurize and be ready for
another fire command from the user. The ASG-204 takes 1 minute to re-pressurize, and the ASG-106
takes about 4 minutes to re-pressurize.
Figure 12-5: Manual Fire
12-7 Appendix B
4.2 PROCESS SIGNAL (F2)
This function processes G#R#.tof signal files stored in the signal file folder (C:\LabTOF\Signals). These
files are either generated via SUPERVISOR MODE operation, manual FIRE mode or are manually loaded
in by user. A given G#R#.tof file corresponds to a specific pathway. The user can select which pathway
most recently acquired signals to process by using the ‘Proc. Path’ control. Selection of ‘Proc.Path’ value
can be done before PROCESS SIGNAL is activated or while active.
Figure 12-6: Process Signal
Appendix B 12-8
4.3 LOAD SIGNAL (F3)
This function allows the user to load a signal file, written in either binary (for legacy system signals) or
text format, from anywhere on the computer, and process it using other functions. Upon activating the
LOAD SIGNAL function, all function column buttons are disabled. Select Wave Type. Select Write Wave
Filename (the default Filename will overwrite the waveform associated with ‘Proc.Path’ when ‘Load
Signal’ is selected). Press green button to load a waveform. Select a waveform file from ‘Select File’
pop-up window. Waveform will appear on graph. To accept the signal and write it to ‘Write Wave
Filename’ press ‘Accept & Process.’ To choose a different waveform, press the green button. To cancel
‘Load Signal’ press ‘Cancel.’
Figure 12-7: Load Signal
4.3.1 Waveform Sampling Info Indicators

The “Sample Rate” indicator displays, in KHz, a sampling rate associated with the uploaded
signal. The rate is defined in the configuration file; it is not derived from the uploaded signal file.
The value displayed in the “Samples/Channel” indicator is determined by the size of the
uploaded signal, ie., the number of data points that make up the signal.
12-9 Appendix B
4.4 SAVE SIGNAL (F4)
Upon activating this function, a Windows directory browser will be made available to the user to save
the waveform file that is associated with ‘Proc. Path’. This signal will be saved as at text file to the
specified directory. Once the signal is saved, the system will exit out of the SAVE SIGNAL function.
Figure 12-8: Save Signal
Appendix B 12-10
4.5 VIEW TREND (F5)
The trend of the analog outputs can be seen with this function and are shown in Figure 12-9 below.
Select up to 8 paths and/or zones to view: Select ‘Displayed Interval.’
Figure 12-9: Trend View
12-11 Appendix B
4.6 AST SIGNAL (F6)
The AST signal is generated from the acoustic signal of the ASG and is obtained through the ASG SIGNAL
function. This signal is referred to as AST or Trigger. The pathway associated with the displayed signal
when this function is active is indicated by Proc.Path.
Figure 12-10: AST Signal with Zoom Views
Appendix B 12-12
4.7 ASR SIGNAL (F7)
The ASR signal is the result of the ASG’s acoustic signal traveling through the boiler as well the sound of
the boiler itself. It is obtained through the ASR SIGNAL function and is referred to as Raw ASR. The
pathway associated with the displayed signal when this function is active is indicated by Proc.Path.
Figure 12-11: ASR Signal
12-13 Appendix B
4.8 FILTERED ASR SIGNAL (F8)
The Filtered ASR signal is the Raw ASR signal with some of the background boiler noise removed. It is
obtained through the FILTERED ASR SIGNAL function and is referred to as Filtered or Processed ASR. The
pathway associated with the displayed signal when this function is active is indicated by Proc.Path.
Figure 12-12: Filtered ASR Signal
Appendix B 12-14
4.9 ASR SPECTROGRAM (F9)
This function performs spectral-analysis for the raw ASR signal. Upon activating the ASR SPECTROGRAM
function button, the Message Box will indicate that the spectrogram is being generated. Once
generated, the Message Box will indicate the spectrogram’s associated path, ASG and ASR. The pathway
associated with the displayed signal when this function is active is indicated by Proc.Path.
Figure 12-13: Spectrogram
12-15 Appendix B
4.10 OPEN SETUP.CSV (F10)
This function allows the user to make changes to the program configuration file and the zone
configuration file currently being used. Upon activation of this function, all function column buttons
become disabled and the Front Panel window display, as seen in Figure 12-3, will become visible. A
detailed description of the configuration parameters are provided in Section 6 of this document.
Figure 12-14: Setup Configuration

4.11 ASR BACKGROUND Mode (F11)
This mode provides the user with ASR background monitoring capability while SUPERVISOR MODE is
activated or deactivated. Upon mode activation, the graphical ASR channel display (see Figure 12-15)
will become visible, and ASR channel monitoring will commence. ASR channel monitoring displays a
strip chart of all ASRs and records data to C:\LabTOF\Data Logs\Background.csv.
Note: Leak channel 4-20mA outputs, as well as LeakLog data logging only occurs while
SUPERVISOR mode is active.
Appendix B 12-16
4.11.1 Background Noise Graphic Display
A real-time graphical display, which indicates the last sampled threshold value for each active
leak channel, as well as each leak channel’s alarm status, can be activated, while SUPERVISOR
MODE is inactive OR active, by pressing the ASR BACKGROUND button. This graphical display is
shown below in the figure below. One can simply revert back to the standard SUPERVISOR
MODE grid display by clicking the LEAK CH. NOISE.
Figure 12-15: Graphic Leak Channel Display
4.12 SUPERVISOR MODE (F12)

Only when SUPERVISOR MODE is active are log files written, historical data maintained, and 4-20mA
output channels active. This mode, once active, is completely automated and performs various data
acquisition and signal processing tasks virtually simultaneously. When SUPERVISOR MODE is active, the
user would see the front panel on the tab indicated by the ‘Initial Tab’ parameter in the setup file.
To change the view to one of five displays, the default tab that is displayed can be setup within the
‘Program Constants’ tab of the “OPEN SETUP.CSV” and changing the ‘Initial Tab’ value. The various
displays are shown in the Figures 12-16 to 12-20 below.
12-17 Appendix B
Figure 12-16: Path Table Tab
Figure 12-17: Block Tab

Appendix B 12-18
Figure 12-18: 2D Tab with Contours
The 2D zone display shown above in Figure 7 has the ability to add contoured lines and measure
temperature at the cursor.
Figure 12-19: ISO Tab

12-19 Appendix B
Figure 12-20: Path Tab
SUPERVISOR MODE functions can be broken down into four categories: Path and Zone Temperature
Display, Leak Channel Monitoring, Data Logging, and 4-20mA Output.
4.12.1 Path and Zone Temp. Display

An ASG firing cycle sequence, defined in the program configuration file, is repeated throughout
SUPERVISOR MODE operation. Signal processing and analysis (signals obtained from ASTs and
ASRs) provide path temperatures; in SUPERVISOR MODE these temperatures are checked for
validity using system parameters and historical trends.
All calculated path and zone temperatures are displayed on the front panel (zones in red grid,
paths in grey grid, see Figure 16). Each column corresponds to temperatures acquired from a
given ASG fire; the time of the fire is displayed in the yellow grid above the path temperature
grid. Data corresponding to the most recent 8 ASG fires is displayed on the front panel.
Invalid path temperatures are displayed as a blank space; if the user wishes to see the actual
temperature value, he or she can either refer to the temperature log file (TemperatureLog.csv),
or the path temperature indicators to the right of the valid path temperature grid.
4.12.1.2 Force Fire

Each ASG is associated with a number of ASRs. Before an ASG fires, the noise level
detected in each associated ASR must be below a threshold level (defined for each
pathway in the program configuration file). If the noise level does not drop below this
level in a given timeout period, even for just 1 associated ASR, the ASG will fire at the
end of the timeout period. Prior to a timeout the user can force the ASG to fire by
pressing the ‘Force Fire’ button.
Appendix B 12-20
NOTE: If SUPERVISOR MODE is active, and no path temperature has been
calculated for a given pathway, a blank reading will be displayed as the path
temperature. Zone temperatures can be blank if outside the Temp limitations
(high and low).
4.12.1.3 Temperature Validity Time Constraint

In the program configuration file, the user can define a time interval for which pathway
temperature calculations, when older than this interval, will be virtually forgotten and
not considered when performing validity calculations for current raw path temperatures.
4.12.2 Leak Channel Monitoring

The ASRs, while mainly used as signal acquiring devices for temperature calculations, can also be
utilized to detect leaks. Parameters defining the system’s leak channel monitoring specifications
are loaded via program configuration file. Up to 12 ASRs (maximum ASR count for PyroMetrix
system) can be used in leak channel monitoring.
Figure 12-21: Edit Setup Files

4.12.2.1 Leak Channel Alarm
Each defined leak channel has a dedicated alarm, which is activated when the sampled
threshold of the leak channel ASR stays above a specified alarm threshold for a specified
period of time (program configuration file). If a sampled threshold level for a given leak
channel ASR descends below this alarm threshold, even one second before the alarm
interval is elapsed, the alarm timer will reset and be inactive until the alarm threshold is
again exceeded.
12-21 Appendix B
4.12.2.2 Background Noise
When SUPERVISOR MODE is active (and ASR BACKGROUND inactive), leak channel
information is displayed in a grid format, beneath the zone temperature grid. Row 1
displays the ASR/Leak Channel #; Row 2 displays the last sampled background noise
value for each leak channel (see Figure 16).
4.12.3 Data Logging

During SUPERVISOR MODE operation, three separate data logs are maintained (C:\LabTOF\Data
Logs); the most recent signal files are also maintained in a separate folder (C:\LabTOF\Signals).
NOTE: If configuration files have been changed via OPEN SETUP.CSV, a new header is
written to each log file. This reflects the creation of a virtually new ValidLog.
4.12.3.1 ValidLog.csv
Each successful ASG fire results in a ValidLog entry. Log columns include the Cold
Count/Validity, Rapidfire Count, date and time (24 hour) for the fired ASG, ASG # Fired.
The last calculated path and zone temperatures (for every path and zone) are also
written to each entry; if a path temperature is determined to be invalid, an empty space
is displayed.
4.12.3.2 LeakLog.csv
Entries in this log are written only during SUPERVISOR MODE operation (like the other
two logs), and after each sampling of ASR thresholds. Log items include date, time (24-
hour), an ASR threshold value for each defined leak channel ASR, and alarm status. The
last item of each entry, “ASR Alarm Set”, contains a list which gives the number of each
ASR with an active alarm.
4.12.3.3 Archive Format

Each log entry, for each of the three types of log, is simultaneously written to an
appropriately named archive log. Archive logs are separated from alike archive logs by
date (each month gets its own archive log), and unalike archive logs are separated by
folder.
The non-archive logs have a maximum length, determined by the user in the program
configuration file. Once the log exceeds this length, it is cut in half, keeping the newer
half. This prevents the log from getting excessively large and unpractical.
Appendix B 12-22
4.12.4 Analog 4-20mA Output
The system is configured to handle up to 32 analog 4-20mA outputs. During SUPERVISOR MODE
operation, a given output channel may reflect a leak channel noise level, a path temperature, or
a zone temperature; the user can set the type of each output channel via program configuration
file.
4.12.4.1 Leak Channel Outputs
In order for a leak channel to be reflected by an output channel, it must be properly

defined in both the leak channel and analog output sections of the program
configuration file. A given leak channel has multiple parameters that determine 4-20mA
output value:
• Low Threshold – Noise level that corresponds to a 4mA output (Low mA); if the
leak channel threshold drops below this value, the corresponding output
channel would still show 4mA (defined in program configuration file).
• High Threshold – Noise level that corresponds to an 18mA output (High mA); if
the leak channel threshold exceeds this value, and the channel’s alarm is
inactive, the corresponding output channel would still show 18mA (defined in
the program configuration file).
• Alarm – If the leak channel’s alarm is active, the leak channel’s corresponding
output channel will be frozen at 20mA. Upon pressing the “Alarm OFF” button,
the channel’s output will revert back to its normal 4-18mA range.
• Low – Noise level that corresponds to 4 mA analog output.
• High – Noise level that corresponds to 18 mA analog output.
12-23 Appendix B
4.12.4.2 Path and Zone Temperature Outputs
All paths and zones share common 4mA (Low mA) and 20mA (High mA) reference
values. The 4mA reference value is the “Low_Temp” parameter defined in the
“Constants” section of the program configuration file. The High mA reference value is
the “High_Temp” parameter defined in the same section. If a temperature is below the
Low mA benchmark, or above the High mA benchmark, the corresponding output would
be Low mA (typically 4) or High mA (typically 20), respectively.
An invalid (blank value) cannot be reflected by an output channel; instead, the latest
valid path temperature is used by an output channel defined for a pathway. If no valid
temperature exists, the last valid mean temperature for the given pathway is used. Zone
temperatures calculated from valid pathway temperatures are used for zone
temperature outputs. The zone display can be seen below.
Figure 12-22: Block Display
4.12.5 Exiting SUPERVISOR MODE

To exit SUPERVISOR MODE, press the AUTO FIRE SEQUENCE button again. If ‘Security Code’ has
a value other than 0, then you will be prompted to key in the code before exiting SUPERVISOR
MODE. The ASG firing sequence will cease, and the system will either go to its default mode
(blank front panel) or to a different function. The former occurs if one simply turns the
SURPERVISOR MODE button off; the latter if one presses a different function button to
deactivate SUPERVISOR MODE.
Appendix B 12-24
5.0 Data Logging Examples
This section will display screen shots of the three types of logs. Screen shots are accompanied by comments,
pointing out the features of each log’s format discussed in Sections 4.12.4.1 – 4.12.4.4.
5.1 LeakLog.csv
Figure 12-23: LeakLog.csv

5.1.1 Leak Log Features
• The Leak Log (shown above, Figure 12-22) has a log column for every leak channel ASR.
• 24 hour time-stamp and current date.
• The ASRs are listed in increasing order from left to right.
• The “Alarm On” column shows if the alarm is on (1) or off (0).
• “Alarm ASR Set” shows if the alarm came on.
12-25 Appendix B
5.2 ValidLog.csv
Figure 12-24: ValidLog.csv
5.2.1 Valid Log Features

• The Valid Log (shown above, Figure 12-24) has a log column for every Path and Zone.
• Each row represents one ASG firing.
• The “ASG” column shows which ASG is associated with that shot.
• 24 hour time-stamp and current date.
• Valid Log only displays temperatures that are seen as valid. Invalid temperatures are
replaces with blank space as seen above.
• “Cold Count” column shows the firing state of the ASG.
• “Rapid Fire” column displays the current rapid fire state.
Appendix B 12-26
6.0 Descriptions of Configuration Parameters
This section will go over each of the parameters in the configuration and set up files that LabTOF uses.
6.1 Constants
Constants: Default Value Description
SamplingRate(kS/s) 40 Sample Rate for each Channel.
Samples/channel 12800 Number of samples for each device.
ListenTimeout (s) 1000 If ASG noise level is greater than Listen_Threshold, Time ASG will
wait before switching to next ASG in sequence.
LkChInterval (s) 60 Time between evaluating, recording and reporting LeakChannels.

Older versions use LkChSampleRate.
Low_Temp [C (F)] 0 (32) Lowest valid temperature. Lowest (4 mA) value of Analog Output.
High_Temp [C (F)] 1800 Highest valid temperature. Highest (20 mA) value of Analog Output.
(3272)
Cold Counts 4 Number of times each ASG will fire while using Cold Start validation
algorithm. Starts when no valid temperatures exist for at least one
Path.
Average_Count 3 Number of members in Path moving average.
Valid_Threshold [C (F)] 150 Used in Threshold Validity algorithm. Path must be within this value
(302) of previous Valid Path Temperature.
Valid_Time (minutes) 30 Longest a Path Temperature can be Valid.
RapidFire_Counts 6 Number of shots that a system will remain in Rapid Fire mode.
RapidFire_Threshold 75 Rapid Fire mode will start if Path is within this value of previous Valid
[C (F)] (167) Path Temperature.
MULT_CORRECT 1 Not used in normal operation.
Gamma 1.3 Calculated value at 2200 K for combustion gases.
MolecularWeight 29.8 Calculated value at Path’s “Full Load Temp” for combustion gases.
Valid_Count 2 Number of members in “Last Valid Temperature” moving average.
12-27 Appendix B
6.2 Inputs
Inputs: Default Description

Value
Input 1 Analog Input channel. (1 indicates 1st channel).
ASG# 1 ASG designation number.
ASG Model 106 ASG Model number. Used in Offset Calculations.
Barrel length [cm (in)] 30.48 (12) From center of Trigger Tube fitting to end of
Barrel.
Trigger Tube Length 182.9 (72) From overall length of Trigger Tube Hose.
[cm (in)]
Pressure [kPa (psi)] 2748 Operating Pressure of ASG.

(398.6)
Barrel Temperature [C (F)] 280 (536) At Full Load.
Ambient Temp [C (F)] 20 (68) Average yearly temperature at 1 meter from boiler
near AST while boiler is running.
Trigger Tube temp [C (F)] 25 (77) At Full Load.
Acquire Delay (ms) 5 Delay between firing digital output and acquiring
analog inputs.
CompareFactor (AST Steps) 20 Used in AST Slope Validation. If there are more
than this value of steps in the AST signal then all
Paths associated with this ASG will be invalid.
Appendix B 12-28
6.3 Inputs: ASR
Inputs: ASR Default Description

Value
Input 5 Analog Input channel. (5 indicates 5th channel).
ASR# 1 ASR designation number.
Ambient Temp [C (F)] 20 (68) Average yearly temperature at 1 meter from

boiler near ASR while boiler is running.
Microphone Tube Length 91.44 (36) Length of 3/8” SST tubing.

[cm (in)]
Microphone temp 50 Temperature corresponding to the offset time of

the ASR tube when boiler is at Full Load.
6.4 Sequencing
Sequencing Default Description

Value
ASG# 1 ASG to Fire.
Fast (s) 30 Delay before next* ASG fires if DI (7) Jumper is Open or
removed.
Slow (s) 30 Delay before next* ASG fires if DI (7) Jumper is Closed.
RapidFire (s) 150 Delay before next ASG fires system is in Rapid Fire Mode
regardless of DI (7) Jumper.
6.5 Paths
Paths: Default Description

Value
Path 1 Path Designation Number.
Associated_ASG 1 This Path’s ASG.
Associated_ASR 3 This Path’s ASR.
Length [m (ft)] 8.581 Path Length. Measured from tip of barrel to tip
(28.15) of ASR Tube.
12-29 Appendix B
Offset Not used at this time.
Filter_Type Not used at this time.
Low_Filter 0.1 Lower limit coefficient of ASR bandpass filter.
High_Filter 0.3 Upper limit coefficient of ASR bandpass filter.
Trigger 0.5 Fraction of AST Signal that determines AST Event

at first occurrence.
ListenThreshold 35 ASR Background Noise (rms) must be below this

value to allow ASG to fire.
Default Mean Temp [C (F)] 850 Temperature value used for calculations if no
(1562) other value is available.
Full Load temp [C (F)] 1350 This Path’s average temperature when boiler is
(2462) at Full Load.
Boiler temp at length 20 (68) Boiler Temperature when geometry is measured

measure [C (F)] to calculate Path Length.
Peak Width (ms) 0.8 Not used at this time.
ReVal Windows(ms) 0.8 Time period before and after ASR Event used for
ASR Validation.
Compare Signal/Noise 4 Minimum Signal/Noise needed to ReValidate

Path temperature value in ASR Validation.
Appendix B 12-30
6.6 Leak Channels
leakchannels * Default Description

Value
ASRx 1 ASR associated with this leakchannel.
Threshold 400 Background Noise Level (rms) that must be exceeded to alarm.
alarmInterval (min) 240 Time that Back Ground Noise must continuously exceed
threshold before leakchannel will alarm.
low 0 Back Ground Noise level (rms) equal to lowest analog output
level (4mA).
high 1000 Back Ground Noise level (rms) equal to highest analog output
level (18mA).
*leakchannels are assigned designation numbers based on the order they appear in ConfigTOF.csv
6.7 ASG Model Parameters
ASG Model Parms Default Description

Value
ASG type 106 Model number of parameters being defined.
length [cm (in)] 30.48 Length of Trigger Tube Hose not accounted for in Trigger Tube Length.
(12)
DO on (seconds) 3 Duration control valve is open when ASG is fired.
12-31 Appendix B
6.8 Program Constants
ProgramConstants: Default Description

Value
MaxLogLength (kB) 1000 LeakLog, TemperatureLog and ValidLog will reduce their size by half
when they exceed this many lines.
MaxAverageTime 1000 Not used at this time.
US = 0 or SI = 1 1 Unit system used.
LkChSamplingRate 0.1 Frequency of evaluating, recording and reporting leak channels.

(Hz)
MaxTrendLog(kB) 1000 TrendLog reduces itself by half when its size exceeds this amount.
AinResource 1 2=NI Analog Inputs, 1= UEI Analog Input, 0=simulated Analog Inputs.
AoutResource 1 2=NI Analog Inputs, 1= UEI Analog Input, 0=simulated Analog Inputs.
DinResource 1 2=NI Analog Inputs, 1= Digital Input, 0=simulated Digital Inputs.
DoutResource 1 2=NI Analog Inputs, 1= Digital Output, 0=Do not send Digital Output.
Security Code (0 = na) 0 Numeric code required to exit Supervisor mode. If blank or 0 user
can exit from Supervisor mode, prompt for code will not appear.
Initial Tab 2 Initial Tab display when entering Supervisor mode.

<Blank> or 0 = Table, 1 = Block, 2 = 2D, 3 = Iso, 4 = Path
Appendix B 12-32
6.9 Analog Out Channels
AOChannels: Value Description
ChannelNumber 1-32 Analog Output number 1 is 1st = AO(0).
ASR* 1-x Leakchannel analog output.
Path* 1-x Path analog output.
Zones* 1-x Zone analog output.
Zero 4 Analog value corresponding to Low_Temp. (4mA).
Span 20 Analog value corresponding to High_Temp. (20mA)**.
* Use only one of ASR, Path or Zones. Leave the other two blank.
** For leakchannels use 18mA.
x: Value range will vary from install to install.
6.10 File Directories
Directories: Default Description

Value
LogFileFolderName C:\LabTOF Name of Folder that contains Validlog, Leaklog,

\Data Logs TemperatureLog, TrendLog and errorLog.
LogFileFolderDirectory C:\LabTOF Parent Directory of Log File Folder.
SignalFolderName C:\LabTOF Name of Folder that contains TOF signal files.

\Signals
SignalFolderDirectory C:\LabTOF Parent Directory for Signal Folder.
12-33 Appendix B
13. APPENDIX C
INSTALLATION DRAWINGS

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TM

P.O. Box 469 © 2014 Enertechnix Incorporated Phone: 360-753-8831

 Jan 2007 Original Issue 

7-16-2010 July 2010 Lubricator Information Updated 

Dec 2011 Updated Section 8 to Reflect Change to SPCW REH

1-25-2012 Dec 2011 Updated Section 9 to Reflect Change to SPCW REH

April 2012 Sections 12 (TempView Software Guide) Removed HAH

Section 9 (Fault Isolation & Troubleshooting) Removed and

April 2012 Updated Sections 1 to 7 plus Introduction HAH

April 2012 Sections 10 and 11 Renumbered to Sections 9 and 10 HAH

5-08-2012 April 2012 Updated Renumbered Sections 9 and 10 HAH

Remove Pressure Switch; Add Oiler Information, New Air

Section 1.0 Safety

Section 2.0 General System Description

Section 3.0 ASG Recommended Installation

Section 4.0 System Sub-Component Installation

Section 5.0 Pneumatics, Lubricator & Low/High Pressure

Section 6.0 Electrical Connections

Section 7.0 Measurement Verification

Section 8.0 System Power ON/OFF

Section 9.0 Periodic Maintenance and Repair

Section 10.0 Replacement Parts and Repair Kits

Section 11.0 Appendix A: AP106 Troubleshooting Manual

Section 12.0 Appendix B: PyroMetrix Software User Guide

Section 13.0 Appendix C: Installation Drawings

Figure 1 PyroMetrix System Concept ............................................................ ix

Figure 6-4 SPCW Panel Connection Detail ....................................................... 6-6

Figure 12-1 The Front Panel ............................................................................... 12-4

Figure 1 – PyroMetrix System Concept

Notes call attention to methods that make the job easier.

Material Recommendation Used in…

Abbreviations and Acronyms

The following is a list of abbreviations and acronyms used in this manual.

AAC Amps Alternating Current

A/D Analog to Digital

AP106 Acoustic Pyrometer AP106 System

ASG Acoustic Signal Generator

ASR Acoustic Signal Receiver

AST Acoustic Signal Trigger

AWG American Wire Gauge

bar PSIG multiplied by a factor of .0689

BNC British Naval Connector or Bayonet Nut Connector

CFM Cubic Feet per Minute

D/A Digital to Analog

DCS Distributed Control System

DIN Deutsche Industrinorm - German Standard

in-lbs Inch Pounds

JIC Joint Industrial Council

MPC Multiple Processing Control

N/A Not Applicable

NPTF National Pipe Thread Female

NPT National Pipe Thread

O.D. Outside Diameter

psi Pounds Per Square Inch

PSIG Pounds Per Square Inch Gage

RMS Root Mean Squared

SCFM Standard Cubic feet Per Minute

SPCW Signal Processing Computer with Windows software

SST Stainless Steel

TOF Executable File TOF.exe

UNS Unified National Standard

VAC Volts Alternating Current

VDC Volts Direct Current

SSR Solid State Relay