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1. A 2 Service Record February 2007 Index A E Acceleration Limit 1 6 Electronics Console Assembly 5 9 5 10 Analog Inputs Electronics Error Messages 4 1 Calibration 2 02 e 3 4 Error Limits Option 1 5 TESNE cui 22 nn estere als ibis 3 4 Error Messages 4 1 Analog Outputs Errors Allowed 1 4 Calibration mI titine ws 3 2 TESNE vd ei nn 3 2 F B Factory Defaults Option 2 2 Flash Update Option 2 6 Backlight Cable 5 3 5 5 Fuse Bracket Option Card 5 4 Holder x oec ri 5 2 Rating eh brevi ie it 5 2 C Replacing corr rue ue 5 2 EE 5 2 Cable e E era re 5 2 Back tuner oe EE at 5 3 5 5 Display ere RENS Diss 5 7 G Calibration Analog Inputs 3 4 Gas Analog Outputs 3 2 Contamination 4 4 Digital Outputs 3 6 Physical Requirements 4 4 RDS nn ne 3 8 Problems vin eos sehen 4 4 Circuit Board Guides Option Card 5 4 See Printed Circuit Board Contamination Gas 4 4 L D LED Display iie sero wane Li 5 7 LVD Statement 5 1 Defaults Resetting 2 2 Diagnostics 4 1 O Error Messages 4
2. 2 1 Resetting to Factory Default Parameters 2 2 Updating CTF878 Software 2 3 February 2007 Introduction Entering the Service Menu For user convenience the CTF878 offers a Service Menu This menu enables users to perform a variety of functions that they might occasionally require Those covered in this chapter include return to factory default parameters load updated versions of the meter program into the CTF878 To enter the Service Menu press the MENU key at the lower right of the CTF878 keypad The Menu Bar replaces the Status Bar at the top of the screen Press the P arrow key to scroll from the Site Menu to the Service Menu At the Service Menu press ENTER The screen appears similar to Figure 2 1 below Site Program Meter Logging ES Diagnostics Signal Setup 15 38 Error Limits e Test Factory Defaults Corr SNR Flash Update Calibrate Test 34 Test EEProm Figure 2 1 Service Menu To scroll to a particular option press the V or AT arrow keys until you reach the option Then press ENTER to open the option window When entering parameters in an option press the V key to step through the available parameters the A key to scroll back to a previously entered parameter the F2 key Cancel or the ESC key to exit an option at any time and return to Operate Mode
3. 00000000 00000000 00000000 0000000 Backlight Cable Clear Plastic LVD Shroud Cap Fuse Holder Power Connector Option Cards LVD Shroud Mounting Screw 2 pl Figure 5 1 CTF878 Electronics Console Assembly Parts Replacement Edging Grommet to protect cables Clear Plastic LVD Shroud w 2 mounting screws NX Display Shroud Conduit Plate Option Card Labels Shroud Label Main Aluminum Shroud w 5 mounting screws Standoffs 7pl Main PC Board Cable Clamps Option Cards Backlight Cable Display Detail C February 2007 Cable Key pad Cables Figure 5 2 CTF878 Electronics Console Assembly Isometric Dwg 705 1024 Parts Replacement Appendix A Service Record Introduction Data Entry February 2007 Introduction Whenever any service procedure is performed on the CTF868 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 Data Entry Record complete and detailed service data for the CTF868 in Table A 1 below Make additional copies of the table as needed Table A 1 Service Record Service Record A 1 February 2007 GE zz Table A 1 Service Record Continued
4. A 1 Watchdog Test 1 10 Shroud Aluminum 5 1 5 5 Z Clear Plastic osse ra 5 6 LCD Display 5 7 Zero Cutoff 1 4 EN cs curvis a patin 5 6 Signal Parameters Setting up 1 3 Signal Setup Option 1 3 Sockets Option Card 5 4 Software Updating 2 3 Spare Parts List 5 8 2 Index DECLARATION Sensing OF CONFORMITY We Panametrics Limited Shannon Industrial Estate Shannon County Clare Ireland declare under our sole responsibility that the CTF878 Ultrasonic Flowmeter to which this declaration relates are in conformity with the following standards e EN 61326 1998 Class A Annex A Continuous Unmonitored Operation e EN 61010 1 1993 A2 1995 Overvoltage Category Il Pollution Degree 2 following the provisions of the 89 336 EEC EMC Directive and the 73 23 EEC Low Voltage Directive Shannon April 15 2004 Aaa FATUM Mr James Gibson GENERAL MANAGER C gt y I T V ESSEN LS EN 1809002 Shannon ISO 9001 U S CERT DOC HO August 2004 DECLARATION Sensing DE CONFORMITE Nous Panametrics Limited Shannon Industrial Estate Shannon County Clare Ireland d clarons sous notre propre responsabilit que les CTF878 Ultrasonic Flowmeter r latif cette d claration sont en conformit avec les documents s
5. 4mA 20mA High Actual 4 mA Actual 20 mA Calibrate Reset Y Analogins Y Test Analogin Y Digital Outputs Y Test Freq Tot Calibrate Analogin Read Calibrate Freq Tot Freq in Hz Set Read tal Pulses Set Calibrate Reset 1 Y Y Test EEProm RTDs Test RTD Calibrate RTD Low Read High Read Calibrate Reset Figure 3 10 Service Menu Map Calibration Chapter 4 Troubleshooting Introduction sl qo cy dcp bete Or b Few ES terii re as 4 1 Error Code Messages e per eon cae Rn AQUA eR ewes 4 1 Displaying Diagnostic Parameters 4 3 Pipe Fluid Problems an 4 4 Transducer Problems 4 6 February 2007 Introduction Error Code Messages The CTF878 is a reliable instrument that is easy to maintain It will provide accurate flow measurement readings as long as it is operated as described in this manual If problems do arise with the electronics the pipe the fluid or the transducers the CTF878 displays an error message specifying the possible problem The CTF878 also has a set of diagnostic parameters to help you find and remedy the problem In general troubleshooting may be necessary if the C
6. 421 700 Conduit Plate 1 2 421 701 421 702 Conduit Plate 3 4 Conduit Plate Blank 421 1490 Clear Plastic LVD Shroud 421 1491 193 046 Main Aluminum Shroud 1 Amp Fuse 215 018 Fuse Cap 255 026 Flat Cable Display To purchase the parts listed in Table 5 2 above 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 CTF878 at the time of purchase Parts Replacement February 2007 Keypad Cables Display Shroud Display Cable Main Shroud Mounting Screw 5 pl Main Aluminum Shroud SLOTS SLOTS WARNING DISCONNECT POWER BEFORE REMOVING FUSE CONNECTION DIAGRAM SLOTS SLOTS SLOT2 2 4 e SL eje d s Y E naros our sia amt sia ante as amt ae amt ANALOG IN CL CL Toruraec no c F no c Fe no c F no c H RTD IN com com ke COM can Ja SINGLE RTD SINGLE 4 20 RTN NLO INHI b EN com com le 100240 VAG FUSE El ARTN amp Ur SC VDOOX O DN ER x S o D x S O AC D00000000 Doooonnnn
7. run diagnostics setup signal and data processing parameters define error limits test the CTF878 screen and keys diagnose setup problems To enter the Service Menu press the MENU key at the lower right of the CTF878 keypad The Menu Bar replaces the Status Bar at the top of the screen Press the P arrow key to scroll from the Site Menu to the Service Menu At the Service Menu press ENTER The screen appears similar to Figure 1 1 below SE Diagnostics Signal Setup Error Limits Test Factory Defaults Corr SNR Flash Update Calibrate Test 34 Test EEProm Figure 1 1 Service Menu To scroll to a particular option press the V or A arrow keys until you reach the option Then press ENTER to open the option window When entering parameters in an option press the W key to step through the available parameters the A key to scroll back to a previously entered parameter the F2 key Cancel or the ESC key to exit an option at any time and return to Operate Mode without changing the parameters Diagnostics 1 1 February 2007 Displaying Diagnostic Parameters The Diagnostics option enables you to view current diagnostic parameters without having to open a display window in Operate Mode To enter the option scroll to the Diagnostics entry on the Service Menu and press ENTER The screen appears similar to Figure 1 2 below Diagnostic Tests Meter
8. 2 4 Resetting and Updating February 2007 Setting Up the PC 1 From the Start Menu click Programs Accessories Hyperterminal to open the Hyperterminal window Note fthis is the first time that Hyperterminal has been launched a Location Information window will pop up see Figure 2 4 below Enter any area code and then click OK Location Information 2 xl Before you can make any phone or modem connections Windows needs the following information about your current location What country region are you in now What area code or city code are you in now IF you dial a number to access an outside line what is it The phone system at this location uses Tone dialing C Pulse dialing Cancel Figure 2 4 Location Information Window 2 A New Connection window appears see Figure 2 5 below Enter a name for the New Connection Click OK Connection Description Y New Connection Enter a name and choose an icon for the connection Name CTF Icon Figure 2 5 New Connection Window Resetting and Updating 2 5 February 2007 Setting Up the PC cont 3 A Connect To window appears see Figure 2 6 below Under Connect using select the correct communication port Click OK Note COMI was selected here as an example S CTF Enter details for the phone number that you want to dial Country region United States of America 1 Area code 434 Phone number 5 Conne
9. 3 Compare the value entered with the reading on the frequency counter They should be very close within 1 Hz for frequencies below 1 KHz To verify the accuracy of the digital output using the totalizer follow these instructions 4 The next prompt asks you to enter the total number of pulses d Press ENTER to open the text box b Use the numeric keys to enter the desired value C Press ENTER to confirm your entry Calibration 3 7 February 2007 Calibrating Verifying the Accuracy of Digital Outputs cont Testing and Calibrating RTD s Testing RTD s 5 Press the P arrow key to move to the SET box and then press ENTER to set the number of pulses 6 Compare the value entered with the reading on the frequency counter They should be very close within 1 Hz for frequencies below 1 KHz You have verified the accuracy of the digital outputs To leave the Totlizer Frequency window press F3 to exit The CTF878 returns to Operate Mode Repeat the process to verify the accuracy of additional Digital Outputs The Calibration Test option can be used to test and calibrate RTD s To enter the option scroll to the RTDs option under the Calibrate Test Menu and press ENTER The screen appears similar to Figure 3 2 on page 3 2 To test an RTD you must connect an RTD to the RTD board Proceeding as above select the Test RTD option for the RTD to be tested and press ENTER A clock appears in t
10. 111 Checksum verify 0 Figure 3 9 EEPROM Test Window Press ENTER or F3 OK repeatedly to check each EEPROM by observing the information for the corresponding option card When the Test EEPROM information has appeared for every option card present the screen returns to the Operate Mode Calibration February 2007 F3 accept or i F2 not accept Y 1 Diagnostics Signal Setup Y Signa Reverse Flow Zero Cutoff Velocity Averaging None Y Y Y Program Logging Y Y Y RTE Y Error Limits Test SNR Min Velocity Min Max Acceleration Carrier Min Max DMod Min Max LP Filter Filter Mode Y 5 Manual 25 100 rors Allowed Y AgcMgc AGC E MGC HFHI HFLO LFSP HFGain LFGain Y Filter Type None 45 Hz CCorr Avg 90Hz CCorr Mo Auto 150 Hz Manual CCorr Average Elec System 60 Hz 50 Hz 400 Hz 1 Factory Defaults Flash Update 1 Calibrate Test Test Screen Test Keys Watchdog Test Y Main Board Y Test AnalogOut Calibrate _ AnalogOut
11. ENTER 3 The next prompt asks you to enter the actual value shown on the multimeter or ammeter a Press ENTER to open the text box b Use the numeric keys to enter the value shown on the multimeter c Press ENTER to confirm your entry d Scroll to Calibrate then press ENTER That setpoint has been calibrated 4 Repeat steps 2 and 3 for the other setpoint If you are unsatisfied with the calibration you can reset the inputs to factory defaults Press the P arrow key to move to the Reset box and then press ENTER to undo the calibration You have completed calibrating the outputs To leave the Output window Press F2 Cancel to return to Operate Mode without confirming the changes Press F3 OK to confirm the new data The CTF878 returns to Operate Mode Calibration 3 3 February 2007 Testing and Calibrating Analog Inputs Testing Analog Inputs The Calibration Test option can be used to test and calibrate the analog inputs To enter the option scroll to the AnalogIns option under the Calibrate Test Menu and press ENTER The screen appears similar to Figure 3 2 on page 3 2 To test an Analog Input you must connect a current source to the analog input Proceeding as above select the Test AnalogIn option for the Analog In to be tested and press ENTER The screen appears as in Figure 3 4 below It displays the analog input current RAW count from the A D When the input curr
12. Average LP Filter Low Pass Digital Filter They should be set up only by field service engineers 1 4 Diagnostics February 2007 Setting Error Limits The Error Limits option enables you to set limits for the signals received from the transducers and the limits for some outputs When the parameter falls outside the programmed limits an error indication appears To enter this option scroll to the Error Limits entry on the Service Menu and press ENTER The screen appears similar to Figure 1 4 below Signal Error Limits Min Max SNR Min YT Velocity 100 100 m s Acceleration 15 m s Carrier 75 1200 mV DMod 75 1500 mV Cancel OK Figure 1 4 Signal Error Limits Option 1 The first prompt asks for the minimum error limit for the correlation signal to noise ratio SNR calculated by the CTF878 The default value is 10 The E8 SNR error message appears if the SNR falls below the limit programmed here IMPORTANT SNR Min should be changed from factory default settings only if absolutely necessary These settings may be changed by qualified field service engineers only To enter the minimum SNR a Press ENTER to open the text box b Use the numeric keys to enter the desired value c Press ENTER to confirm your entry d Press the P or V key to move to the next limit 2 The next prompt calls for the low and high velocity lim
13. Error 0x0004 Carr A Carr G IA QA Mod G TAU Corr SNR Cancel OK Figure 1 2 Diagnostics Tests Window Press F2 Cancel or F3 OK to close the window and return to Operate Mode Note Foran explanation of diagnostic parameters refer to Chapter 4 Troubleshooting 1 2 Diagnostics February 2007 nn Signal Setup The Signal Setup option enables you to set parameters that affect the flowmeter s signal processing and outputs Zero Cutoff Velocity Averaging Errors Allowed To enter the option scroll to the Signal Setup entry on the Service Menu and press ENTER The screen appears similar to Figure 1 3 below Signal Setup STE ocVoc CCor Avg LP Filter Reverse Flow Zero Cutoff 5 m s Velocity Averaging None Errors Allowed 2 Cancel Figure 1 3 Signal Parameter Window Setting Up Signal 1 Press the V arrow key to enter the window Parameters 2 The first prompt allows you to select or not select Reverse Flow a Press ENTER to select Reverse Flow and press the W arrow key to enter the next prompt or b Press ENTER again to deselect Reverse Flow and press the V arrow key to enter the next prompt Diagnostics 1 3 February 2007 SS x Setting up Signal 3 The next prompt asks for the Zero Cutoff Near zero flow the Parameters cont CTF878 may have fluctuating readings due to insufficient flow information The zero cutoff causes velocity measuremen
14. cause inaccurate readings Refer to Initial Setup Chapter 3 in the Startup Guide for instructions on programming the pipe data Also see Setting the Transducer Spacing and Tag Path in Chapter 2 of the Startup Guide for a discussion of this topic Troubleshooting 4 5 February 2007 Transducer Problems The most common clamp on transducer problems are listed below 1 POOR COUPLING TO PIPE Clamp on transducers must be in intimate contact with the pipe The pipe wall must be smooth and generally free of paint The couplant material must fill voids between the transducer and the pipe and must be firmly bonded to both the pipe and the transducer The pipe and transducer must be clean and dry for permanent couplant such as grease or epoxy to adhere properly Enough pressure must be applied to the transducer by its clamp to hold it firmly against the pipe 2 EXCESS COUPLANT Clamp on transducers must be in intimate contact with the pipe If there is too much couplant it may prevent the transducer from making that contact 3 MISALIGNMENT The transducer transmits relatively narrow beams of ultrasound and therefore transducer alignment is critical to assure that the beam can travel from one transducer to the other without undue attenuation Be sure to follow exactly the instructions that came with your transducers and clamping fixture Also be sure that the transducer spacing agrees with the calculated spacing as a function
15. following procedures IMPORTANT Keep a detailed record all service procedures performed on the CTF878 in Appendix A Service Record This service history may prove very helpful in diagnosing any future problems Farts Replacement 5 1 February 2007 Replacing the Fuse If it has been determined that the fuse in the CTF878 requires replacement complete the following steps IWARNING The main power to the CTF878 must be disconnected before proceeding 1 Open the cover on the electronics console 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 5 1 on page 5 9 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 5 1 below and on the wiring diagram label Table 5 1 Line Voltage amp Fuse Rating Line Voltage Fuse Rating 85 264 VAC 1 0 A Slo Blo 5 Press the new fuse into the fuse holder cap and insert the
16. fuse into the fuse holder While applying a slight pressure with the screwdriver twist the fuse holder cap 1 4 turn clockwise 6 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 CTF878 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 5 2 Parts Replacement February 2007 Removing the Printed Circuit Board Some of the maintenance procedures require removal of the printed circuit board To accomplish this refer to Figure 5 1 on page 5 9 and Figure 5 2 on page 5 10 while completing the following tasks 1 Remove the main power to the electronics console IWARNING The main power to the CTF878 must be disconnected before proceeding 2 Open the electronics console Remove the two mounting screws and lift the clear plastic shroud out of the electronics console Remove the five mounting screws and lift the main aluminum shroud out of the electronics console 3 Disconnect the main power leads from terminal block TB1 on the printed circuit board Remove the electrical connections from all installed option cards and terminal blocks Disconnect the twisted pair backlight cable from connector J6 the two striped ribbon keyboard cables from connector J5 and the white
17. of soundspeed 4 INTERNAL DAMAGE Ultrasonic transducers consist of a ceramic crystal bonded to the transducer case The bond between the crystal and the case may be damaged by extreme shock and by temperature extremes The crystal itself can also be damaged by the same conditions The internal wiring can be corroded or shorted if contaminants enter the transducer housing 5 PHYSICAL DAMAGE Transducers may be physically damaged by dropping them onto a hard surface or striking them against another object The connector on the transducer is usually the part that is damaged Minor damage may be repaired by carefully bending the connector back into shape If the connector cannot be repaired replace the transducers After replacement the flowmeter parameters should be checked see Programming Site Data Chapter 1 of the Programming Manual or Chapter 3 of the Startup Guide Contact the factory if you cannot solve a transducer related problem 4 6 Troubleshooting Chapter 5 Parts Replacement Introduction es Bale RR ab 5 1 Replacitig the PUSO ES E ae 5 2 Removing the Printed Circuit Board 5 3 Installing an Option Card ccs ae EE E PEE COO 5 4 Installing the Printed Circuit Board 5 5 Replacing the LCD Display 5 7 Spare PARES osse a eek o deb E orale Nei du tte tes 5 8 February 2007 tii Introduction The electronic
18. output Proceeding as above select the Test AnalogOut option see Figure 3 2 above for the Analog Output to be tested and press ENTER A clock appears in the middle of the screen with the message TESTING IO below it while the multimeter is displaying the test current output The test current output value should go through the full range When the test is complete the screen returns to Operate Mode Repeat the process to test additional Analog Outputs The Analog Output calibration procedure consists of calibrating the analog output zero point 0 or 4 mA and then calibrating the full scale point 20 mA First you will enter the setpoint and then the actual value derived from an ammeter or digital voltmeter The analog outputs have a resolution of 5 0 uA To calibrate an Analog Output proceed as above select the desired Calibrate AnalogOut option and press ENTER The screen appears as shown in Figure 3 3 on page 3 3 Proceed as follows 1 Connect a digital multimeter to the analog output and step through the options using the arrow keys 3 2 Calibration February 2007 Calibrating Analog Outputs cont Calibrate AnalogOut 0 A Set Point SEM 2m Actual 4 mA Actual 20 mA 20 4 Calibrate Cancel Figure 3 3 Calibrate Analog Output Window 2 The first prompt asks for the setpoint 4 or 20 mA Use the and D arrow keys to move to the appropriate radio button and press
19. ribbon display cable from connector J7 4 Using a Phillips screwdriver and a 3 8 inch nutdriver or open end wrench remove the three mounting screws just left of center and the five standoffs along the sides of the main circuit board 5 While supporting the printed circuit board remove the two standoffs along the bottom edge of the printed circuit board 6 Carefully lift the printed circuit board out of the enclosure Caution During this procedure be very careful not to damage the upright components along the top edge of the printed circuit board Severe or repeated bending of these components will break their leads 7 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 Installing the Printed Circuit Board on page 5 5 Otherwise refer to Installing an Option Card on page 5 4 Farts Replacement 5 3 February 2007 Installing an Option Card The CTF878 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 Ifthe CTF878 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 5 1 on page 5 9 and Figure 5 2
20. without changing the parameters Resetting and Updating 2 1 February 2007 Resetting to Factory Default Parameters For various reasons you might wish to return the CTF878 to its original settings The Factory Defaults option enables you to return the meter to its preprogrammed default settings To enter the option scroll down to the Factory Defaults entry in the Service Menu and press ENTER The screen will appear similar to Figure 2 2 below IMPORTANT All sites and logs will be lost if you use the Factory Defaults option Site Program Meter Logging Es Factory Defaults u WARNING You will LOSE all changes by KO pressing OK Choose CANCEL to exit or OK to proceed M E Cancel Figure 2 2 The Factory Defaults Option 1 To restore Factory Default settings Press F2 Cancel to return to Operate Mode without changing the current settings Press F3 OK to confirm that you wish to restore the factory default settings 2 The program asks for confirmation Are you SURE Repeat the procedure shown in Step 1 above The CTF878 replaces the default site file and the global meter settings with the factory default settings and returns to Operate Mode 2 2 Resetting and Updating February 2007 Updating CTF878 Software By using a Windows based PC with an RS232 connection CTF878 users can update the meter s operating software This software can include the bootloade
21. ys eh 4 se epee Soy ewm xe RR Eee deo Er 3 1 Entering the Calibration Test Menu 3 1 Testing and Calibrating Analog Outputs 3 2 Testing Analog Outputs 3 2 Calibrating Analog Outputs 3 2 Testing and Calibrating Analog Inputs 3 4 Testing Analog Inp ts2 r 2 un oe eg eb RISE ee Gane IPs 3 4 Calibrating Analog Inputs 3 5 Testing and Calibrating Digital Outputs 3 6 Testing Digital Oumuts c risu i a a oE E E E AAE A E E a E i 3 6 Calibrating verifying the accuracy of Digital Outputs 3 7 Testing and Calibrating RTD s 3 8 Lesung Ke 2 2 het ea nah adi 3 8 Calibrating RTD S eui sheet ettet ads 3 9 Testing EEPROM Sr ninne ninae senene tas p beer puel Destin Peu 3 10 February 2007 SSS ss Table of Contents cont Chapter 4 Troubleshooting Introductions re er tule de LENA e UE CERE 4 1 Error Code Messages s san a dis wes Mom aes Gerais ae ee ngu um mi 4 1 Displaying Diagnostic Parameters 4 3 Pipe Fluid Problems its 22 edes as Gua eed eidg 4 4 Gas Problems Loeb da ew bvb
22. 1 OPHION MERDA ROME 1 2 Option Card Parameters Displaying 1 2 4 3 Bracket EA ee 5 4 Digital Outputs Guides OA A RS 5 4 Calibration accuracy verification 3 6 Installing 5 4 Ta do ae 3 6 SOCKES Mp 5 4 Display Cable 2 sua ia oia 5 7 ECD ses iaa las en 5 7 Replacing 5 7 Index February 2007 Index cont P T Parts List Spare uan pb 2 0 TestKRe6ysv oot IR ME 1 9 Pipe Test Serec ess anga Sono e poe 1 8 Measurements 4 5 Testing NA et 4 4 4 5 Analog Inputs 3 4 Printed Circuit Board Analog Outputs 3 2 Replacing ic anette tA Ee WD 5 3 Digital Outputs 3 6 Problems RID Si IER REV 3 8 Debris none 4 5 Timer Circuit 1 10 Gas an neh 4 4 Timer Circuit Testing 1 10 Inaccurate Measurements 4 5 Transducers Pipe ua A ia 4 4 4 5 Placement 2 0 6 013 22 EE 4 5 Transducers 4 6 Problems oder ert imis 4 6 Signal Limits 1 5 R Troubleshooting 4 1 Error Messages 4 1 Replacing See Part Name V RTD s Calibration 3 8 Velocity Testing xli EEN Sea en EN 3 8 Averaging 1 4 Limits na enr t sale 1 5 S Sud W ervice Menu Entering 1 1 2 1 3 1 Service Record
23. GE Sensing Model CTF878 Clamp On Tag Flowmeter User s Service Manual GI Sensing Model CTF878 Clamp On Tag Flowmeter User s Service Manual 910 254SA3 February 2007 The Model CTF878 Clamp On Tag Flowmeteris a GE Panametrics product GE Panametrics has joined other GE high technology sensing businesses under a new name GE Sensing February 2007 Warranty Return Policy Each instrument manufactured by GE Infrastructure Sensing Inc is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument at the sole discretion of GE Infrastructure Sensing Inc Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Infrastructure Sensing Inc determines that the equipment was defective the warranty period is one year for general electronic failures of the instrument one year for mechanical failures of the sensor If GE Infrastructure Sensing Inc 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 Infrastructure Sensing Inc the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties wh
24. Limits 15 38 res Factory Defaults Flash Update Corr SNR Calibrate Test Main Board 0 Analoglns 2 Digital Outputs 3 RTDs 4 Figure 3 1 Calibrate Test Menu To scroll to a particular option press the V or A arrow keys until you reach the option Then press ENTER to open the option window When entering parameters in an option press the W key to step through the available parameters the A key to scroll back to a previously entered parameter the F2 key Cancel or the ESC key to exit an option at any time and return to Operate Mode without changing the parameters Calibration 3 1 February 2007 Testing and Calibrating Analog Outputs Testing Analog Outputs Calibrating Analog Outputs The Calibration Test option can be used to test and calibrate the analog outputs To enter the option scroll to the Main Board or to an AnologOut option under the Calibrate Test Menu and press ENTER The screen appears similar to Figure 3 2 below Site Program Meter Logging MEME Diagnostics Signal Setup Error Limits 15 38 res gt Factory Defaults Flash Update Corr SNR Calibrate Test p Main Board 0 gt Test AnalogOut 0 A Calibrate AnalogOut 0 A Test AnalogOut 0 B Calibrate AnalogOut 0 B Figure 3 2 Analog Outputs Test Calibration Window To test an Analog Output you must connect a digital multimeter to the analog
25. TF878 displays an error message the flow readings are erratic or you have other reasons to doubt the accuracy of readings for example readings do not agree with other flow measuring devices connected to the same process This section describes error messages and diagnostic parameters and shows you how to isolate problems to one of the following areas Electronics including programmed values Pipe and fluid Transducers and cables Error Code messages appear on the screen while you are displaying measurements When logs appear in graph form errors are indicated by a vertical gray bar at the point of error When they appear in a spreadsheet format errors are indicated by their number in place of the measurement The Error Code messages are only general descriptions of the possible problems Use Table 4 1 on page 4 2 to isolate and remedy the problem If you are unable to remedy the problem contact the factory Troubleshooting 4 1 February 2007 Problem Table 4 1 Error Messages Possible Cause Action No error Displays briefly after display of another error message None required Measurement is valid Receiver Board Error FPGA not loaded etc Power CTF878 down Remove shroud Make sure receiver board is seated correctly and its screws are on tight Power up Contact factory if problem persists DSP Error Acknowledgement not received after program is loaded or checksum erro
26. and remove any loose hardware that may have fallen into the electronics console during the maintenance procedure Place the main shroud over the five upper standoffs on the printed circuit board Making sure that the shroud is oriented with the wiring diagram label upright fasten the shroud to the standoffs with the five sets of screws and washers Reconnect the power line wires to terminal block TB1 on the printed circuit board Plug all other electrical connectors into the appropriate sockets on the printed circuit board and option cards See Installation Chapter 2 of the Startup Guide for instructions on proper wiring of the CTF878 Farts Replacement 5 5 February 2007 Installing the Printed 9 Position the clear plastic LVD shroud over the electrical Circuit Board cont 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 CTF878 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 CTF878 Before takin
27. approval to proceed the instrument will be repaired and returned Y February 2007 Table of Contents Chapter 1 Diagnostics Introduction SR Ser RS eere E UEM A ean 1 1 Entering the Service Menu 1 1 Displaying Diagnostic Parameters 1 2 Signal Setup ose ebore Eet e laa be elisa eibi Wed Euer WD vob pM ah wade 1 3 Setting Up Signal Parameters 1 3 Setting Error Limits oot ee Ae ea eei eir eda oe Ere d 1 5 The Test Option 2 4 2208 ek y Lex Le vex eve rese y e REED REP 1 7 Testing the Sereen ass aie ee beet e qus 1 8 Testing the Keys ui ste ane eee koa a ae 1 9 Testing the Watchdog Timer Circuit 1 10 Chapter 2 Resetting and Updating Introduction 4 shot EE EE Ae a Rag Beh UE eet 2 1 Entering the Service Menu 44444 ee eee e dee be net sen 2 1 Resetting to Factory Default Parameters 2 2 Updating CTF878 Software 2 3 Preparation A dat ged donee eee ys air EG ah D POL Du 2 3 Setting Up the PC aves ones ttes tele e sache trot qe Mashed Masia 2 4 Installing New Software 2 6 Completions oo ne d Ok ee EE aa tie Sale a Sa tot E Og 2 9 Chapter 3 Calibration Introduction
28. arrow key to move to the Read box and press ENTER b Scroll to the Calibrate box and press ENTER to calibrate the low point 3 The next prompt asks for the value to which you want to set the high input 20 mA d Press ENTER to open the text box b Use the numeric keys to enter the desired value C Press ENTER to confirm your entry Calibration 3 5 February 2007 Calibrating Analog Inputs cont Testing and Calibrating Digital Outputs Testing Digital Outputs 4 Set the current source to output the current for the High point 20 mA a Press the P arrow key to move to the Read box and press ENTER b Scroll to the Calibrate box and press ENTER to calibrate the high point 5 If you are unsatisfied with the calibration you can reset the inputs to factory defaults Press the D gt arrow key to move to the Reset box and then press ENTER to undo the calibration You have completed calibrating the inputs To leave the Inputs window Press F2 Cancel to return to Operate Mode without confirming the changes Press F3 OK to confirm the new data The CTF878 returns to Operate Mode Repeat the process to calibrate additional Analog Inputs The Calibration Test option can be used to test and calibrate verify the accuracy of the digital outputs To enter the option scroll to the Digital Outputs option under the Calibrate Test Menu and press ENTER The screen appears simi
29. ating 2 7 February 2007 Installing New Software 2 The meter asks for confirmation Repeat the options shown in cont Step 1 above The screens on both the PC and the CTF878 now appear similar to Figure 2 10 below 7 CTF HyperTerminal File Edit View Cal Transfer Help GE Panametrics PCI Loader CTF BOOT 001 E 10 22 2003 VALID Reload requested by Software Reload Flash V N Figure 2 10 Flash Reloading Window 3 The meter now asks if you wish to reload the flash memory Press F3 Yes or Y on the PC keyboard twice to begin reloading or Press F2 No or ESC on the keyboard to stop the reloading procedure 4 If you chose to reload flash a message appears as in Figure 2 11 below On the PC in the Hyperterminal Window select the Send File entry under Transfer CTF HyperTerminal File Edit View Cal Transfer Help GE Panametrics PCI Loader CTF BOOT 001 E 10 22 2003 Backup Battery Firmware CRC VALID Reload requested by Software Reload Flash V N Ready to receive update via KMODEM CRC Start upload now or CTRL to cancel CCCCCCC Figure 2 11 Ready To Receive Update Window 2 8 Resetting and Updating February 2007 Installing New Software 5 The Send File window appears see Figure 2 12 below Select cont the replacement software designated by a cod extension from the folder where it has been stored Send File Folder C Documents an
30. ct using 7 Figure 2 6 Connect To Window 4 The Communication Port Properties window appears Enter the settings shown in Figure 2 7 below Click OK COM1 Properties Port Settings Bits per second Data bits Parity Stop bits Flow control Restore Defaults Cancel Apply Figure 2 7 Communication Port Properties Window 2 6 Resetting and Updating February 2007 Setting Up the PC cont The CTF878 is now connected to the PC In the lower left hand corner of the Hyperterminal window it reads Connected with the connection duration see Figure 2 8 below IMPORTANT Jf the proper settings are not made the CTF878 software update will fail Connected 0 00 41 Auto detect Auto detect SCROLL Figure 2 8 Connected Window Installing New Software To begin the loading procedure scroll down to the Flash Update entry in the Service Menu and press ENTER The screen appears similar to Figure 2 9 below Site Program Meter Logging Ste Flash Update WARNING This will ERASE the existing Meter Program Choose CANCEL to exit or OK to proceed W E Cancel Figure 2 9 Flash Update Option 1 As shown in Figure 2 9 above the Flash Update option erases all instrument coding Press F2 Cancel to return to Operate Mode without erasing the program Press F3 OK to confirm that you wish to erase the program Resetting and Upd
31. d Settings lavinigi Desktop Filename CAD ocuments and Settings lavinigit Desktop Dsp Browse Protocol modem Close Cancel Figure 2 12 Send File Window 6 From the protocol drop down menu select Xmodem The software update now begins as the Xmodem file send appears see Figure 2 13 below Xmodem file send for CTF Sending C Documents and SettingsVavinigADesktopNDspMTA D cd Packet re Error checking nr Retries o Total retries p StS Last error E A File zu fi Ok of 83K Elapsed 00 00 03 Remaining 00 00 23 Throughput 51 14 cps Figure 2 13 Xmodem File Send Window Resetting and Updating 2 9 February 2007 Installing New Software cont Completion 7 After the update is done the Final Window appears as the CTF878 reboots see Figure 2 14 below GE Panametrics PCI Loader CTF BOOT 001 E 10 22 2003 Backup Battery Firmware CRC VALID Reload requested by Software Reload Flash V N Ready to receive update via XMODEM CRC Start upload now or CTRL X to cancel CCCCCCCCCCCQ CCCCCCCCCCCCCCCC Writing to Flash Done Program CRC Valid Writing Signature Block Done Bootloader Resetting GE Panametrics PCI Loader CTF BOOT 001 E 10 22 2003 Backup Battery Firmware CRC VALID Program CRC VALID Figure 2 14 Final Window When the transfer is complete to prepare the CTF878 for operation 1 Disconnect the power t
32. ent changes you can press F3 OK to update the RAW count or F2 Cancel to exit Site Program Meter Logging EAAS Analogin Test Counts 65535 Press Cancel to exit or OK for B another reading Figure 3 4 Analogin Test Window If you pressed F5 OK a clock appears in the middle of the screen with the message TESTING IO below it When the test is complete the screen returns to Operate Mode Repeat the process to test additional Analog Inputs 3 4 Calibration February 2007 Calibrating Analog Inputs The Analog Input calibration procedure consists of calibrating the analog input zero point 0 or 4 mA and the full scale point 20 mA Note Calibrating analog inputs requires use of a current source Calibrated analog outputs may be used as a current source To calibrate an Analog Input proceed as above select the desired Calibrate AnalogIn option and press ENTER The screen appears as in Figure 3 5 below Step through the options using the arrow keys Calibrate Analog Input Low mA High 20 mA Calibrate Figure 3 5 Calibrate Analog Input Window 1 The first prompt asks you to set the low input 0 or 4 mA a Press ENTER to open the text box b Use the numeric keys to enter the desired value c Press ENTER to confirm your entry 2 Set the current source to output the current for the Low point 0 or 4mA a Press the gt
33. ether statutory express or implied including warranties of merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade If a GE Infrastructure Sensing Inc instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Infrastructure Sensing Inc 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 Infrastructure Sensing Inc will issue a RETURN AUTHORIZATION number RA and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Infrastructure Sensing Inc instructs 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 Infrastructure Sensing Inc will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken fthe 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 Infrastructure Sensing Inc 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
34. ference with the ultrasound transmissions through the gas will cause inaccurate flow rate measurements 2 The gas must not excessively attenuate ultrasound signals Some gases i e high purity carbon dioxide hydrogen etc readily absorb ultrasound energy In such a case an E4 and or E6 error code message will appear on the display screen to indicate that the ultrasonic signal strength is insufficient for reliable measurements Troubleshooting February 2007 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 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 measurements are not possible Realignment of the transducers often cures such problems Refer to Installation Chapter 2 of the Startup Guide for more details on proper installation practices 2 Inaccurate pipe measurements The accuracy of the flow rate measurements is no better than the accuracy of the programmed pipe dimensions 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
35. g measurements with the CTF878 refer to Initial Setup Chapter 3 in the Startup Guide and to Calibration Chapter 3 in this 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 CTF878 in Appendix A Service Record 5 6 Parts Replacement February 2007 Replacing the LCD Display The CTF878 s measurements are displayed on 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 replace the LCD display see Figure 5 1 on page 5 9 for the component locations and complete the following steps IWARNING The main power to the CTF878 must be disconnected before proceeding 1 Open the cover on the electronics console 2 Disconnect the white ribbon display cable from connector J7 open the two cable brackets inside the enclosure and on the inside surface of the cover and free the display cable See Figure 5 2 on page 5 10 3 Using a 3 16 inch 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 4 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 5 Place the new LCD d
36. he middle of the screen with the message TESTING IO below it This is followed immediately by a screen similar to Figure 3 8 below Site Program Meter Logging RI e RTD Test Counts 65535 Press Cancel to exit or OK for m another reading Cancel OK Figure 3 7 RTD Test Window Note The window shows a count dependent on the output from the RTD When the output from the RTD changes you can press F3 OK to update the count or F2 Cancel to exit When the test is complete press F2 Cancel and the screen returns to Operate Mode Repeat the process to test additional RTD s 3 8 Calibration February 2007 Calibrating RTD s The RTD calibration procedure consists of setting the low and high temperature readings To calibrate an RTD you must connect an RTD to the RTD board Proceeding as above select the desired Calibrate RTD option and press ENTER The screen appears as in Figure 3 8 below Step through options using the arrow keys Calibrate RTD ZE High 100 C Calibrate Reset Cancel Figure 3 8 RTD Calibration Window 1 The first prompt asks you to set the low temperature d Press ENTER to open the text box b Use the numeric keys to enter the desired value C Press ENTER to confirm your entry 2 Press the P arrow key to move to the Read box and then press ENTER to read the low temperature 3 Scroll to the Calib
37. ing to Installing the Printed Circuit Board on page 5 5 5 4 Parts Replacement February 2007 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 5 1 on page 5 9 and Figure 5 2 on page 5 10 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 Severe or repeated bending of these components will break their leads Carefully position the printed circuit board within the electronics console up against the nine standoffs in the enclosure Do not damage the transformers and any installed option cards as they are maneuvered between the standoffs Loosely install the three standoffs on the right side of the printed circuit board and the two standoffs along the bottom edge Then install the two mounting screws just left of center and the top and bottom standoffs on the left side 3 Securely tighten all nine standoffs and or screws Connect the twisted pair backlight cable to socket J6 This plug is polarized so that it can only be installed in the proper orientation with the black wire above the red wire Connect the keyboard cable to socket J5 and the display cable to socket J7 Check for
38. isplay assembly over the mounting studs on the console cover in the same orientation as the one being replaced and secure it with the four standoffs Caution Do not overtighten the standoffs or the display assembly may be damaged 6 Install the display shroud over the mounting studs with the bent edges on the top and bottom extending toward the cover 7 Fasten the display shroud to the console cover with the four sets of nuts and washers Caution Do not overtighten the nuts or the mounting threads may be damaged 8 Feed the white ribbon display cable through the cable brackets close the brackets and connect the cable to connector J7 Farts Replacement 5 7 February 2007 Spare Parts All of the necessary components to upgrade or repair the CTF878 flowmeter are readily available from GE Sensing As a convenient reference some of the more common spare parts are listed in Table 5 2 below Table 5 2 Spare Parts List Port Number 703 1127 02 Option Card Alarms Hermetically Sealed 703 1127 03 Option Card Alarms General Purpose 703 1144 02 703 1145 02 Option Card Totalizer Frequency Outputs Option Card Analog Inputs 703 1145 03 Option Card RTD Inputs 421 1479 Card Cage Metal Bracket 417 027 Card Guide Nylon 703 1344 01 Main Printed Circuit Board Standard 703 1344 02 705 1036 Main Printed Circuit Board RS485 LCD Display Assembly
39. its The E9 VELOCITY RANGE error message appears if the velocity falls outside these limits Repeat Step 1 above to enter the desired limits Diagnostics 1 5 February 2007 Setting Error Limits 3 The next prompt asks for the acceleration limit for detecting cont erroneous velocity outputs The E10 ACCELERATION ERROR message appears if the velocity changes by more than this limit from one reading to the next d Press ENTER to open the text box b Use the numeric keys to enter the acceleration limit C Press ENTER to confirm your entry Note n the velocity and acceleration boxes if the CTF878 currently displays metric measurements the F1 softkey displays the word English If it displays English measurements the F1 softkey displays Metric Press F1 to display the measurement in the alternate format 4 The last four prompts ask for the minimum and maximum values in millivolts for the Carrier and DMod categories IMPORTANT Carrier and DMod should be changed from factory default settings only if absolutely necessary These settings may be changed by qualified field service engineers only To change the Carrier and or DMod settings d Press ENTER to open the text box b Use the numeric keys to enter the desired voltage C Press ENTER to confirm your entry You have completed entering signal error limits Press F2 Cancel to return to Operate Mode without confirming the error limi
40. l demodulated signals and Q 16 to 31dB Tau The time it takes for fluids to move from the upstream channel to the downstream channel N A Correlation SNR The Correlation Signal to Noise Ratio gt 10 Troubleshooting February 2007 Pipe Fluid Problems Gas Problems If preliminary troubleshooting with the Error Code Messages and or the Diagnostic Menu indicates a possible pipe fluid problem proceed with this section Pipe fluid problems fall into two categories gas problems pipe problems Read the following sections carefully to determine if the problem is indeed related to the pipe fluid If the instructions in this section fail to resolve the problem contact the factory for assistance Most gas related problems result from a failure to observe the flowmeter system installation instructions Refer to Installation Chapter 2 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 requirements 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 CTF878 excessive amounts of solid or liquid particles will absorb or disperse the ultrasound signals This inter
41. lar to Figure 3 2 on page 3 2 To test a Digital Output you must connect a frequency counter to the digital output Proceeding as above select the option for the Digital Output to be tested and press ENTER A clock appears in the middle of the screen with the message TESTING IO below it while the frequency counter is displaying the test frequency output The test frequency output should be a sweep from the low point to the high point When the test is complete the screen returns to Operate Mode Repeat the process to test additional Digital Outputs 3 6 Calibration February 2007 Calibrating verifying the accuracy of Digital Outputs To verify the accuracy of a Digital Output you must connect a frequency counter to the digital output Proceeding as above select the desired option for the Digital Output to be verified and press ENTER The screen appears as in Figure 3 6 below Step through options using the arrow keys Totalizer Frequency 3 0 Freq uU Hz Total 50 Pulses Figure 3 6 Calibrate Digital Outputs Window To verify the accuracy of a digital output using the frequency follow these instructions 1 The first prompt asks you to enter the frequency d Press ENTER to open the text box b Use the numeric keys to enter the desired value C Press ENTER to confirm your entry 2 Press the gt arrow key to move to the SET box and then press ENTER to set the frequency value entered
42. ldeeeyeb b ev PERS De PVERT pi uM 4 4 Pip Problems o loo ERA eM eoe Presta E GRE Ba npe ei 4 5 Transducer Problems 4 6 Chapter 5 Parts Replacement Introduction matas ATA Ie EAST VEO PO PORE 5 1 Replacing the Fuse 6h Rel A den Eee hea luy es 5 2 Removing the Printed Circuit Board 5 3 Installing an Option Card 2 5 4 Installing the Printed Circuit Board 5 5 Replacing the LCD Display 2 5 7 Spare Parts sets nb sew spend ls qwe is aut pu euin AER uie A Pew ed i en cq els eb od ob 5 8 Appendix A Service Record Introduction 2 22er ar Ei te ee eee Ree p A 1 Data E Em A 1 Vi Chapter 1 Diagnostics Introduction eoe nanas Rete an 1 1 Entering the Service Menu 1 1 Displaying Diagnostic Parameters 1 2 Signal Setup serene p or ce P peat otn Ne pe 1 3 Setting Error Limits rane AS a 1 5 The Test ODHON ee e ae er 1 7 February 2007 Introduction Entering the Service Menu For convenience the CTF878 offers a Service Menu see the Service Menu Map Figure 3 10 on page 3 11 This menu enables the user to perform a variety of functions that might occasionally be required Those covered in this chapter include
43. o the CTF878 IWARNING The main power to the CTF878 must be disconnected before proceeding Open the enclosure remove the main aluminum shroud and locate the J13 header connector above the display connector on the main board see Figure 2 3 on page 2 4 3 Reinstall the CONFIG jumper on the top two pins Reinstall the shroud close the cover and reapply power to the CTF878 2 10 Resetting and Updating Chapter 3 Calibration Introduction aus ttv ha ne A 3 1 Entering the Calibration Test Menu 3 1 Testing and Calibrating Analog Outputs 3 2 Testing and Calibrating Analog Inputs 3 4 Testing and Calibrating Digital Outputs 3 6 Testing and Calibrating RTD s 3 8 Testing EEPROM S 4 a dos ma uada Ee RH EOS 3 10 February 2007 Introduction For user convenience the CTF878 offers a Calibration Test Menu This menu enables users to perform a variety of functions that might occasionally be required to calibrate the CTF878 Refer to the Service Menu Map Figure 3 10 on page 3 11 while moving through the following procedures Entering the Calibration Enter the Service Menu as described on page 1 1 then select the Test Menu Calibrate Test option The screen appears similar to Figure 3 1 below Site Program Meter Logging Seem Diagnostics Signal Setup Error
44. on page 5 10 and complete the following steps 1 Remove the printed circuit board as described on page 5 3 2 Place the printed circuit board face down on a clean flat surface 3 If one 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 discarded as new plastic snap rivets will be provided 4 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 5 Repeat step 4 to install any additional option cards 6 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 See the installed assembly in Figure 5 1 on page 5 9 and Figure 5 2 on page 5 10 Complete the option card installation by proceed
45. oor flow conditions Check the programming transducer pipe fluid path and transducer setup If they are correct and in agreement make sure that the transducers are well cou pled to the pipe Contact factory if problem persists Velocity Range Error Incorrect TAG Path Incorrect Velocity Error Limits Poor flow conditions Check TAG Path under Program Path Check Veloc ity Error Limits under Service Error Limits Contact factory if problem persists Acceleration Error Incorrect Acceleration Error Limit Poor flow conditions Check acceleration error limit under Service Error Limits Contact factory if problem persists Note When errors E4 through E10 occur consistently the first action to take is to check the programming transducer pipe fluid path and the transducer setup f they are correct and in agreement make sure that the transducers are well coupled to the pipe 4 2 Troubleshooting Displaying Diagnostic Parameters Diagnostic Parameter February 2007 As part of its measurement menu the CTF878 offers a list of diagnostic parameters to aid in troubleshooting in the event of flowcell transducer or electrical problems You can select any diagnostic parameter for display as a measurement see Displaying and Configuring Data Chapter 2 of the Programming Manual or Chapter 4 of the Startup Guide Table 4 2 below shows all the available diagnostic parameter
46. r Power CTF878 down Remove shroud Make sure DSP board is seated correctly and its screws are on tight Power up Contact factory if problem persists DSP Timeout Error DSP board not seated correctly or corrupted code Power CTF878 down Remove shroud Make sure DSP board is seated correctly and its screws are on tight Power up Contact factory if problem persists Carrier Underrange Error Broken cable Pipe Fluid problem Transducer problem Electronic failure Check transducer cables See Pipe Fluid Problems on page 4 4 and 7ransducer Problems on page 4 6 Contact factory if problem persists Carrier Overrange Error Gas composition Power CTF878 down Open receivers GUAL boxes Disconnect preamplifiers from transducers and from receiving cables Connect transducers directly to receiving cables Switch preamplifiers power jumper to OFF position Power up Contact factory if problem persists Modulation Underrange Error Poor flow conditions See Pipe Fluid Problems on page 4 4 and Transducer Problems on page 4 6 Contact factory if problem persists Modulation Overrange Error Gas composition Power CTF878 down Open receivers GUAL boxes Discon nect preamplifiers from transducers and from receiving cables Connect transducers directly to receiving cables Switch preamplifiers power jumper to OFF position Power up Contact factory if problem persists SNR Error P
47. r FPGA software timing software for transit time instrument software the meter string file and the Help string file The updating procedure involves three steps 1 Setting up the CTF878 in Flash Update mode 2 Selecting the loading interface 3 Loading the new software from the PC into the CTF878 Caution To guard against mishap you should print out download or otherwise record all logs settings and other data you wish to save IMPORTANT When uploading new software the CTF878 uses a bootloader program Be sure the software you are installing is compatible with the installed bootloader version see The About Option on page 4 11 of the StartUp Guide or page 3 11 of the Programming Manual If both programs are to be replaced install the new bootloader first before any other software Resetting and Updating 2 3 February 2007 A A Preparation To prepare the CTF878 for a software update 1 Disconnect the power to the CTF878 IWARNING The main power to the CTF878 must be disconnected before proceeding 2 Open the enclosure remove the main aluminum shroud and locate the J13 header connector above the display connector on the main board see Figure 2 3 below 3 Remove the CONFIG jumper from the top two pins CONFIG JUMPER CONFIG Uu U16 DISPLAY JCONNECTOR 50M Figure 2 3 J13 Header Connector 4 Reinstall the shroud close the cover and reapply power to the CTF878
48. rate box and press ENTER The low point has been calibrated 4 The next prompt asks for the value to which you want to set the high temperature d Press ENTER to open the text box b Use the numeric keys to enter the desired value C Press ENTER to confirm your entry 5 Press the P arrow key to move to the Read box and then press ENTER to read the high temperature 6 Scroll to the Calibrate box and press ENTER The high point has been calibrated Calibration 3 9 February 2007 Calibrating RTD s cont Testing EEPROM s 7 If you are unsatisfied with the calibration you can reset the temperatures to factory defaults Press the P gt arrow key to move to the Reset box and then press ENTER to undo the calibration You have completed calibrating the inputs To leave the Calibrate RTD window Press F2 Cancel to return to Operate Mode without confirming the changes Press F3 OK to confirm the new data The CTF878 returns to Operate Mode Repeat the process to calibrate additional RTD s To check the EEPROM on each option card scroll to the Test EEProm option under the Service menu and press ENTER The screen appears similar to Figure 3 9 below This is information regarding the option card located in Slot 1 Note Option card slots are numbered from right to left Site Program Meter Logging ie Test EEPROM Slot 1 Board Type 11144A1 0 Week Year 27 2 Serial
49. s and ranges Table 4 2 Diagnostic Parameters Displays Good Bad Carrier Amplitude Up The peak voltage amplitude millivolts of the upstream channel received signal before demodulation 75 1100mV lt 75mV or gt 1100mV Carrier Amplitude Dn Carrier Gain Up The peak voltage amplitude millivolts of the downstream channel received signal before demodulation The gain of the variable stage of the upstream channel received signal 75 1100mV 6 to 31dB lt 75mV or gt 1100mV Carrier Gain Dn Amplitude Up The gain of the variable stage of the downstream channel received signal The RMS voltage amplitude millivolts of the upstream channel demodulated signal I 6 to 31dB 295 1180mV lt 295mV or gt 1180mV Amplitude Dn The RMS voltage amplitude millivolts of the downstream channel demodulated signal 295 1180mV 295mV or gt 1180mV Q Amplitude Up Q Amplitude Dn The RMS voltage amplitude millivolts of the upstream channel demodulated signal Q The RMS voltage amplitude millivolts of the downstream channel demodulated signal Q 295 1180mV 295 1180mV 295mV or gt 1180mV 295mV or gt 1180mV Modulation Gain Up The gain of the variable stage of the upstream channel demodulated signals and Q 16 to 31dB Modulation Gain Dn The gain of the variable stage of downstream channe
50. s console of the CTF878 has been designed to permit easy on site upgrades and parts replacement See Figure 5 1 on page 5 9 and Figure 5 2 on page 5 10 for details The instructions in this chapter along with a few common tools are all that is required to perform the following tasks fuse replacement printed circuit board PCB removal and installation option card installation LCD display replacement WARNING Prior to performing any maintenance procedures be sure to disconnect the main power from the unit 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 CTF878 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 73 23 EEC 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 Figure 5 1 on page 5 9 and Figure 5 2 on page 5 10 to locate the relevant components while completing the
51. ts or Press F3 OK to confirm the new limits and return to Operate Mode 1 6 Diagnostics February 2007 The Test Option Within the Service Menu the Test option includes three tests to ensure that the CTF878 is performing properly Test Screen Test Keys and Watchdog Test To enter this option scroll to the Test entry on the Service Menu and press ENTER The screen appears similar to Figure 1 5 below Site Program Meter Logging Diagnostics Signal Setup Error Limits Test Test Screen Test Keys Watchdog Test Figure 1 5 Test Option under Service Menu Scroll to the desired entry in the option menu and press ENTER Diagnostics 1 7 February 2007 Testing the Screen To test the proper functioning of the CTF878 screen scroll to the Test Screen option in the Test Menu and press ENTER The screen then shows the message Press Any Key To Continue Once you press a key a screen with a checkerboard pattern appears as in Figure 1 6 below Figure 1 6 A Functioning Test Screen Pressing a key two more times should result in two more checkerboard patterns followed by a series of dark and light screens Pressing the key through this sequence should return the CTF878 to Operate Mode If the test does not proceed according to this sequence please consult the factory 1 8 Diagnostics February 2007 ti Testing the Keys The Test Keys option checks the functioning of the
52. ts less than the cutoff to be reported as zero To set the cutoff d Press ENTER to open the text box b Use the numeric keys to enter the desired value C Press ENTER to confirm your entry d Press the V arrow key to enter the next prompt 4 The next prompt asks for Velocity Averaging d Press ENTER to open the drop down list from 2 to 100 b Use the W or A arrow keys to scroll to the desired number of velocity measurements to average together to smooth out noise in the system C Press ENTER to confirm your selection d Press the V arrow key to enter the next prompt 5 The final prompt Errors Allowed specifies the number of errors the meter can record before displaying an error message The default 1s 2 d Press ENTER to open the text box b Use the numeric keys to enter the desired value C Press ENTER to confirm your entry You have finished entering data in the Signal Parameter window To leave this window Press the A key to return to the Signal Parameter tab and the D arrow key to move to the other tabs When the desired tab is highlighted press ENTER to view its contents Or press F2 Cancel to return to Operate Mode without confirming the changes Or press F3 OK to confirm the new data The CTF878 returns to Operate Mode IMPORTANT Do not change the remaining Signal Setup options AgcMgc Automatic or Manual Gain Control CCorr Avg Cross Correlation
53. uivants EN 61326 1998 Class A Annex A Continuous Unmonitored Operation e EN 61010 1 1993 A2 1995 Overvoltage Category Il Pollution Degree 2 suivant les r gles de la Directive de Compatibilit Electromagn tique 89 336 EEC et de la Directive Basse Tension 73 23 EEC Shannon April 15 2004 cis Lis Mr James Gibson DIRECTEUR G N RAL nsal IS ENISO9002 T V ESSEN Shannon ISO 9001 U S CERT DOC HO August 2004 KONFORMITATS Sensing ERKLARUNG Wir Panametrics Limited Shannon Industrial Estate Shannon County Clare Ireland erkl ren in alleiniger Verantwortung da die Produkte CTF878 Ultrasonic Flowmeter folgende Normen erf llen e EN 61326 1998 Class A Annex A Continuous Unmonitored Operation e EN 61010 1 1993 A2 1995 Overvoltage Category Il Pollution Degree 2 gem den Europ ischen Richtlinien Niederspannungsrichtlinie Nr 73 23 EG und EMV Richtlinie Nr 89 336 EG Shannon April 15 2004 Aaa D Mr James Gibson GENERALDIREKTOR LS EN IS0 9002 Shannon CERT DOC H0 CE e H MI T V ESSEN ISO 9001 U S August 2004 USA 1100 Technology Park Drive Billerica MA 01821 4111 Web www gesensing com Ireland Sensing House Shannon Free Zone East Shannon Co Clare
54. various keys on the keypad To start the test scroll to the Test Keys option on the Test Menu and press ENTER The screen appears similar to Figure 1 7 below Press any key on the keypad and a cell representing that key should darken Test Keys Figure 1 7 The Test Keys Window Pressing the F3 key returns the meter to the Operate Mode If any key does not appear on the screen contact the factory Diagnostics 1 9 February 2007 Testing the Watchdog The CTF878 includes a watchdog timer circuit If a software error Timer Circuit causes the meter to stop responding this circuit automatically resets the meter A properly functioning CTF878 restarts if you run the Watchdog Test To start the Watchdog Test scroll to the Watchdog Test option in the Test Menu and press ENTER The screen appears similar to Figure 1 8 below Site Program Meter Logging REINAS Watchdog Test WARNING This test should automatically E restart your meter Press Yes to start the test Press No to cancel the test Figure 1 8 Watchdog Test Screen Press F2 No to cancel the test and return to the Menu screen or press F3 Yes to start the test The CTF878 should go blank for a few seconds and then restart If it does not follow this sequence consult the factory 1 10 Diagnostics Chapter 2 Resetting and Updating Introduction sense 2 1 Entering the Service Menu

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