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DigitalFlow GF868 Service Manual 1 MB

1. dooooooo0 00000000 00000000 00000000 00000000 Standoffs typ PC Board Screw LVD Shroud 8 places Cover Ground Wire PC Board Power Fuse Holder Ground Wire Connector LVD Shroud Internal d nternal Groun Option Cards Connection Side View Figure 8 Standard Model GF868 Electronics Console Assembly D Fuse Holder Cap Card Guide Metal Bracket Bottom View DigitalFlow GF868 Service Manual 1 and 2 Channel 37 Chapter 4 Parts Replacement Keypad Cable Short Standoff Vertical Components 3 places Backlight Cable Long Standoff EPROM U4 3 places LCD Display Beveled Corner Keypad Connector J50 ULTRASONIC FLOWMETER Display Connector J52 Display Cable O Fasteners typ Metal Bracket Option Card C
2. ANALOG OUTPUT ANALOG INPUT ALARMS m am F1 F2 F3 F4 F1 F2 F3 F4 F1 F1 F2 F3 4ma 20mA rEsr ExT aow aHiGH 4ma 20ma ExT Close open EXIT Full Scale LOW REFERENCE HIGH REFERENCE CALIBRATING LOW REF HIGH REF CALIBRATING F1 F2 F3 F4 F1 F1 F2 F1 F2 P Down Numer STORE ABORT STORE ABORT STORE ABORT Numeric Slot x Outputs Freq Total RTD Inputs FREQUENCY Slot x Outputs Analog Outputs E F2 EY ES F3 El Probe Numer PULSES La Ce Ce C2 Figure 6 Calibration Menu Map Slot x Inputs ANALOG OUTPUT F1 F2 F3 F4 4mA 20mA TEST ExT Probe 96 Full Scale CALIBRATING F1 F2 F2 F1 F2 F3 F4 F1 SetPt Slope Set Slop P DOWN Numer ISTORE ABORT Set Point Slope Point Set Point Slope Number Numeric Temp F1 F2 Set NOTE Plain text represents prompt area messages and STORE ABORT boxed text represents option bar choices Fx represent fu
3. 18 le adzcecueumiT ge MM 19 Action EG CVS SKIP ACCEL PTT 19 Action Ey ANO hene e gecaaces arouse A DUI PR RO A e abeatis 19 Action 9 1 001 TECH PTT 19 Action E9 PreSS TTT 19 Action ELO SPECIAL et EE EE E RR EN A E OR ga 20 Action ELL NOt USE A p 20 Action ELZ NOt e A E A TRIS E EE E EE 20 Action ELS Over RONGE ra A A A A RAS 20 Action mes TAGS OVER lA 20 Aton ELS EQUAL A A AI AA Ad 20 ae SCS Mess E olaa 21 Chapter 3 Diagnostics St MMO o o asee a aE e NA E EEEE E E E EAA E EAEE EA 23 Az Displaying Dinos POPE e sano ood nid te Ideo d RAS EE EE EEEE RE ORE 25 22 MIME DEG A a Lace 25 34 POV Ce Obie iis hae 4 427 He 4 A aba Foo be 25 34 A E ere Oe Se E E T LUI I 26 34 2 Pipe PrODleMS escrit id a dtes Ide Resa tuas boi de 26 35 Mansd cer Pro ais ia DA bee aa 27 Chapter 4 Parts Replacement MEI Coa ini iii 29 42 PUSE REPITE MEN pr ii A E EA E I a E E 30 43 Removing the Printed Circuit BOQA css eto AER RUE aeo HORA CAO re ODIO Ea RR 31 44 Replacing the EPROM A A A A AA E AR 32 4 5 Installing an Option Card dak CR aoes eed anetetaeacted saan ekenareihounleias 33 46 Replacing the LCD DIS rs dis 34 e installing the Printed Laire n BOTA biat as ida 34 A48 Spare POMS ua A AA AA AR a 36 Appendix A Service Record Pu IA Onda idad nia Eod HR D 39 AZ DOLO ENY ii dio dia 39 vi DigitalFlo
4. Complete the LCD Display replacement by proceeding to the Installing the Printed Circuit Board section of this chapter 4 7 Installing the Printed Circuit Board Whether the printed circuit board was removed for replacement or for one of the other procedures discussed in this chapter reinstallation of the printed circuit board is the final step in the process Refer to Figure 8 on page 37 and complete the following steps CAUTION During this procedure be very careful not to damage the vertical components along the top edge of the printed circuit board see Figure 9 on page 38 Severe or repeated bending of these components will break their leads 34 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 4 Parts Replacement 4 7 Installing the Printed Circuit Board cont 1 Position the printed circuit board within the electronics console with the top edge tilted forward Insert the display ribbon cable and keypad ribbon cable connectors into their sockets on the rear of the printed circuit board See Figure 8 on page 37 and Figure 9 on page 38 to identify the cables and sockets Note that the keypad cable connects to the upper socket and the display cable connects to the lower socket IMPORTANT The ribbon cables must be installed with the edges that were marked during removal oriented toward the top of the printed circuit board 2 Carefully position the printed circuit board up against the eight standoffs in the enclo
5. 40 DigitalFlow GF868 Service Manual 1 and 2 Channel Appendix B Optional Enclosures Appendix B Optional Enclosures B 1 Introduction The Model GF868 is available in optional enclosure types each of which has been designed to permit easy on site upgrades and parts replacement See the foldout drawings at the end of this appendix for details of the applicable GF868 electronics console assembly The instructions in this appendix along with a few common tools are all that is required to perform the following tasks e fuse replacement option card installation e EPROM replacement e LCD display replacement e printed circuit board PCB replacement IMPORTANT For meters supplied in the standard Type 4X enclosure see Chapter 4 Parts Replacement for instructions specific to that unit WARNING Prior to performing any maintenance procedures disconnect the main power from the unit Note For compliance with the European Union s Low Voltage Directive this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model GF866 B 2 Rack Mount Enclosure Refer to Figure 10 on page 49 and Figure 11 on page 50 for the location of the relevant components while completing the following procedures If the top panel of the meter is accessible service may be performed without removin
6. DigitalFlow DF8688 Liquid Ultrasonic Flowmeter DigitalFlow GC868 Clamp On Gas Ultrasonic Flowmeter DigitalFlow GF868 Flare Gas Mass Ultrasonic Flowmeter DigitalFlow GM868 General Purpose Gas Ultrasonic Flowmeter DigitalFlow GS868 Steam Mass Ultrasonic Flowmeter to which this declaration relates are in conformity with the following standards EN 60079 0 2007 EN 60079 1 2004 e EN50281 1 1 1998 2 G EEx d IIC T6 ISSePOSATEX1153 ISSeP B7340 Colfontaine Belgium NoBo 492 EN 61326 1 2006 Class A Table 2 Industrial Locations EN 61326 2 3 2006 e EN 61010 1 2012 Overvoltage Category II Other standards Used e EN 50014 1997 A1 A2 EN 50018 2000 A1 following the provisions of the 2004 108 EC EMC 2006 95 EC Low Voltage and 94 9 EC ATEX Directives Where products were initially assessed for compliance with the Essential Health and Safety Requirements of the ATEX Directive 94 9 EC using earlier harmonized standards a subsequent review has determined that technical knowledge is unaffected by the current harmonized standards listed above The unit listed above and any ancillary equipment supplied with it do not bear CE marking for the Pressure Equipment Directive as they are supplied in accordance with Article 5 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN 25 A ba A Aud Billerica October 31 2013 Issued Mr Gary
7. Note lfaSlotO analog output will be used to calibrate the analog inputs make sure that the Slot 0 analog output calibration procedure has already been completed Connect the Slot 0 analog output s or an independent calibrated current source to the analog input s on the option card as shown in Figure 3 Refer to the menu map in Figure 6 on page 15 as a guide Analog Input Option Card Terminal Block I O Slot 0 Figure 3 Analog Input Calibration Connections 6 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration 14 Calibrating the Analog Inputs cont For this discussion assume that the option card has been installed in Slot x Note The zero point of the analog input may be set for either O mA or 4 mA However the calibration procedure always uses the 4 mA point as the meter will extrapolate this value to obtain the 0 mA point 1 4 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press Fx to select the desired input The procedure for calibrating Input A is identical to that for calibrating Input B However when calibrating Input B be sure a calibrated current source is connected to th
8. age T Log Active END only hit any key When in the LOG menu this message indicates that the log is still compiling data Only the End Time may be edited Log DONE to inspect hit any key When in the LOG menu this message indicates that the log is complete Hit any key to display the log Log hasn t started hit key When in the LOG menu this message indicates that the log has not yet started OK settling The measurement has not stabilized Wait before taking a reading Outside limits value rejected When in the CAL menu this message indicates that the calibration of the analog out put is invalid Hit any key to clear the message and the GF868 will default to the last valid calibration The message will also appear if there is no ammeter connected to the analog output during calibration Overflow The display value overflowed Reduce the number of decimal digits or change the units P L Enter L again The entered path length P is less than the axial dimension L Enter a new value for L range is X XX to X XX When in the User Program this message indicates that the entered number is unac ceptable Hit any key and enter a number within the allowable range Review calibration An option card error indicating a programming failure or a loss of memory Contact the factory Review parameters An option card error indicating a programming failure or a loss of memory Con
9. Kozinski Certification Standards Lead Engineer CE Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com Ireland Sensing House Shannon Free Zone East Shannon County Clare Ireland Tel 353 0 61 470200 E mail gesensingsnnservices ge com An ISO 9001 2008 Certified Company www ge mcs com en about us quality html WWW ge mcs com 2015 General Electric Company All rights reserved Technical content subject to change without notice 910 194S Rev F
10. aca deca 32 Esplacile cosas vastes Fr RE PRSSESES ES 31 PROBE Option ior RTD Option Cale iua ec o eo 9 Problems TransducerS oooooo o 27 R Reboot Automatic eee 1 Replacing See Part Name Ret r Policy 422355392345 239449 BOWE SARS EE 53 S Screen Messages Table iss eve o RS 21 Service RECORRE el SOCCER Hn 39 Shroud ALUMNA eee nn 29 35 LCD Displays e tine ed YA VERE EA 34 IND RR sand a e saws 35 Plastice hum epee Et RN ae eee a ee Bek 35 Signal Quality Error EA i esses Rn 18 Sockets Option Cari sas radar aes 33 Soundspeed Bir SES Oo e Saa 18 c o a TREE A R RR TRE E A E 26 Spare Parts Lists lt do vts dr 36 Special Input Error EIO ds 20 52 T Temperature Input Error E8 19 Totalizer Frequency Option Card Testing 13 Totals Overflow Error EIA 20 Transducers COMOSION i seed Rd SI TREE AE 27 interval Damage 222221929 4 ricas 27 A 27 Physical Damage oa u dcos avere ear dios 27 Plenos dorems a a e 26 Problems rex TE rinier ere Rx EO REA 27 U User Program EPROM sente ox dada a Sale tada RC 32 UBEradifg n 2 42 5p ev eh ahd a da d ED 32 V Velocity Range Error E3 o oooooooo 18 W Ke A 53 DigitalFlow GF868 Service Manual 1 and 2 Channel Warranty Warranty Each instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restor
11. log there are no more logs to clear logging data user has hit ENT instead of selecting an old log or entering a new name printing a log there are no logs to print displaying a log there are no logs to display Hit any key to resume taking measurements All Sites Cleared hit key This message may appear during one of the following tasks 1 saving a new site a new site name was not entered or overwrite existing site was not selected recalling a site there are no site files to recall clearing a site there are no sites to delete printing a site there are no sites to print displaying a site there are no sites to display Hit any key to resume taking measurements Do you want to SAVE This message appears upon exiting the User Program if the new site data has not been saved Failure to save will result in loss of the new data next time the site data is changed or recalled Duplicate name Enter another The site file or log name is already in use Enter a different name End Time must exceed Start Time by 5 min This message appears when in the LOG menu Enter an end time that is at least five minutes later than the start time Header invalid An option card error indicating a programming failure or a loss of memory Contact the factory DigitalFlow GF868 Service Manual 1 and 2 Channel 21 Chapter 2 Error Codes and Screen Messages Table 2 Screen Messages cont
12. nuts or damage to the mounting threads may occur 8 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model GF868 flowmeter may now be placed back into service Reconnect the main power and resume taking measurements Note Be sure to record the LCD Display replacement in Appendix A Service Record DigitalFlow GF868 Service Manual 1 and 2 Channel 45 Appendix B Optional Enclosures B 7 Rack Mount Printed Circuit Board Replacement If troubleshooting procedures have indicated a defective printed circuit board follow the instructions in this section to replace the defective board with a new one B 7 1 Circuit Board Removal Refer to Figure 11 on page 50 and complete the following steps 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated WARNING The main power to the Model GF868 must be disconnected before proceeding 2 Disconnect all external option card connectors at the rear panel of the meter Then remove all installed option cards from the printed circuit board as described earlier in this chapter 3 Disconnect the main POWER LEADS from the screw terminals at the rear of the printed circuit board Make a sketch of the terminal block and the locations of the black white and green power leads t
13. of the currently selected relay See Figure 4 on page 11 for the correct pin numbers on the option card terminal block 4 Pressing F1 CLOSE should yield an ohmmeter reading of about zero Pressing F2 OPEN should yield an infinite ohmmeter reading 5 Press F3 to EXIT 6 Repeat the above procedure until both the normally open and normally closed contacts for all three alarm relays have been tested Then proceed to Procedure Options below 1 61a Procedure Options You have completed testing the alarm relays Do one of the following To calibrate test additional slots press F4 EXIT and proceed to the appropriate section e To leave the Calibration Menu press F4 EXIT twice 12 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration 1 7 Testing the Totalizer Frequency Outputs Totalizer Frequency outputs may be added to the Model GF868 by installing a Totalizer Frequency Option Card in one or more of the six expansion slots Each option card includes four outputs which are designated as A B C and D To test the outputs connect a frequency counter to the card s terminal block as shown in Figure 5 Refer to the menu map in Figure 6 on page 15 as a guide Terminal Block Option Card Frequency Counter Figure 5 Frequency Counter Connections For this discussion assume that t
14. the option bar Press the appropriate Fx key to select this option error codes appear here M SEE SU PTS Note Fora 1 Channel Model GF868 the above prompt does not appear and the following prompt is the initial screen Chi label PME Press the lt or gt keys until DIAG appears on the option bar Press the Velocity Ft s appropriate Fx key to select this option 6 95 error codes appear here TIME AN Note Chl or Ch2 which is shown in parentheses above appears in the locator bar only with a 2 Channel Model GF86 8 For example pressing F1 displays the Tdown parameter as shown in the following prompt DigitalFlow GF868 Service Manual 1 and 2 Channel 23 Chapter 3 Diagnostics 3 2 Displaying Diagnostic Parameters cont Chi Ch1 DN Transit usec 519 7 error codes appear here Tdown DELTA nal Qup diagnostic parameter or to EXIT the Diagnostics Menu PS Press the lt and gt keys and the appropriate Fx key to display a different Table 3 lists the available diagnostic parameters for the Model GF868 The first column in the table shows the parameter as it appears on the option bar while the second column shows the parameter as it appears in the prompt area after it has been selected Option Bar Screen Display UP Sig Strength SS up Table 3 Available Diagnostic Parameters Description Displays signal strength for the upstream transducer 50 or gt
15. yA of the 20 mA setting contact the factory for assistance 3 Press F4 to STORE the setting or press gt and F1 to ABORT the calibration Note Skip the next section if the linearity test will not be performed at this time Proceed to Procedure Options on the next page 4 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration 1 3 4 Testing the Analog Output Linearity Note If you exited this menu and are returning follow steps 1 through 3 in Accessing the Calibration Menu on page 3 1 Press F3 to TEST the linearity of the currently selected analog output 2 Check the ammeter reading at the 50 output level 3 Then enter a different output level 0 10096 and press ENT 4 Check the ammeter reading at this setting and press ENT when done Table 1 lists the expected ammeter readings at various Full Scale settings for both 4 20 mA and 0 20 mA scales Refer to this table to verify the accuracy of the ammeter readings taken above Table 1 Expected Ammeter Readings 96 Full Scale 4 20 mA Scale 0 20 mA Scale 4 000 0 000 5 600 2 000 7 200 4 000 8 800 6 000 10 400 8 000 12 000 10 000 13 600 12 000 16 800 16 000 18 400 18 000 i 2000 All ammeter readings should be 0 005 mA 0 10 20 30 40 50 60 70 80 90 100 If the linearity test readings are not within 5 uA of the values listed in Table 1 above check the accuracy and wiring o
16. 75 SS do DN Sig Strength Displays signal strength for the downstream transducer 50 or gt 75 SNDSP Soundspeed Ft s Displays the measured sound speed of the fluid N A Tup UP Transit S usec Displays the upstream transit time of the ultrasonic signal in microseconds N A Tdown DN Transit usec Displays the downstream transit time of the ultrasonic signal in microseconds N A DELTA DeltaT usec Displays the difference in usec between upstream and downstream transit times 210 000 nsec Tot K K Re MultiK KFactor Displays combination of all K factors N A PEAK96 PEAK96 UP Signal Q Displays the percentage of peak set to 50 by default Displays the signal quality for the upstream transducer N A 400 to 400 DN Signal Q Displays signal quality for the downstream transducer 400 to 400 UP Amp Discrim Displays the value for the amplitude discriminator of the upstream transducer 19 or gt 29 DN Amp Discrim Displays the value for the amplitude discriminator of the downstream transducer lt 19 or gt 29 UP DAC Counts Displays AGC DAC count for upstream gain setting N A DN DAC Counts Displays AGC DAC count for downstream gain setting N A UP Peak Displays signal peaks for the upstream transducer 100 or 22300 DN Peak Displays signal peaks for the downstream tra
17. GE Measurement amp Control Gas Analysis DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 1 and 2 Channel P K 910 1945 Rev F imagination at work February oE DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 1 and 2 Channel 910 194S Rev F February 2015 WWW ge mcs com 2015 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page Preface Information Paragraphs Note These paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions IMPORTANT These paragraphs provide information emphasizing instructions which are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance WARNING Indicates a potentially hazardous situation which can result in serious personal injury or death if it is not avoided CAUTION Indicates a potentially hazardous situation which can result in minor or moderate injury to personnel or damage to the equipment if it is not avoided HIGH VOLTAGE This symbol indicates the presence of high voltage It calls your attention to situations or operations that could be dangerous to you and other persons operating the equipment Read these messages and follow the instructions carefully Safety Issue
18. Ground Lead Green A JL f nnnalL i Top Panel Mounting Hole Power Tem inal Bick 4 places Prhted Circuit Board Display Cable Red Lead Snap Rivets yp Optibn Card Bracket PCS Mounting Screw y p Beck Lead Figure 11 Model GF868 Rack Mount Console Assembly ref dwg 705 849 EPROM U4 Back ight Cable Nut amp Washers yp Key pad Cable mg DigitalFlow GF868 Service Manual 1 and 2 Channel 50 A Acceleration Error E6 2 044404 sero ae eas 19 Alarms Option Card Testing 24 4423 40ss 04e20 11 Amplitude Error ES 422 ous ao A ER R 19 Analog Inputs Option Card Calibrating 6 Analog Output Error ET 19 Analog Outputs Slot 0 As Calibrated Current Source 6 ANDEAN mes dt a eX ERE oda eS ENT 2 Ostia head T 2 Resolutions 5 oP RRS ows GK xe AT KEE ROS S 2 Analog Outputs Option Card A ee N hee sexe 2 Linea A 2 Resol ae cds As 2 B Bracket Option Calo in 33 C Cable A es SUP EA bad we 31 33 A e PP ee eee hae we 31 34 WS Pl anos 31 Calibrating See Parameter Name Calibration Menu Entering 1 Circuit Board See Printed Circuit Board Contamination GaS oooooo oo 26 Corrosion Transducers o oooooomo o 27 D Diagnostics Menu Enter gt conercartoor radeon ARS SA EE 23 EXE oa odres ns a bee ees da 25 Display Cable rm 31 LCD ud a e ud LE 34 Replacing 222259 bho stead EE ES AES 34 Display Screen Errot Mess
19. High End of the Output Ronge 2 ccc cece cence eee e cent n 4 1 34 Testing the Analog Output Linearity dir 5 Calibrating the a A e on II PE P OPPIDO p PRER I d 6 1 4 1Aecessing the Calibration MS pot cd a ii i ii 7 LG 2 GLOW Eie ode TTT 8 LAS a TFT s iaa aq E ERHEAOE eens snare EEE RA EE EE aeenendears EAA AER 8 VERLA OpNOD SES suae ta ud ies a aor De ata A p Od rice RA AE da Enel 8 UTE 20 MA o T 8 Calibra TiS RUD JAPUS osi EE di bi 9 1 5 1 Accessi the Calibration MS orto ceat Ead Sede sed D Who EUST I SU WE Se Cien dU Rare 9 15 2 Probe Oren IF Es 9 L5 Numer DIR S E ooi rg SOUL MIR AP RES QUCRE dea mean aid Ip S Ra RERBA EIE ES eee 10 Testing the Alarm R OS oec oaa cepe eter deg a Eoo tor Eodem RED dac qudd ice s a dada cud ed etg 11 1 6 1 Accessing the Calibration Menu icone aee eb eec er Rer CERCA EROS Gd ed bed canes 12 Testing the Totalizer Frequency OUtDUts i242 rtr Ero RR HG Ra iE RE EIER SURE REPERI aS ac Ae REPRE DIE 13 1 7 1 Accessing the Calibration MISA Prem 14 1 7 2 Entenng SUENA ii 14 LeS BB A o A 14 DigitalFlow GF868 Service Manual 1 and 2 Channel V Contents Chapter 2 Error Codes and Screen Messages 2 els e ARA A A E 17 Note EQ NO EMO uer eee hr aora DECIR eb erben i a asta Free es 18 Action as MC 18 Action sueco P ael olio PERTH 18 PICHON ES elus M UU 18 Action E4 Signal eee o
20. J41 J46 on the rear of the printed circuit board By removing the screw on the rear panel remove the appropriate option slot cover to make room for the external connector on the new option card 4 To install the option card insert its 32 pin connector into the chosen option card socket and gently press the card into place Make sure that the pins in the connector are straight and properly aligned with the socket and that the option card is oriented with its external connector positioned in the opening on the rear panel CAUTION Do not force the option card into the socket If the card does not enter the socket easily check for and straighten any bent pins in the connector and try again 5 Repeat steps 3 and 4 to install any additional option cards 6 Place the metal bracket over the option cards making sure that all installed option cards are inserted into the plastic card guides in the bracket The bracket must be oriented so that the six card guides are directly above the six sockets on the printed circuit board do not install the bracket rotated 180 out of position Secure the metal bracket to the printed circuit board with the four plastic snap rivets provided 7 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model GF868 flowmeter may now be placed back into service Reconnect the main
21. Model GF868 must be disconnected before proceeding 1 Open the cover on the electronics console For LVD compliant units remove the two mounting screws and lift the clear plastic shroud out of the electronics console 2 Locate the black plastic fuse holder that is mounted on the printed circuit board between the power terminal block TB1 and the RS232 terminal block As shown in Figure 8 on page 37 the fuse holder extends below the main aluminum shroud and the fuse holder cap is located on the bottom of the fuse holder 3 Using a small standard screwdriver turn the fuse holder cap counterclockwise about 1 4 turn The fuse holder cap with the captive fuse will be ejected from the fuse holder 4 Replace the defective fuse with a new one of the same rating and type Use only 1 1 4 x 1 4 Slo Blo fuses having a rating as indicated in Table 4 and on the wiring diagram label Table 4 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 100 120 VAC 1 0 A Slo Blo 220 240 VAC 0 5 A Slo Blo 12 28 VDC 3 0 A Slo Blo 5 Press the new fuse into the fuse holder cap and insert the fuse into the fuse holder While applying a slight pressure with the screwdriver twist the fuse holder cap 1 4 turn clockwise 6 For LVD compliant units place the clear plastic shroud over the standoffs in the electronics console and secure it in place with its two mounting screws Close the cover on the electronics console The Mode
22. aced back into service Reconnect the main power and resume taking measurements Note Be sure to record the fuse replacement in Appendix A Service Record 42 DigitalFlow GF868 Service Manual 1 and 2 Channel Appendix B Optional Enclosures B 4 Rack Mount Option Card Installation The Model GF868 flowmeter can accommodate up to six option cards in a manner similar to that used in a PC The option cards are installed into sockets on the printed circuit board and they are held in place with a metal bracket A single metal bracket is used to secure all the installed option cards Note If the Model GF868 presently has no option cards installed be sure to purchase the metal mounting bracket along with the first option card Refer to Figure 11 on page 50 and complete the following steps 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated WARNING The main power to the Model GF868 must be disconnected before proceeding 2 Ifone or more option cards are already installed remove the four fasteners that secure the metal bracket to the printed circuit board Lift the metal bracket straight up and away from the printed circuit board Note The fasteners may be either plastic snap rivets or metal hardware in some older meters In either case they may be discarded as new plastic snap rivets will be provided 3 There are six 32 pin option card sockets
23. ag x eua s pREX RR UE RERO eor 17 A sU DROCER UN Ra ARRAS 17 DigitalFlow GF868 Service Manual 1 and 2 Channel Index E EPROM A a ee ees 32 User Proprait edad A ads 32 Error Codes 42 E beUi 18 19 20 Error Message Display Screen 17 Expansion Slots ooa de dedere PRICES SOSA 1 F Flowcell Problems A AK 26 PRG 002025 ad ideas dad ds 26 Fuse lo TCI 30 o P 30 Replacing 122529 pa Pn dap EUR 30 vp I C C 30 A 2303 uu RO 3S POP A Eua SEE 30 G Gas Contaminati n s cesis ee bre RES ER ERIS 26 Physical Requirements 23475 Rr PER ES 26 Problems 22 u4asiu sibOIaRESR seh TREE Pes 26 PouBdspeed uos douces dero RR EAS 26 Grounding Strap eaa V ab as ACRAS iasi 35 Guides Option Card dra cad 33 K A A sa le hese eters 31 L LCD Display ia sia dias dia 34 Leaks Transducers e o 27 Low Signal Brror BT esse sR R RRR iris 18 LVD Statement esee icr deine es esas 29 N INO Error EU quu 3 299 RARA AAA 18 Numer Option tor RTD Option Card lt sa 20 R RE 0 T SS 10 51 Index O Option Card Analog OUDDUDS E AAA 2 Bracket A Ae e 33 Egpa sion S ols a dt a 1 qu ab R 33 lle crios 2239924 idas dades 33 SOCKS corr daras pias 33 Over Range Error Eld c c ceecavsesve pobres 20 P Pipe Measurements ETT ET ESI IU TE TTC II C 26 Problem uy drip p e AS Pep 26 Pressure Input Error E9 vidas 19 Printed Circuit Board EPROM isis
24. aintain the equipment The product is an electrical apparatus and must be installed in the hazardous area in accordance with the requirements of the EC Type Examination Certificate The installation must be carried out in accordance with all the appropriate international national and local standard codes and practices and site regulations for flameproof apparatus and in accordance with the instructions contained in the manual Access to the circuitry must not be made during operation 1100 Technology Park Drive Billerica MA 01821 U S A CSS 0013 Rev A Telephone 978 437 1000 or 800 833 9438 August 2014 Sensing House Shannon Free Zone East Shannon County Clare Ireland Telephone 353 61 470200 Certification Safety Statements for GE Infrastructure Products Used in Hazardous Locations August 2014 Special Conditions for Safe Use 1 Consult the manufacturer if dimensional information on any flameproof joint is necessary 2 Follow the manufacturer s instructions to reduce the potential of an electrostatic charging hazard 3 Consult the manufacturer for genuine replacement flange fasteners M10x35 hexagon socket cap screws of ISO 12 9 DIN912 grade steel zinc plated or better with a minimum yield strength of 135 000 psi are acceptable alternatives 4 The sensor body temperature code rating is dependent on the process temperature It is assumed that the external surface of the sensor body will be at worse case equal to the process temp
25. ansmitter and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs on the option card E11 Not Used This error code message is not currently in use E12 Not Used This error code message is not currently in use E13 Over Range Problem This error code message indicates that the present measurement exceeds the capacity of the meter Cause A internal mathematical overflow has occurred in either the volumetric or mass flow calculations Action Select larger measurement units or a shorter time interval for the current measurement parameter For example choose KSCF M instead of SCF M See Chapter 2 Initial Setup of the Startup Guide for instructions E14 Totals Overflow Problem The totalizers are unable to keep up with the total flow signals Cause The programmed units pulse value is too small Action Select a larger number of units pulse value E15 Equation Limit Problem The meter cannot resolve the molecular weight of the gas based on the measured sound speed temperature pressure and N concentration Note The mw reading will appear as 2 0e3 or 3 0e3 in order to flag this condition Cause One or more of the above measurements must be incorrect Action Verify the pressure and temperature readings are correct Verify the programmed or input nitrogen concentration is correct Verify that the acoustic transit time measurements are operating properly and that the pro
26. asten the shroud to the standoffs with the six sets of screws and washers 8 Reconnect the power line wires and the PC board ground wire to terminal block T81 on the printed circuit board Plug all other electrical connectors into the appropriate sockets on the printed circuit board and option cards See Chapter 1 Installation of the Startup Guide for instructions on proper wiring of the Model GF868 Note For an LVD compliant meter with the clear plastic shroud over the electrical connectors there will be standoffs in the two mounting locations along the bottom edge of the printed circuit board For meters not equipped with this shroud there will be Phillips head screws in these two locations 9 ForLVD compliant units position the clear plastic LVD shroud over the electrical connections so that the two holes in the shroud align with the standoffs on the printed circuit board Secure the shroud to the standoffs with the two sets of screws and washers 10 After carefully checking for and removing any loose hardware in the enclosure close the electronics console and reconnect the main power to the Model GF868 Note For compliance with the European Union s Low Voltage Directive 73 23 EEC this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model GF868 The power cord is the main dis
27. aused by poor flow conditions or improper transducer spacing Action Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems E7 Analog Out Error Problem The current in the analog output circuit exceeds the limits for the analog output port Cause The output load exceeds the specified limits for the analog output port Action Make sure the output load is 550 ohms for the Slot O analog outputs or is 1000 ohms for an analog outputs option card slots 1 6 E8 Temp In Problem This message indicates a temperature input error Cause The temperature exceeds the specified limits for the analog inputs option card or no input device is connected Action Check the temperature transmitter and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs on the option card E9 Press In Problem This message indicates a pressure input error Cause The pressure exceeds the specified limits for the analog inputs option card Action Check the pressure transmitter and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs on the option card DigitalFlow GF868 Service Manual 1 and 2 Channel 19 Chapter 2 Error Codes and Screen Messages E10 Special Input Problem This message indicates a special input error Cause The special input exceeds the specified limits for the analog inputs option card Action Check the special tr
28. by poor flow conditions and or excessive turbulence Make sure the actual flow rate is within the programmed limits See the Programming Manual for details Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems E4 Signal Quality Problem Cause Action 18 The signal quality is outside the limits programmed in the SETUP submenu of the User Program The peak of the upstream or downstream correlation signals has fallen below the correlation peak limit as set in the SIGNL submenu This may be caused by a flowcell or electrical problem Check for sources of electrical interference and verify the integrity of the electronics console by temporarily substituting a test flowcell that is known to be good Check the transducers and relocate them if necessary See Chapter 3 Diagnostics for instructions DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 2 Error Codes and Screen Messages ES Amplitude Error Problem The signal amplitude exceeds the limits programmed in the SETUP submenu of the User Program Cause Excessive levels of an attenuating gas such as CO are present in the flowcell Solid or liquid particulates may be present in the flowcell Action Refer to Chapter 3 Diagnostics to correct any flowcell problems E6 Cycle Skip Accel Problem The acceleration exceeds the limits programmed in the SETUP submenu of the User Program Cause This condition is usually c
29. cludes two built in analog outputs A and B at terminal block 170 which is designated as Slot 0 Additional analog outputs may be added to the Model GF868 by installing an Analog Outputs Option Card in one or more of the six expansion slots Each option card contains four analog outputs which are designated as A B C and D Both the zero point and full scale values for each output must be calibrated After calibrating the outputs which have a resolution of 5 0 uA 0 03 full scale their linearity should be tested Note The zero point of the analog output may be set for either 0 mA or 4 mA However the calibration procedure always uses the 4 mA point as the meter will extrapolate this value to obtain the 0 mA point Prepare for the calibration procedure by connecting an ammeter to the desired analog output of Slot X as shown in Figure 1 and Figure 2 on page 3 on the next page Refer to the menu map in Figure 6 on page 15 Terminal Block I O Slot 0 Ammeter Figure 1 Ammeter Connection for Slot 0 Output A 2 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration 13 Calibrating the Analog Outputs cont Terminal Block Option Card Ammeter Figure 2 Ammeter Connection for Slots 1 6 Output A 1 3 1 Access
30. connect device DigitalFlow GF868 Service Manual 1 and 2 Channel 5 Chapter 4 Parts Replacement 4 7 Installing the Printed Circuit Board cont Before taking measurements with the Model GF868 refer to Chapter 2 Initial Setup of the Startup Guide and Chapter 1 Calibration of the Service Manual for instructions on properly setting up the meter for accurate flow rate measurements Note Be sure to enter a complete and detailed account of the service procedure performed on the Model GF868 in Appendix A Service Record 4 8 Spare Parts All of the necessary components to upgrade or repair the Model GF868 flowmeter are readily available from GE As a convenient reference some of the more common spare parts are listed in Table 5 Table 5 Spare Parts List 703 1127 02 Option Card Alarms Hermetically Sealed 703 1145 02 Option Card Analog Inputs 703 1126 02 Option Card Analog Outputs 703 1145 03 Option Card RTD Inputs 703 1144 02 Option Card Totalizer Frequency Outputs 703 1358 Option Card MODBUS 421 703 Card Cage Metal Bracket 417 027 Card Guide Nylon 703 1247 Printed Circuit Board 705 671 LCD Display Assembly 147 744 EPROM 421 700 Conduit Plate 1 2 421 701 Conduit Plate 3 4 421 702 Conduit Plate Blank 421 946 LVD Plastic Shroud 421 686 Main Aluminum Shroud 442 484 Label Wiring Diagram To purchase the parts listed in Table 5 abov
31. e appropriate pins on the terminal block See Figure 3 on the previous page for the correct pin numbers To calibrate a 0 4 20 mA input card see the section below Note To calibrate an RTD input card refer to page 9 4 Press F1 F4 to select the reference point to be calibrated Do one of the following e If you selected F1 aLOW proceed to aLOW Option on the next page If you selected F2 aHIGH proceed to aHIGH Option on the next page If you selected F3 4 mA proceed to 4 mA Option on the next page If you selected F4 20 mA proceed to 20 mA Option on the next page DigitalFlow GF868 Service Manual 1 and 2 Channel 7 Chapter 1 Calibration 1 4 2 aLOW Option F1 1 2 3 Enter the low reference value and press the ENT key Press F1 to store the current low reference value or press F2 to cancel the entry In either case the ANALOG INPUT prompt will reappear Press F2 to proceed to the next section 1 4 3 aHIGH Option F2 1 2 3 Enter the high reference value and press the ENT key Press F1 to store the current high reference value or press F2 to cancel the entry In either case the ANALOG INPUT prompt will reappear Proceed to Procedure Options below 1 4 4 4mA Option F3 1 2 3 Connect the 4 mA current source to the currently selected analog input as shown in Figure 3 on page 6 Press F1 to store the current 4 mA value or pr
32. e or any items not listed in the table contact the factory for assistance To make sure the proper components are obtained be sure to specify the serial number of the Model GF868 at the time of purchase 36 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 4 Parts Replacement Front View Keypad Cable Mounting Screw 8 places Main Shroud Main Shroud o O Nuts amp Washers WARNING amp 4 places Display Cable Nuts amp Washers DISCONNECT POWER BEFORE REMOVING FUSE drat dn Display Shroud 4 i Option Card Socket SLOT4 SLOT3 SLOT ANALOGOUT T ANALOGIN TOTUFREQ EEES LCD Display Metal Bracket 8 NW sio INHI No emt yoy o te sic RIN No ULTRASONIC FLOUNETER ETE mio c 8 NEMA TYPE S6 iH no F lt gt RIN 24 an 14 ws Te so C 100120 Vc BIA m Fasteners U GNL 1 AMP E CODES Option Card Backlight Cable 299 Hui Te Standoffs Display Shroud
33. east 10 C above rated ambient Connecting cables shall be mounted securely and protected from mechanical damage pulling and twisting Cable entry thread types are identified on the equipment label Cable glands of an approved flameproof design are required for Ex d rated equipment These must be installed according to the manufacturer s instructions Where the cable glands are provided by GE the manufacturer s instructions as supplied to GE will be included in the documentation Unused cable entries must be sealed using a suitably certified threaded plug Modifications to any flameproof enclosure are not permitted The apparatus must be de energized before opening servicing and conducting any routine maintenance Installation shall be in accordance with the installation instructions and the National Electrical Code ANSI NFPA 70 the Canadian Electrical Code C22 1 or IEC EN 60079 14 as applicable The product contains no exposed parts which produce surface temperature infrared electromagnetic ionizing or non electrical dangers The product must not be subjected to mechanical or thermal stresses in excess of those permitted in the certification documentation and the instruction manual The product cannot be repaired by the user It must be replaced by an equivalent certified product Repairs should only be carried out by the manufacturer or by an approved repairer Only trained competent personnel may install operate and m
34. erature up to 140 C In all cases the electronics assembly will be marked T6 as it will be locally mounted for process temperatures up to 85 C and will be remotely mounted for process temperatures exceeding 85 C Markings Markings appear on the instrument label which identifies the product model serial number operating ranges hazardous area ratings entry thread type and warning and caution information EU EEA Installation Compliance The use of this apparatus is subject to the EU directive on minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres Council Directive 1999 92 EC The installer is required to be familiar with this document or the National transposing legislation Increased Safety Wiring Connections Power Connection Maximum Size Solid 4 0 mm 12 AWG Stranded 2 5 mm 14 AWG Number of conductors 2 Solid max 1 5mm 16 AWG 2 Stranded max 1 0 mm 18 AWG All Other Screw Terminal Connections Maximum Size Solid 4 0 mm 12 AWG Stranded 2 5 mm 14 AWG Number of conductors 2 Solid max 1 5mm 16 AWG 2 Stranded max 1 0 mm 18 AWG t Single conductor t Multi conductors of same cross section CSS 0013 Rev A 2of2 GE EC DECLARATION Sensing OF CONFORMITY DOC 0013 Rev B We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the
35. ess F2 to cancel the entry In either case the ANALOG INPUT prompt reappears Press F4 to proceed to the next section 1 4 5 20 mA Option F4 1 2 3 Connect the 20 mA current source to the currently selected analog input as shown in Figure 3 on page 6 Press F1 to store the current 20 mA value or press F2 to cancel the entry In either case the ANALOG INPUT prompt reappears Proceed to Procedure Options below 1 45a Procedure Options You have completed calibration of the analog output Do one of the following o calibrate another input return to Step 3 in Accessing the Calibration Menu on page 7 e To calibrate test additional slots press F4 EXIT and proceed to the appropriate section e To leave the Calibration Menu press F4 EXIT twice DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration 15 Calibrating the RTD Inputs Calibrating an RTD option card involves a different procedure than for other analog input cards However you access the card in the same manner as other cards 1 5 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installed option card If you have installed an RTD option card the following screen appears Press F1 to select the Probe method of calibration or F2 to select the numeric Slot x Inputs m
36. ethod current input selected RTD CALIBRAT last option selected Probe l Numer l The Probe option allows the meter to calculate the temperature vs resistance curve based on input from the RTD in a temperature bath or from an RTD calibrator The Numer option forces the user to calculate and input the curve values numerically IMPORTANT Use only one option for RTD calibration Do not try to calibrate with both options 1 5 2 Probe Option F1 3 Press F1 to select Input A or F2 to select Input B 1 5 2a Set Point Temperature 4 Press F1 to enter the set point temperature formerly known as the zero point This temperature should be at the low end of your expected operating range 5 Enter the desired set point temperature and press ENT 6 Press F1 to STORE the entered temperature or F2 to ABORT the calibration In either case the screen returns to the ANALOG INPUT prompt 1 5 2b Slope Point Temperature 7 Press F2 to enter the slope point temperature This temperature should be as far from your set point as your temperature bath will allow within the range 100 to 350 C 8 Enter the desired slope point temperature and press ENT 9 Press F1 to STORE the entered temperature or F2 to ABORT the calibration In either case the screen returns to the ANALOG INPUT prompt 10 Proceed to Procedure Options on the next page DigitalFlow GF868 Service Manual 1 and 2 Channel 9 Chapter 1 Cal
37. f the ammeter Then repeat the low and high end calibrations If the analog output still does not pass the linearity test contact the factory for assistance 1 3 4a Procedure Options You have completed calibration of the analog output Do one of the following To calibrate or test another output press F4 EXIT and return to Step 3 in Accessing the Calibration Menu on page 3 To calibrate test additional slots press F4 EXIT twice and proceed to the appropriate section e To leave the Calibration Menu press F4 EXIT three times DigitalFlow GF868 Service Manual 1 and 2 Channel 5 Chapter 1 Calibration 14 Calibrating the Analog Inputs Analog inputs may be added to the Model GF868 flowmeter by installing an Analog Inputs Option Card in one or more of the six expansion slots The option card contains two analog inputs which are designated as A and B Each of the inputs which may be either a 0 4 20 mA input or an RTD input must be calibrated at both the zero point and full scale values After calibrating the inputs their linearity should be tested Calibration of the analog inputs requires the use of a calibrated current source If an independent calibrated current source is not available one of the Slot 0 analog outputs may be used for the calibration During the analog input calibration the Slot 0 analog output will supply the low reference high reference 4 mA and 20 mA signals at the appropriate times
38. g the meter from the rack Otherwise disconnect all rear panel electrical connections and remove the meter from the rack before proceeding IMPORTANT Keep a detailed record of all service procedures in Appendix A Service Record This record may prove very helpful in diagnosing any future problems DigitalFlow GF868 Service Manual 1 and 2 Channel 41 Appendix B Optional Enclosures B 3 Rack Mount Fuse Replacement If it has been determined that the fuse in the Model GF868 requires replacement refer to Figure 10 on page 49 and Figure 11 on page 50 and complete the following steps 1 On the rear panel of the meter set the power switch to the OFF position and pull the power cord out of its receptacle WARNING The main power to the Model GF868 must be disconnected before proceeding 2 Locate the black plastic fuse cover on the back panel at the bottom of the power cord receptacle and pull it straight out 3 Replace the defective fuse with a new one of the same rating and type Use only 5 x 20 mm Slo Blo fuses having a rating as indicated in Table 7 and on the rear panel label Table 7 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 100 120 VAC 1 0 A Slo Blo 220 240 VAC 0 5 A Slo Blo 12 28 VDC 3 0 A Slo Blo 4 Reinstall the black plastic fuse cover and insert the power cord back into the receptacle Then position the power switch in the ON position The Model GF868 flowmeter may now be pl
39. gile part and is the one most subject to damage Minor damage may be repaired by carefully bending the connector back into shape If the connector can not be repaired the transducers must be replaced Note Transducers must be replaced in pairs Refer to Chapter 2 Initial Setup of the Startup Guide to program the replacement transducer data into the meter If the instructions in this section fail to resolve the problem contact the factory for assistance DigitalFlow GF868 Service Manual 1 and 2 Channel 27 Chapter 3 Diagnostics no content intended for this page 28 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 4 Parts Replacement Chapter 4 Parts Replacement 4 1 Introduction The electronics console of the Model GF868 has been designed to permit easy on site upgrades and parts replacement See Figure 8 on page 37 and Figure 9 on page 38 for details of the standard GF868 electronics console assembly The instructions in this chapter along with a few common tools are all that is required to perform the following tasks e fuse replacement e printed circuit board PCB removal and installation e EPROM replacement option card installation e LCD display replacement IMPORTANT For meters supplied in any of the optional enclosure types see Appendix B Optional Enclosures for instructions specific to that unit WARNING Prior to performing any maintenance procedures be sure to disconnect the mai
40. grammed path and axial length dimensions are correct 20 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 2 Error Codes and Screen Messages 2 2 Screen Messages A variety of messages may appear on the display screen during the performance of a task Since the error codes have already been discussed in this chapter and the locator bar messages are discussed in detail in Chapter 3 Operation of the Startup Guide they will not be repeated here All other messages are listed in Table 2 below Table 2 Screen Messages Mesa T l Backup Battery FAIL Power Up Messages The backup battery that powers non volatile RAM has failed Contact the factory Backup Battery OK The backup battery that powers the non volatile RAM has passed DSP Processor OK The DSP digital signal processor has passed DSP RAM Failed The DSP digital signal processor RAM has failed Contact the factory DSP RAM OK EPROM sum XXXX The DSP digital signal processor RAM has passed Record the EPROM sum at the initial power up and periodically thereafter FRIGID_INIT Executed The NVR non volatile RAM was automatically initialized due to a memory fault Contact the factory NVR FAIL The non volatile RAM has failed Contact the factory NVR OK All Logs Cleared hit key The non volatile RAM has passed Measurement Mode Messages This message may appear during one of the following tasks clearing a
41. he EPROM The Model GF868 s User Program is stored on an erasable programmable read only memory EPROM chip The EPROM which is designated as component U4 is located in the top left corner of the rear of the printed circuit board See Figure 9 on page 38 for a rear view of the printed circuit board EPROM replacement may be required to replace a defective chip or to upgrade to a newer software version To replace the EPROM complete the following steps 1 Remove the printed circuit board as described in a previous section of this chapter 2 Place the printed circuit board face down on a clean flat surface Locate the EPROM socket in the top left corner of the board CAUTION The EPROM is easily damaged by static electricity Before handling the new chip touch a grounded metal object to discharge any built up static electricity and avoid touching the leads on the side of the chip 3 Usinga chip puller remove the EPROM from its socket If a chip puller is unavailable a straightened paper clip may be used in the notches at the upper right and lower left corners of the socket Gently pry the EPROM up a little at a time at each notch until it comes free 4 Make sure that the beveled corner on the new EPROM is aligned with the beveled corner of the socket and place the EPROM into the socket 5 Byapplying equal pressure on all four corners gently press the EPROM into the socket until it is fully seated Do not strike the EPROM or appl
42. he option card has been installed in Slot x DigitalFlow GF868 Service Manual 1 and 2 Channel 13 Chapter 1 Calibration 1 7 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press F1 F4 to select output A B C or D respectively 1 7 2 Entering Frequency 4 Entera new frequency in the range of 1 10 000 Hz and press the ENT key Verify that the frequency counter reads the correct value 1 7 3 Entering Pulse Number 5 Enter a new frequency in the range of 1 10 000 Hz and press the ENT key Verify that the frequency counter reads the correct value 6 Repeat Steps 3 4 and 5 to test all four of the frequency totalizer outputs If any of the outputs fails to pass the test contact the factory for assistance 1 7 3a Procedure Options You have completed testing the totalizer frequency outputs Do one of the following To calibrate test additional slots press F4 EXIT and proceed to the appropriate section e To leave the Calibration Menu press F4 EXIT twice 14 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration F1 F2 F3 F4 F1 F2 F3 Slot x Option Card Slot 0 Outputs TB I O Slot x Inputs Analog Inputs Slot x Outputs Alarms F1 F2 F1 F2 F1 F3 F2 a B aj 8B a B ce
43. hip 3 Make sure that the beveled corner on the new EPROM is aligned with the beveled corner of the socket and place the EPROM into the socket 4 By applying equal pressure on all four corners gently press the EPROM into the socket until it is fully seated Do not strike the EPROM or apply excessive force during this procedure 5 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model GF868 flowmeter may now be placed back into service Reconnect the main power and resume taking measurements Note Be sure to record the EPROM replacement in Appendix A Service Record 44 DigitalFlow GF868 Service Manual 1 and 2 Channel Appendix B Optional Enclosures B 6 Rack Mount LCD Display Replacement The Model GF868 measurements are displayed on a two pane LCD graphic display panel The LCD display normally provides years of dependable service but it is field replaceable when necessary To replace the LCD display refer to Figure 11 on page 50 and complete the following steps 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated WARNING The main power to the Model GF868 must be disconnected before proceeding 2 Using a 3 16 in nutdriver remove the four nut washer sets that secure the display shroud to the ins
44. iance Waste Electrical and Electronic Equipment WEEE Directive GE Measurement amp Control Solutions is an active participant in Europe s Waste Electrical and Electronic Equipment WEEE take back initiative directive 2012 19 EU The equipment that you bought has required the extraction and use of natural resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the appropriate take back systems Those systems will reuse or recycle most of the materials of your end life equipment in a sound way The crossed out wheeled bin symbol invites you to use those systems If you need more information on the collection reuse and recycling systems please contact your local or regional waste administration Visit http www ge mcs com en about us environmental health and safety weee html for take back instructions and more information about this initiative iv DigitalFlow GF868 Service Manual 1 and 2 Channel Contents Chapter 1 Calibration 1 1 1 2 1 5 1 4 1 5 1 6 1 7 gs AA A A A A TEN 1 Missae ia ran ati ei 1 Calibrating the Analog OUTPUTS crap arde 2 1 31 Accessing the Calibration MENU euo dizi o E RR TRRETC Rer CE Rr BEP a 3 1 3 2 Calibrating the Low End of the Output Ronge or or 4 1 3 3 Calibrating the
45. ibration 1 5 3 Numer Option F2 The Numer option forces the user to calculate the temperature vs resistance information To do this the user must first collect data using the RTDs option in the PRINT menu discussed in Chapter 5 of the Programming Guide The RTDs option allows you to know what point value the GF868 is reading at a given temperature With this information the Numer option enables you to enter the Set Temperature and the slope of the RTD input in points degree allowing absolute control over RTD calibration Before attempting this step follow the instructions in Chapter 5 of the Programming Manual The RTDs Submenu to obtain point values at your set point and slope point 1 Press F1 to select Input A or F2 to select Input B 1 5 3a Set Number 2 Press F1 to enter the set number formerly known as the zero point 3 Enter the set point temperature and press ENT 4 The program then asks for the set point number Enter the points measured at the set temperature and press ENT 1 5 36 Slope Number 5 Press F2 to enter the slope number Calculate the slope number with the formula Slope Slope points set points slope temp set temp 6 Enter the RTD slope number and press ENT 1 5 3c Procedure Options You have completed calibration of the RTD input Do one of the following To calibrate another input press EXIT To calibrate additional slots press EXIT and then F4 EXIT and p
46. ide of the front panel Pull the display shroud off its mounting studs 3 Using a 1 4 nutdriver remove the four standoffs that secure the LCD display assembly to the front panel Pull the LCD display assembly off its mounting studs 4 Place the new display in the enclosure and replace the circuit board connections of the data and power cables of the old display with those of the new display Be sure to orient the new cables in the same way as the old ones when making the connections to the printed circuit board Remove and discard the old LCD display 5 Place the new LCD display assembly over the mounting studs on the front panel and fasten it in place with the four standoffs Make sure that the LCD display assembly is oriented with the cables pointing toward the left side away from the keypad of the meter CAUTION Do not overtighten the standoffs or the display assembly may be damaged 6 Position the LCD display cables between the two mounting studs and install the display shroud over the mounting studs The top and bottom edges of the shroud are bent at a 90 angle to the main surface and these edges must face inwards toward the display assembly Note One edge of the display shroud is covered with a piece of black electrical tape This side of the shroud should be over the cables to protect them against abrasion 7 Fasten the display shroud to the front panel with the four sets of nuts washers CAUTION Do not overtighten the
47. ing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press Fx to select the desired output IMPORTANT The procedure for calibrating all the outputs is the same However when calibrating a different output be sure to reconnect the ammeter to the appropriate pins on terminal block I O See Figure 1 on page 2 or Figure 2 above for the correct pin numbers DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration 1 3 2 Calibrating the Low End of the Output Range 1 Press F1 to calibrate the low end of the output range 2 Press F1 or F2 to adjust the ammeter reading UP or DOWN until a 4 mA reading is achieved If you press F3 Numer enter a numeric value for the calibration point and press ENT 3 Press F4 to STORE the setting or press gt and F1 to ABORT the calibration Note If the ammeter reading cannot be adjusted within 5 0 uA of the 4 mA setting contact the factory for assistance 1 3 3 Calibrating the High End of the Output Range 1 Press F2 to calibrate the high end of the output range 2 Press F1 or F2 to adjust the ammeter reading UP or DOWN until a 20 mA reading is achieved If you press F3 Numer enter a numeric value for the calibration point and press ENT Note If the ammeter reading cannot be adjusted within 5 0
48. ing the instrument to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period is e one year from delivery for electronic or mechanical failures one year from delivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties or merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Sensing giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory service GE Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Sensing instruc
49. l GF868 flowmeter may now be placed back into service Reconnect the main power and resume taking measurements Note Be sure to record the fuse replacement in Appendix A Service Record 30 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 4 Parts Replacement 4 3 Removing the Printed Circuit Board All of the remaining maintenance procedures discussed in this chapter require removal of the printed circuit board To accomplish this task see Figure 8 on page 37 and Figure 9 on page 38 while completing the following 1 Remove the main power to the electronics console WARNING The main power to the Model GF868 must be disconnected before proceeding 2 Open the electronics console For LVD compliant units remove the two mounting screws and lift the clear plastic shroud out of the electronics console Remove the six mounting screws and lift the main aluminum shroud out of the electronics console 3 Disconnect the main power leads and the PC board ground wire from terminal block TB1 on the printed circuit board Remove the electrical connectors from all installed option cards and terminal blocks Disconnect the twisted pair display backlight cable from connector J2 on the left side of the printed circuit board 4 Using a 3 8 in nutdriver or open end wrench remove the three short standoffs along the left side of the main circuit board and the three long standoffs along the right side of the main circuit board 5 Whi
50. le supporting the printed circuit board remove the two screws or standoffs along the bottom edge of the printed circuit board Note For an LVD compliant meter with the clear plastic shroud over the electrical connectors there will be standoffs in these two locations For meters not equipped with this shroud there will be Phillips head screws in these two locations 6 Carefully lift the printed circuit board out of the enclosure Continue to support the printed circuit board as the keypad and display cables are still connected to the rear of the board CAUTION During this procedure be very careful not to damage the upright components along the top edge of the printed circuit board see Figure 9 on page 38 Severe or repeated bending of these components will break their leads 7 Tilt the top of the printed circuit board forward and mark the top edges of the two ribbon cable connectors Then remove these cables from their connectors on the rear of the board 8 The printed circuit board is now free and may be removed to a clean work area If the printed circuit board is being replaced proceed to the section on nstalling the Printed Circuit Board page 34 now Otherwise refer to the appropriate section for instructions on nstalling an Option Card page 33 Replacing the EPROM below or Replacing the LCD Display page 34 DigitalFlow GF868 Service Manual 1 and 2 Channel 31 Chapter 4 Parts Replacement 4 4 Replacing t
51. measurements are not possible Realignment of the flowcell or transducers often cures such problems and in some cases transducers that protrude into the flow stream may be used Refer to Chapter 1 Installation of the Startup Guide for more details on proper installation practices Inaccurate pipe measurements The accuracy of the flow rate measurements is no better than the accuracy of the programmed pipe dimensions For a flowcell supplied by GE the correct data will be included in the documentation For other flowcells measure the pipe wall thickness and diameter with the same accuracy desired in the flow rate readings Also check the pipe for dents eccentricity weld deformity straightness and other factors that may cause inaccurate readings Refer to Chapter 2 Initial Setup of the Startup Guide for instructions on programming the pipe data In addition to the actual pipe dimensions the path length P and the axial dimension L based on the actual transducer mounting locations must be accurately programmed into the flowmeter For a GE flowcell this data will be included with the documentation for the system If the transducers are mounted onto an existing pipe these dimensions must be precisely measured See Appendix D Measuring P and L Dimensions of the Startup Guide for a thorough discussion of this topic DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 3 Diagnostics 3 5 Transducer Problems Ultrasonic tra
52. n every Model GF868 flowmeter includes two built in analog outputs A and B at terminal block 1 0 which is designated as Slot 0 Note Convention in this manual identifies any expansion slot as Slot x where x is a number from 0 6 See Chapter 1 Installation of the Startup Guide for a complete description of the available option cards and the procedures for wiring them 1 2 Menu Map The Calibration Menu is accessed by pressing the CAL key on the keypad Use this menu to calibrate and test the Slot 0 analog outputs as well as to calibrate and test any option cards that are installed in the expansion slots Refer to the menu map in Figure 6 on page 15 as a guide in following the calibration instructions Note The instructions on the next page apply to both the 1 Channel and 2 Channel versions of the Model GF868 flowmeter The following discussion assumes that the left screen pane is active If the right screen pane is active only the function key designations change That is replace F1 F4 with F5 F8 Proceed to the appropriate sections of this chapter to calibrate and test all of the installed inputs and or outputs Note While in the Calibration Menu if there is no keypad activity for two minutes the Model GF868 will automatically reboot and return to measurement mode DigitalFlow GF868 Service Manual 1 and 2 Channel 1 Chapter 1 Calibration 1 3 Calibrating the Analog Outputs Every Model GF868 flowmeter in
53. n power from the unit Note For compliance with the European Union s Low Voltage Directive this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model GF868 The power cord is the main disconnect device An aluminum shroud over the printed circuit board shields the electrical components and serves as a location for the wiring diagram label All of the procedures discussed in this chapter except for fuse replacement require removal of this shroud Note For compliance with the European Union s Low Voltage Directive a transparent plastic shroud protects the electrical connections The shroud must remain in place except while wiring the unit Reinstall the shroud after the wiring has been completed Use the foldout drawings at the end of this chapter to locate the relevant components while completing the following procedures IMPORTANT Keep a detailed record all service procedures performed on the Model GF868 in Appendix A Service Record This service history may prove very helpful in diagnosing any future problems DigitalFlow GF868 Service Manual 1 and 2 Channel 29 Chapter 4 Parts Replacement 4 2 Fuse Replacement If it has been determined that the fuse in the Model GF868 requires replacement complete the following steps WARNING The main power to the
54. nction keys to select option bar choices DigitalFlow GF868 Service Manual 1 and 2 Channel l 15 Chapter 2 Error Codes and Screen Messages Chapter 2 Error Codes and Screen Messages 2 1 Introduction The Model GF868 ultrasonic flowmeter is a reliable easy to maintain instrument When properly installed and operated as described in the Startup Guide the meter provides accurate flow rate measurements with minimal user intervention However if a problem should arise with the electronics console the transducers or the flowcell a built in error code message system greatly simplifies the troubleshooting process All of the possible Model GF868 error code messages are discussed in this chapter along with the possible causes and the recommended actions When an error code is generated it will appear on the active pane of the display screen in the location shown in Figure 7 Prompt Area Locator Bar Pointer Velocity 6 95 Ch1 E1 Low Signal Option Bar Error Message Figure 7 A Typical Display Screen Note Fora 2 Channel Model GF868 the channel number is displayed in front of the error message Only the error message appears with a 1 Channel Model GFS amp 68 If an error message appears on the display screen during operation of the Model GF868 refer to the appropriate section of this chapter for instructions on how to proceed DigitalFlo
55. nsducer 100 or 22300 Temperature F Displays the gas temperature 4 20 mA input N A Pressure psia Displays the gas pressure 4 20 mA input N A 24 Molecular Wt Displays the average molecular weight of the gas N A DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 3 Diagnostics Table 3 Available Diagnostic Parameters cont Option Bar Screen Display Description ACVOL Act Vol Displays actual volumetric flow KACF MIN StVOL Std Vol KSCF MIN Displays standard volumetric flow if STANDARD equation is used ToffS Skan T Offset Displays dynamically calculated signal timing offset in plays dy y g g usec skan signal measurement Tu S UP Transit S usec Displays Skan Tup Td S DN Transit S usec Displays Skan Tdn DT S DeltaT S usec Displays Skan DELTA UP Transit M usec Displays Measure Tup DN TransitM Displays Measure Tdn usec DeltaT M usec Displays Measure Delta Vinst Ft s Displays the instantaneous velocity for comparison with Vel without averaging Last parameter Leave the Diagnostics Menu These options are available only in the Skan Measure mode 3 3 Diagnostic Record Upon leaving the Diagnostic Menu via the EXIT key or the EXIT option on the option bar the display screen will continue to show the last diagnostic parameter that was selected To return to normal measurement mode
56. nsducers are rugged reliable devices However they are subject to physical damage from mishandling and chemical attack The most common transducer problems are listed below 1 LEAKS Leaks may occur around the transducer and or the flowcell fittings Repair such leaks immediately If the leaking gas is corrosive carefully check the transducer and cables for damage after the leak has been repaired CORROSION DAMAGE If the transducer material was not properly chosen for the intended application the transducers may suffer corrosion damage The damage usually occurs either at the electrical connector or on the transducer surface If corrosion is suspected remove the transducer from the flowcell and carefully inspect the electrical connector and the transducer surface for roughness and or pitting Any transducer damaged in this manner must be replaced Contact the factory for information on transducers in materials suitable for the application INTERNAL DAMAGE An ultrasonic transducer consists of a ceramic crystal bonded to the transducer case The bond between the crystal and the case or the crystal itself may be damaged by extreme mechanical shock and or temperature extremes Also the internal wiring can be corroded or shorted if contaminants enter the transducer housing PHYSICAL DAMAGE Transducers may be physically damaged by dropping them onto a hard surface or striking them against another object The transducer connector is the most fra
57. o assist in reinstallation on the new circuit board 4 Remove the RS232 ANALOG OUT and TRANSDUCER connectors from the printed circuit board Use a marker to identify pin 1 on the right side keypad side of these connectors Note These connectors should be pulled straight up and off the printed circuit board DO NOT remove the leads from the screw terminals 5 Remove the flat KEYPAD CABLE connector from terminal J50 near the front of the printed circuit board Mark pin 1 of the cable connector which is located nearer the rear of the enclosure 6 Disconnect the twisted pair DISPLAY BACKLIGHT cable from connector J2 beneath the left side of the printed circuit board Although this connector is polarized it will help to note that the red wire is closer to the rear of the enclosure 7 Remove the flat LCD DISPLAY CABLE connector from terminal J52 near the option card sockets Mark pin 1 of the cable connector which is located nearer the front of the enclosure 8 Using a slotted screwdriver remove the three mounting screws along each side of the printed circuit board Carefully lift the printed circuit board out of the enclosure Proceed to the next section for instructions on installing the new printed circuit board 46 DigitalFlow GF868 Service Manual 1 and 2 Channel Appendix B Optional Enclosures B 7 2 Circuit Board Installation Refer to Figure 11 on page 50 and complete the following steps 1 Position the new p
58. onnectors J2 Connector uuuuuuuun 01000000 unuuuuuu Figure 9 Standard Model GF868 Printed Circuit Board Assembly TO Rear View PC Board Ground Wire Screws or Standoffs Front View DigitalFlow GF868 Service Manual 1 and 2 Channel 38 Appendix A Service Record Appendix A Service Record A 1 Introduction Whenever any service procedure is performed on the Model GF868 flowmeter the details of the service should be recorded in this appendix An accurate service history of the meter can prove very helpful in troubleshooting any future problems A 2 Data Entry Record complete and detailed service data for the Model GF868 in Table 6 Make additional copies of the table as needed Table 6 Service Record DigitalFlow GF868 Service Manual 1 and 2 Channel 39 Appendix A Service Record _ _ _ __ ____ _ gt gt z___________ QQ a mA o gt QA RR a ao Qa Qo ro QRQQQRReDzzAS Table 6 Service Record cont
59. place the LCD display see Figure 8 on page 37 for the component locations and complete the following steps 1 Remove the printed circuit board as described in a previous section of this chapter 2 Using a 3 16 in nutdriver remove the four nut washer sets that secure the display shroud to the inside of the console cover Lift the display shroud off its mounting studs 3 Using a 1 4 nutdriver remove the four standoffs that secure the LCD display assembly to the console cover Lift the LCD display assembly off its mounting studs 4 Place the new LCD display assembly over the mounting studs on the console cover and fasten it in place with the four standoffs Make sure that the LCD display assembly is oriented as shown in Figure 9 on page 38 CAUTION Do not overtighten the standoffs or the display assembly may be damaged 5 Position the LCD display cables between the two right side mounting studs and install the display shroud over the mounting studs The top and bottom edges of the shroud are bent at a 90 angle to the main surface and these edges must face inwards toward the display assembly Note One edge of the display shroud is covered with a piece of black electrical tape This side of the shroud should be on the right to protect the cables against abrasion 6 Fasten the display shroud to the console cover with the four sets of nuts washers CAUTION Do not overtighten the nuts or damage to the mounting threads may occur
60. power and refer to Appendix C Optional Enclosures of the Startup Guide for instructions on wiring the new option card s Note Be sure to record the option card installation in Appendix A Service Record DigitalFlow GF868 Service Manual 1 and 2 Channel 43 Appendix B Optional Enclosures B 5 Rack Mount EPROM Replacement The Model GF868 s User Program is stored on an erasable programmable read only memory EPROM chip The EPROM which is designated as component U4 is located on the corner of the printed circuit board just behind the keypad on the front panel EPROM replacement may be required to replace a defective chip or to upgrade to a newer software version To replace the EPROM refer to Figure 11 on page 50 and complete the following steps 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated WARNING The main power to the Model GF868 must be disconnected before proceeding 2 Using a chip puller remove the EPROM from its socket If a chip puller is unavailable a straightened paper clip may be used in the notches at opposite corners of the socket Gently pry the EPROM up a little at a time at each notch until it comes free CAUTION The EPROM is easily damaged by static electricity Before handling the new chip touch a grounded metal object to discharge any built up static electricity and avoid touching the leads on the side of the c
61. quirements 1 The gas must be homogeneous single phase and relatively clean Although a low level of entrained particles may have little effect on the operation of the Model GF868 excessive amounts of solid or liquid particles will absorb or disperse the ultrasound signals This interference with the ultrasound transmissions through the gas will cause inaccurate flow rate measurements In addition temperature gradients in the gas flow may result in erratic or inaccurate flow rate readings The gas must not excessively attenuate ultrasound signals Some gases 1 e high purity carbon dioxide hydrogen etc readily attenuate ultrasound energy In such a case an El error code message will appear on the display screen to indicate that the ultrasonic signal strength is insufficient for reliable measurements The gas sound speed may vary The Model GF868 will tolerate relatively large changes in the gas sound speed as may be caused by variations in gas composition and or temperature 3 4 2 Pipe Problems Pipe related problems may result either from a failure to observe the installation instructions as described in the Startup Guide or from improper programming of the meter By far the most common pipe problems are the following 1 26 The collection of material at the transducer location s Accumulated debris at the transducer location s will interfere with transmission of the ultrasound signals As a result accurate flow rate
62. re in some older meters In either case they may be discarded as new plastic snap rivets will be provided 3 There are six 32 pin option card sockets J41 J46 on the rear of the printed circuit board To install an option card insert its 32 pin connector into any available option card socket and gently press the card into place Make sure that the pins in the connector are straight and properly aligned with the socket and that the connector is positioned on the right side of the option card CAUTION Do not force the option card into the socket If the card does not enter the socket easily check for and straighten any bent pins in the connector and try again 4 Repeat step 3 to install any additional option cards 5 Place the metal bracket over the option cards making sure that all option cards are aligned with the plastic card guides in the bracket Secure the metal bracket to the printed circuit board with the snap rivets provided Refer to the installed assembly in Figure 8 on page 37 Complete the option card installation by proceeding to the nstalling the Printed Circuit Board section of this chapter DigitalFlow GF868 Service Manual 1 and 2 Channel 33 Chapter 4 Parts Replacement 4 6 Replacing the LCD Display The Model GF868 s measurements are displayed on a a two pane LCD graphic display panel The LCD display normally provides years of dependable service but it is easily field replaceable when necessary To re
63. rinted circuit board within the electronics console so that it rests on the six standoffs in the base of the enclosure and the option card sockets are located near the rear of the enclosure Secure the circuit board in place with the six screws previously removed 2 Connect the flat LCD DISPLAY CABLE connector to terminal J52 near the option card sockets Make sure the marked pin 1 side of the cable connector is located nearer the front of the enclosure 3 Connectthe twisted pair DISPLAY BACKLIGHT cable to connector J2 beneath the left side of the printed circuit board This connector is polarized and can only be installed with the red wire closer to the rear of the enclosure 4 Connect the flat KEYPAD CABLE connector to terminal J50 near the front of the printed circuit board Make sure the marked pin 1 side of the cable connector is located nearer the rear of the enclosure 5 Install the RS232 ANALOG OUT and TRANSDUCER connectors onto the printed circuit board at the locations indicated in Figure 11 on page 50 Make sure the marked pin 1 sides of the connectors face the right side keypad side of the enclosure Note If any leads have come loose from the screw terminals on these connectors refer to Appendix C Optional Enclosures of the Startup Guide for wiring instructions 6 Reconnect the main POWER LEADS to the screw terminals at the rear of the printed circuit board When properly installed the lead colors should be green whi
64. roceed to the appropriate section To leave the Calibration Menu press F4 EXIT twice 10 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration 1 6 Testing the Alarm Relays Alarm relays may be added to the Model GF868 by installing an Alarms Option Card in one or more of the six expansion slots Each option card includes three alarm relays which are designated as A B and C To test the alarm relays connect an ohmmeter to the option card terminal block as shown in Figure 4 Refer to the menu map in Figure 6 on page 15 as a guide Terminal Block Option Card Ohmmeter Figure 4 Typical Ohmmeter Connections For this discussion assume that the option card has been installed in Slot x DigitalFlow GF868 Service Manual 1 and 2 Channel 11 Chapter 1 Calibration 1 6 Testing the Alarm Relays cont 1 6 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press FX to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press F1 F3 to select alarm relay A B or C respectively Note The procedure for testing Alarm Relay A is identical to that for testing Alarm Relays B and C However make sure that the ohmmeter is connected to the desired normally open or normally closed contact
65. s WARNING It is the responsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe operating conditions are met for each installation gt Auxiliary Equipment Local Safety Standards The user must make sure that he operates all auxiliary equipment in accordance with local codes standards regulations or laws applicable to safety Working Area WARNING Auxiliary equipment may have both manual and automatic modes of operation As equipment can move suddenly and without warning do not enter the work cell ofthis equipment during automatic operation and do not enter the work envelope of this equipment during manual operation If you do serious injury can result WARNING Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maintenance procedures on the equipment DigitalFlow GF868 Service Manual 1 and 2 Channel iii Preface Qualification of Personnel Make sure that all personnel have manufacturer approved training applicable to the auxiliary equipment Personal Safety Equipment Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment Examples include safety glasses protective headgear safety shoes etc Unauthorized Operation Make sure that unauthorized personnel cannot gain access to the operation of the equipment Environmental Compl
66. select a channel to display for a 2 Channel meter only and then select the desired display parameter See Chapter 3 Operation of the Startup Guide for detailed instructions The values for the diagnostic parameters immediately after initial installation of the meter and verification of proper operation should be entered in Table 6 on page 39 These values can then be compared to future values to help diagnose any future malfunction of the system 3 4 Flowcell Problems If preliminary troubleshooting with the Error Code Messages and or the Diagnostic Menu indicates a possible flowcell problem proceed with this section Flowcell problems fall into two categories gas problems pipe problems Read the following sections carefully to determine if the problem is indeed related to the flowcell If the instructions in this section fail to resolve the problem contact the factory for assistance DigitalFlow GF868 Service Manual 1 and 2 Channel 25 Chapter 3 Diagnostics 3 4 1 Gas Problems Most gas related problems result from a failure to observe the flowmeter system installation instructions as described in the Startup Guide Refer to Chapter 1 Installation of the Startup Guide to correct any installation problems If the physical installation of the system meets the recommended specifications it is possible that the gas itself may be preventing accurate flow rate measurements The gas being measured must meet the following re
67. sure Do not damage the transformers and any installed option cards as they are maneuvered between the standoffs 3 Loosely install the three long standoffs on the right side of the printed circuit board and the two standoffs or screws along the bottom edge of the printed circuit board Then install only the top and bottom short standoffs on the left side of the printed circuit board 4 Insert the free end of the green grounding strap between the printed circuit board and the middle standoff beneath the left side of the board Making sure to capture the grounding strap lug between the printed circuit board and the standoff beneath it install the remaining short standoff on the left side of the printed circuit board Securely tighten all eight standoffs and or screws IMPORTANT Correctly installing the grounding strap may require some patience but resist the temptation to place the grounding strap on top of the printed circuit board 5 Connect the twisted pair backlight cable to socket J2 on the left edge of the printed circuit board This plug is polarized so that it can only be installed in the proper orientation with the black wire above the red wire 6 Check for and remove any loose hardware that may have fallen into the electronics console during the maintenance procedure 7 Place the main shroud over the six upper standoffs on the printed circuit board Making sure that the shroud is oriented with the wiring diagram label upright f
68. tact the factory Staring time must exceed current time This message appears when in the LOG menu STD option Enter a start time that is later than the current time Write error 22 An option card error indicating a programming failure or a loss of memory Contact the factory DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 3 Diagnostics Chapter 3 Diagnostics 3 1 Introduction This chapter explains how to troubleshoot the Model GF868 if problems arise with the electronics console the flowcell or the transducers Indications of a possible problem include e display of an error message on the active display screen e erratic flow readings readings of doubtful accuracy 1 e readings that are not consistent with readings from another flow measuring device connected to the same process If any of the above conditions occurs proceed with the instructions presented in this chapter 3 2 Displaying Diagnostic Parameters The Model GF868 has a built in Diagnostics Menu to aid in the troubleshooting of flowcell transducer and or electrical problems The Diagnostics Menu may only be entered from the Big or Dual measurement mode display See Chapter 2 Displaying Data in the Programming Manual for instructions on setting the display screen to the desired format and enter the Diagnostics Menu as shown below Chi label eM Press the lt or gt keys until the desired channel option appears on
69. te and black from left to right as viewed from the front of the enclosure 7 Reinstall all option cards as described earlier in this chapter Insert all external option card connectors at the rear panel of the meter 8 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model GF868 flowmeter may now be placed back into service Reconnect the main power and refer to Chapter 2 Initial Setup of the Startup Guide and Chapter 1 Calibration of this Service Manual for instructions on properly setting up the meter for accurate flow rate measurements Note Be sure to record the printed circuit board replacement in Appendix A Service Record DigitalFlow GF868 Service Manual 1 and 2 Channel 47 48 no content intended for this page DigitalFlow GF868 Service Manual 1 and 2 Channel Appendix B Optional Enclosures 4 18 106 3 31 84 DigitalFlow GF868 Service Manual 1 and 2 Channel 14 83 377 16 98 432 18 25 464 19 00 483 11 82 300 1313 335 Figure 10 Model GF868 Rack Mount Enclosure Dimensions ref dwg 712 1076 49 Appendix B Optional Enclosures Lhe Lead Black Opin Can Slot Cover Option Can Socket M Neutral Lead Whke up Aralog Output Connector CH1 Transducer Conector Fuse RS232 Connecior CH2 Transducer Connector
70. ts you to send your instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 3 Upon receipt GE Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken e If the damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e f GE Sensing determines that the damage is not covered under the terms of the warranty or if the warranty has expired an estimate for the cost of the repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned DigitalFlow GF868 Service Manual 1 and 2 Channel 53 Warranty no content intended for this page 54 DigitalFlow GF868 Service Manual 1 and 2 Channel GE Certification amp Measurement amp Control Safety Statements GE Infrastructure Products Used in Hazardous Locations Installation and operation manuals in their complete forms along with product specific certification and safety statement sheets are included on the CD provided with the product documentation shipped with each instrument Please read and follow all provided manufacturer s instructions prior to installation and the application of power to your equipment Always observe the following Field wiring shall be rated at l
71. w GF868 Service Manual 1 and 2 Channel Contents Appendix B Optional Enclosures 8 1 B 2 B 3 B 4 B 5 B 6 B 7 WONG WON AAA IRIURE ELT II A 41 RACKMOUNT ENCIOSUNE MM EMT 41 Rack Mount FUSS ebldegrmiblMs eua cest urolitictnteckeb E Le pee UII eR ERE E Fes uto Ei 42 Rack Mount Option Card Install O eur oso eic e i E LE ERROR Id ERU A e Up RIPE 45 Rack Mo nt EPROM Replacement ss seissen oL ERAN VER Epi RETE FEM Dues e dad det eor Xd eR 44 Rack Mount LCD Display Replacement aaa ee cecene id 45 Rack Mount Printed Circuit Board Replacement 0 cece cece cece ence corno 46 BEC lose jo a AAA 0 A TTT 46 peas sv drei 0nic ini sonia dit a dai oe 47 DigitalFlow GF868 Service Manual 1 and 2 Channel vii Contents viii DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 1 Calibration Chapter 1 Calibration 1 1 Introduction Calibrating the Model GF868 s analog outputs and inputs is explained in this chapter In addition testing the optional totalizer frequency and alarm relay outputs is discussed The following specific topics are included calibrating Slot 0 6 analog outputs e calibrating Slot 1 6 analog inputs e calibrating Slot 1 6 RTD inputs e testing Slot 1 6 alarm relays e testing Slot 1 6 totalizer frequency outputs The Model GF868 electronics console includes six expansion slots for the installation of option cards These slots are numbered 1 6 from right to left In additio
72. w GF868 Service Manual 1 and 2 Channel 17 Chapter 2 Error Codes and Screen Messages EO No Error Problem No error condition currently exists Cause This message appears briefly to confirm that the response to another error message has corrected the problem Action No action is required E1 Low Signal Problem Poor ultrasonic signal strength or the signal exceeds the limits entered via the User Program Cause Poor signal strength may be caused by a defective cable a flowcell problem a defective transducer or a problem in the electronics console A signal that exceeds the programmed limits is probably caused by the entry of an improper value in the SETUP SIGNL submenu of the User Program Action Using the procedures in Chapter 3 Diagnostics check the components listed above Also check the value programmed into the SETUP SIGNL submenu as described in the Operator x Manual E2 Sound Speed Error Problem Cause Action The receive signal is detected too close to the open or close of the receive window Incorrect programming of the path length Loss of signal so that noise at the start of the window is triggering the measurement Verify programming of the path length Check for loss of signal E3 Velocity Range Problem Cause Action The velocity exceeds the limits programmed in the SETUP submenu of the User Program This error may be caused by the entry of improper programming data or
73. y excessive force during this procedure Complete the EPROM replacement by proceeding to the Installing the Printed Circuit Board section of this chapter page 34 Note Jf you have installed a new EPROM upon reinitialization the GF868 displays a message Slot x Params appended This message directs users to check the slot error handling on the option cards and appears on power up until you review the parameters in the I O submenu OPTN option 32 DigitalFlow GF868 Service Manual 1 and 2 Channel Chapter 4 Parts Replacement 4 5 Installing an Option Card The Model GF868 flowmeter can accommodate up to six option cards The option cards are installed into sockets on the rear of the printed circuit board and they are held in place with a metal bracket A single metal bracket is used to secure all the installed option cards Note If the Model GF868 presently has no option cards installed be sure to purchase the metal mounting bracket along with the first option card To install an option card refer to Figure 9 on page 38 and complete the following steps 1 Remove the printed circuit board as described in a previous section of this chapter 2 Ifone or more option cards are already installed remove the four fasteners that secure the metal bracket to the printed circuit board Lift the metal bracket straight up and away from the printed circuit board Note The fasteners may be either plastic snap rivets or metal hardwa

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