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DigitalFlow™ GF868 - GE Measurement & Control

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1. e C e 7 Fuse d o AR ALI Mem 14 83 377 S T IL 16 99 432 9 4 19 106 eo LOLA An a Honl 1 1 Du 3 5 z m EI e p pe 2 e le d e le 5 o o L E E 2 o E a 11 37 11 82 o 289 300 13 13 5 833 3 o E 5 m z 5 o 9 o i Y To o d e E z x I E Pa z I E e 899 H 3 3 31 84 3 S 2 E 3 gt 5 22 u 2 25 57 139 Fal J t GF868 18 25 464 19 00 483 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 49 Appendix B Optional Enclosures Line Lead Black Option Card Slot Cover Option Card Socket typ Analog Output Connector Neutral Lead White CH1 Transducer Connector Fuse RS232 Connector CH2 Transducer Connector Ground Lead Green Top Panel Mounting Hole Power Terminal Block 4 places Printed Circuit Board Display Cable Red Lead Snap Rivets typ Option Card Bracket Beveled Corner N PCB Mounting S
2. Front View Keypad Cable Mounting Screw ri ain Shrou Main Shroud Display Cable 8 places d Nuts amp Washers 2 Nuts amp Washers x NI 4 4places N d e i K Display Shroud FIL Option Card Socket IN V A LCD Display Metal Bracket Display Shroud Backlight Cable ort Standoffs Cover Ground Wire Internal Ground Connection Fuse Holder Cap PC Board Power Ground Wire Connector Fasteners Option Card EE Standoffs typ PC Board v Screw X LVD Shroud 8 places N A Fuse Holder LVD Shroud Option Cards Side View Card Guide Bottom View Metal Bracket Figure 8 Standard Model GF868 Electronics Console Assembly DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 37 Chapter 4 Stan
3. 1 5 Testing the Alarm Relays cont 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 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 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 5 1a 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 To leave the Calibration Menu press F4 EXIT twice 12 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 1 Calibration 1 6 Testing the Totalizer Frequency Outputs Totalizer Frequency outputs may be added to the Model GF868 by installin
4. 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 Ultrasonic Flowmeter for Flare Gas Service Manual 9 Chapter 1 Calibration 1 4 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 14 5a 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 t
5. 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 of this 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 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 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual iii Preface Environmental Compliance 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 bac
6. 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 Part Number 703 1127 02 Option Card Alarms Hermetically Sealed 703 1127 03 Option Card Alarms General Purpose 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 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 Model GF868 at the time of purchase 36 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 4 Standard Drawings
7. 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 Installing 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 Ultrasonic Flowmeter for Flare Gas Service Manual 31 Chapter 4 Parts Replacement 4 4 Replacing the 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 Rem
8. Ur Cae IDE tes Iur bai 6 1 3 5 Accessing the Calibration Menu sue ots nace oa ead oes Deed eud o a la 7 1G CLOW Option ues lisi bad gas ath Pee OS DPI perque peris henge EISE a POE 8 E E al AAA rt ER RUE ORE EEUU ES artt in e ta veiba Rec tates det 8 155205 OB E lato lame eee mta e eu Re dre b e tuse S rd 8 IATA died xa cd tum rat 8 A Rl sr INDUS xcu Ce ots at aon atem ou et tiae s tede 9 1 4 1 Accessing the Calibration Menia cese uu dac laica eines bees 9 1252 Probe OO E Dose e bM MCN jaa APUL n E pO 9 TE SNP D DUO e e i aatis en ten oS era eR Oo AE E tested remp CO Maret s Cd 10 1 5 Testi The Alarm Relays nore cu Sc Fare cer Leute te a A deci tA edat e tarde Lee dea or fire 11 15 1 Accessingithe Callbratio Ment so a o dde ii ar do Ra R 12 1 6 Testing the Totdlizer Frequency Outputs 1 oio a shee Ce TE Cv ei a ae ee 13 1 6 1 Aecessing the Calibration Man oa quer Qc A ER usta OH Ea 14 1 6 2 Entering Frequency iii pub e dried ped e 14 1 5 3 Entering Pulse NUMBER usse orcas winds Cn tO dw eb K Melo taa eb Fdo LUE ERR EAST 14 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual V Contents Chapter 2 Error Codes and Screen Messages 2 IBILOGUCHOB eot esiste dd NT UAM E Tree 17 Note E02 NO EMO mii A e Ue De ud eeu rar e a 18 Acton ET EOW SIDE cs ruso Lien ostia educ derbi i i rua Juri lot ure los 18 Actions Ez Sound Speed EOR Lits vod oer et odore Vi esc fd e tuetur ELLE 18 POTION ES V elacito RANGES ceca erat ea ES
9. as needed Table 6 Service Record DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 39 Appendix A Service Record eroereeT rTrT_Tt6____r_ r_rr r_ _rrr __ Table 6 Service Record cont 40 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 73 23 EEC this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked
10. 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 Ultrasonic Flowmeter for Flare Gas Service Manual 1 Chapter 1 Calibration 13 Calibrating the Analog Outputs Every Model GF868 flowmeter includes two built in analog outputs A and B at terminal block I O 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 yA 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
11. 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 The DSP digital signal processor RAM has passed EPROM sum XXXX Record the EPROM sum at the initial power up and periodically thereafter 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 The non volatile RAM has passed Measurement Mode Messages FRIGID_INIT Executed This message may appear during one of the following tasks 1 clearing a log there are no more logs to clear 2 logging data user has hit ENT instead of selecting an old log or entering a new All Logs Cleared hit key name 3 printing a log there are no logs to print 4 displaying a log there are no logs to display Hit any key to resume taking measurements 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 All Sites Cleared hit key Lh OU LA This message appears upon exiting t
12. high purity carbon dioxide hydrogen etc readily attenuate ultrasound energy In such a case an E1 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 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 wit
13. if STANDARD equation is used Skan T Offset Displays dynamically calculated signal timing offset in usec skan signal measurement UP Transit S usec Displays Skan Tup DN Transit S usec Displays Skan Tdn DeltaT Susec Displays Skan DELTA UP Transit M usec Displays Measure Tup DN Transit M 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 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 p
14. necessary See Chapter 3 Diagnostics for instructions DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 2 Error Codes and Screen Messages E5 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 caused 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 Chapt
15. o e torques o cea sanete 18 Action E4 SIA HIE c neue ae tos one a e Edo Pr torpe o e e Le do dE 18 Action ES ADDE SE AAA e arie Mirra iii rie a Lehr iaia Led DL ei 19 ACHOH EBSCUOIe SKIP e s ci iet tet Ce mre tieu HA AERE at a Cet tur date Ea Ed 19 Acton EZANA DUE EPIOES nali elena 19 Action ES TEMP Merne eee tee qoe gre Gone eb eue mti padded pedo teg bodega SNP VC Pe dd 19 Acto EO PRESSI aio is am aie trato Viae ORE REG P 4 9 aoe Hen EE ate PUR nte ERAN USO atate ptg ERIS 19 Action EOS Oem NO b INR EE TEE EET e RUM PER e T 20 o dhe ls qe e PREMIER DERI a EO IA NACE RCS USER RU ele CR Me EIE 20 Action Ele NOPUSSO es tree ee elia Erit T aA Cut ic a ETE efr 20 Acton ELSsOVer Range is esce utu e eet E INTE cete e dee ate d e re ete 20 Action LA Totals DUOLDOW d os de dee pU D NEUE pU 20 Achion ELS EUA mrs caos oae de Oe UE ER p a pda do eee x aa 20 2 2 bcreemiMessadges Cero eec enata eoe totale es kA dint o LRL drum 21 Chapter 3 Diagnostics SL Tass EON catu sna Muse o dept uo ew ka ete be Fata ut EISE d don bead ita 23 32 Displaying Diagnostle POFBITIGIES EE OR e COR Oe AS ats n pete 23 SS DIA RA hs Sexe leita die oue aen USt M E ME EAS Mord Pea ea E a 25 SU lee Susie vet Lor e ADM I eU Ane ivi EE A ed e re AA 25 BAP TS A Doors te Cete nei doll ali rio etes 26 DAS PIBEDIOSISITIS AO seco mede vido sd aset ena A dde Pu A e lp EP 26 35 ERONSOUCE PIO DIEING c aaa Nen 27 Chapter 4 Parts Replacement 4 IN OCULARI CE CR RU Eu a
16. 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 While 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
17. 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 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 o
18. 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 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 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 Ifthe damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e If 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 ae DECLARATION Sensing OF CONFORMITY DOC 0013 Rev A We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the DigitalFlow DF8688 Liquid Ultrasonic Flowmeter DigitalFlow GC8
19. the next section 1 3 7 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 3 8 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 press F2 to cancel the entry In either case the ANALOG INPUT prompt reappears Press F4 to proceed to the next section 1 3 9 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 3 9a Procedure Options You have completed calibration of the analog output Do one of the following To calibrate another input return to Step 3 in Accessing the Calibration Menu on page 7 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 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 1 Calibration 1 4 Calibrating the RTD Inputs Calibrating an RTD option card inv
20. 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 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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 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 loca
21. 68 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 e EN 60079 0 2007 EN 60079 1 2004 EN50281 1 1 1998 2 G EEx d IIC T6 ISSePO3ATEX113 ISSeP B7340 Colfontaine Belgium NoBo 492 N 61326 1 2006 Class A Table 2 Industrial Locations e EN 61326 2 3 2006 EN 61010 1 2001 Overvoltage Category II Pollution Degree 2 m Other standards Used e EN 50014 1997 A1 A2 e 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 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN 25 A 4 Peas feynd i Billerica August 2010 Issued Mr Gary Kozinski Certification amp Standards Lea
22. CALIBRATING FI F2 F3 F4 F1 F1 F2 F1 F2 P a es ces x uP DOWN Numer STORE ABORT STORE ABORT STORE ABORT L t j E ABORT STORE y Numeric RTD Inputs Slot x Outputs Analog Outputs Et F2 F1 F2 F3 F4 Probe Numer a sp f c fo Slot x Inputs ANALOG OUTPUT FI F2 F1 F2 F3 F4 Pa BY 4ma 20mA test EXIT Probe Numer Full Scale CALIBRATING B E S ez F1 F2 F3 F4 F1 SetPt Slope Sew Slopt Cue Down Numer STORE ABORT Set Point Slope Point Set Point Slope Number Numeric Temp FI F2 Set NOTE Plain text represents prompt area messages and boxed text represents option bar choices Fx represent function keys to select option bar choices Figure 6 Calibration Menu Map DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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
23. 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 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 34 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 4 Parts Replacement 4 7 Installing the Printed Circuit Board cont 2 Carefully position the printed circuit board up against the eight standoffs in the enclosure 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 t
24. GE Measurement amp Control Solutions Gas Analysis DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 1 and 2 Channel i gt k 910 1945 Rev E Imagination at wor March 2011 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 1 and 2 Channel 910 1945 Rev E March 2011 WWW ge mcs com 2011 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page Preface Information Paragraphs Note paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance Caution paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to property or equipment e Warning paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to personnel Cautionary information is also included when applicable Safety Issues 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
25. To replace the LCD display refer to Figure B 2 on page 11 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 inside 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 o
26. ach 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 Ultrasonic Flowmeter for Flare Gas Service Manual Appendix B Optional Enclosures B 7 2 Circuit Board Installation Refer to Figure B 2 on page 11 and complete the following steps 1 Position the new printed 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 Connect the 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 B 2 on page 11 Make
27. 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 A A Ammeter Figure 1 Ammeter Connection for Slot 0 Output A 2 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 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 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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
28. as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model GF868 B 2 Rack Mount Enclosure Refer to Figure B 1 on page 10 and Figure B 2 on page 11 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 removing 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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 B 1 on page 10 and Figure B 2 on page 11 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 t
29. 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 Note IfaSlot0 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 1 B A SIG SIG Figure 3 Analog Input Calibration Connections 6 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 1 Calibration Analog Inputs Option Card 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 0 mA or 4 mA However the calibration procedure always uses the 4 mA point as the meter will
30. 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 GF866 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 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual T 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 componen
31. ccuracy i 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 CUA Press the or keys until the desired channel option appears on the option Velocity Ft s bar Press the appropriate Fx key to select this option 6 95 error codes appear here M ESTE NEN PIG Note Fora 1 Channel Model GF868 the above prompt does not appear and the following prompt is the initial screen Chi label eM Press the 4 or 2 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 Di c Note Chl or Ch2 which is shown in parentheses above appears in the locator bar only with a 2 Channel Model GF868 For example pressing F1 displays the Tdown parameter as shown in the following prompt DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas S
32. centage of peak set to 50 by default N A Qup UP Signal Q Displays the signal quality for the upstream transducer 400 to 400 Qdown DN Signal Q Displays signal quality for the downstream transducer 400 to 400 AMPup UP Amp Discrim Displays the value for the amplitude discriminator of the upstream transducer lt 19 or gt 29 AMPdn DN Amp Discrim Displays the value for the amplitude discriminator of the downstream transducer 19 or gt 29 CNTup UP DAC Counts Displays AGC DAC count for upstream gain setting N A CNTdn DN DAC Counts Displays AGC DAC count for downstream gain setting N A P up UP Peak Displays signal peaks for the upstream transducer lt 100 or gt 2300 P dn DN Peak Displays signal peaks for the downstream transducer lt 100 or gt 2300 TEMP Temperature F Displays the gas temperature 4 20 mA input N A PRES Pressure psia Displays the gas pressure 4 20 mA input N A Mw 24 Molecular Wt Displays the average molecular weight of the gas N A DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 3 Diagnostics Table 3 Available Diagnostic Parameters cont Option Bar Screen Display Description Act Vol Displays actual volumetric flow KACF MIN Std Vol KSCF MIN Displays standard volumetric flow
33. crew typ a Black Lead EPROM U4 Backlight Cable Nut amp Washers typ Keypad Cable LCD Display Display Shroud Standoff typ Figure 11 Model GF868 Rack Mount Console Assembly ref dwg 705 849 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 50 A Acceleration Error E6 45 cir esae cerea Y nee ats 3 Alarms Option Card Testing nennou sunaa 11 Amplitude Error B55 i ooo de pre aia 3 Analog Inputs Option Card Calibrating 6 Analog Output Error E7 o ooooooomoooo 3 Analog Outputs Slot 0 As Calibrated Current Source o oooooo 6 Calibrating sous islanda 2 EEA A STORE POT AO 2 Resolution i v 2 iG S eps as ea ls SUCRE 9 Analog Outputs Option Card Calibrating ato dan tart V Ed D E oi 2 Lineatiby sedes v quis ho eta Meera Peak SE 2 RESON uc ac ers eo a agate ERE CEN 2 B Bracket Option C aide rias get ag Slate ns 17 C Cable Backlight sip keine pepe doe ad RC 15 19 Display a kx bebe hu ARI Re 15 18 Reypadss ioni ductus UO RE Rete es 15 Calibrating See Parameter Name Calibration Menu Entering 1 Circuit Board See Printed Circuit Board Contamination Gas o oooooooo o ee eee 10 Corrosion Transducers LL 11 D Date of Publication lt e e e ser serres i Diagnostics Menu A eda ee Ne fase nas 7 EXIDE RR 9 Display Cable rab ERU ke Diabet ewes 15 LCD aut epee ber Rae M eR 18 Replace ri
34. d Engineer CE TV 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 470291 E mail gesensingsnnservices ge com An ISO 9001 2000 Certified Company www ge mcs com en about us quality html www ge mcs com 2011 General Electric Company All rights reserved Technical content subject to change without notice 910 1945 Rev E
35. dad 18 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Index D cont Display Screen Error Message nisi io C taeda aa 1 stato a os ad dos OE AAA ae O 1 Document Number 0 1 E Environmental Compliance iv EPROM Replacing ooo Ioa eost a etat M Prae la 16 User Program i229 RE La 16 Error Codes o Rp et EOD ERE E 2 3 4 Error Message Display Screen 1 Expansi n SiS caia adria 1 F Flowcell Problems uc st ae POR amp 10 Pipe tad arin raia a aT aa bed cala 10 Fuse Holder eds sos ts n a E An sua 14 Rating sigo radio QA RENTA 14 Replace at Rhee 14 vp Soe Hind eh Re eek ele o 14 DIP Anita 14 G Gas Contato ts 10 Physical Requirements oooooooooo 10 O e seed eye EAS EEUU 10 SG Dd Speed esos ep h a t deu peu DE 10 Grounding Strap sis per per e 19 Guides Option Card 5 2 o da 17 I Information Paragraphs Lac a ARMEN 111 K Keypad Cable zio pda ea 15 51 Index L LOD DISpIay iai osa Hoe hho dane che ET EVA 18 Leaks Transducers LL 11 Low Signal Error Bla pe Tre RN RS 2 LVD Statement acia aa 13 N No Birot E0 ora gow SEX owner de ew ae ee 2 Numer Option for RTD Option Card o rita 10 O Option Card Analog Outputs ses pirata ares 2 Bracket Spr rei ARI ripe T N 17 Expansion Slots 4 order ira 1 Guides ili AGG ake ee RU UE ee 17 Installing a CR ENS ER 17 Socket a 17 Over Range Error El3 o ooooo o 4 P Pi
36. dard Drawings AAA rra Keypad Cable Short Standoff y Vertical Components X 8places Backlight Cable rA Long Standoff EPROM U4 gt N NL OT 7A AN 3 places YN L E S N DA I E o LCD Display N Ie 7 5 y pe o lt 1 c E Ej Beveled g Corner E Keypad Connector J50 i E S TENE E B n TR Display Connector J52 Display Cable e li E 2 E I La CESE 3 J2 Connector 2 ox Fasteners typ 5 1 L AR 8 9 Metal Bracket Option Card Connectors a Rear View E AAA AOS u PC Board Ground Wire Screws or Standoffs Front View DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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
37. e 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 Contact 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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 a
38. er 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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 transmitter 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 u
39. ervice Manual 23 Chapter 3 Diagnostics 3 2 Displaying Diagnostic Parameters cont Ch1 Ch1 DN Transit usec 019 7 error codes appear here Tdown l DELTA Penice Qup diagnostic parameter or to EXIT the Diagnostics Menu PS Press the and 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 Table 3 Available Diagnostic Parameters Option Bar Screen Display Description Good Bad SS up UP Sig Strength Displays signal strength for the upstream transducer lt 50 or gt 75 SS do DN Sig Strength Displays signal strength for the downstream transducer lt 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 gt 10 000 nsec Tot K K Re MultiK KFactor Displays combination of all K factors N A PEAK PEAK Displays the per
40. extrapolate this value to obtain the 0 mA point 1 3 5 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 the 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 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 Ultrasonic Flowmeter for Flare Gas Service Manual 7 Chapter 1 Calibration 1 3 6 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
41. f 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 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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 B 2 on page 11 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 i
42. f 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 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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 B 2 on page 11 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 disconnec
43. g 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 the option card has been installed in Slot x DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 13 Chapter 1 Calibration 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 F4 to select output A B C or D respectively 1 6 2 Entering Frequency 4 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 1 6 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 6 3a Procedure Opt
44. gitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 Ifthe 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 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 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 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 connect
45. h 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 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 3 Diagnostics 3 5 Transducer Problems Ultrasonic transducers 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 2 CORROSION DAMAGE If the transducer material was not properly chosen for the intended application the transducers may suffer corrosion damage The damage
46. he User Program if the new site data has not Do you want to SAVE been saved Failure to save will result in loss of the new data next time the site data is changed or recalled Duplicate name The site file or log name is already in use Enter a different name Enter another End Time must exceed Start This message appears when in the LOG menu Enter an end time that is at least five Time by 5 min minutes later than the start time An option card error indicating a programming failure or a loss of memory Contact Header invalid the factory DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 21 Chapter 2 Error Codes and Screen Messages Table 2 Screen Messages cont age ening 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 Th
47. he 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 fasten 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 TB1 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 a
48. he rear panel label Table 7 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 100 120 VAC 1 0A 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 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 42 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 B 2 on page 11 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 If one or more option cards are already installed
49. hen asks for the set point number Enter the points measured at the set temperature and press ENT 145b 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 4 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 proceed to the appropriate section To leave the Calibration Menu press F4 EXIT twice 10 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 1 Calibration 1 5 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 Ultrasonic Flowmeter for Flare Gas Service Manual 11 Chapter 1 Calibration
50. ions 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 To leave the Calibration Menu press F4 EXIT twice 14 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 1 Calibration ca Cal FA F2 F3 F4 F1 F2 F3 Loro amp or Lora Lors Lora ors Lore Slot x Option Card Slot x Outputs Alarms F1 Aa B ES F3 ALARMS F1 F2 F3 CLOSE oP EN EXIT JE Slot x Outputs Freq Total CL A S STORE ABORT F1 F2 F3 F4 N r 4 E Ce o FREQUENCY PULSES Slot 0 Outputs TB 1 0 Slot x Inputs Analog Inputs FI F2 FI F2 La CB a eB ANALOG OUTPUT ANALOG INPUT FI F2 F3 F4 F1 F2 F3 F4 F1 4mA 20ma Test ExT alow aHiGH 4mA 20ma ExT 12918 JET SLOW A Cem y LS Soke LOW REFERENCE HIGH REFERENCE CALIBRATING LOW REF HIGH REF
51. irectye codices pyre taeda re tei ERIE hY iv DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 restoring 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 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
52. k initiative directive 2002 96 EC 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 1741 weee reg html for take back instructions and more information about this initiative iv DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Contents Chapter 1 Calibration Li MMPOG ION ef esce oet eos anor ean aera ded be 1 1 2 MM A ear aeneon 1 es pedi AAA A Jae bs Maker ne die EL 2 1 3 1 Accessing the Calibration Met id ill iris ici 3 1 3 2 Calibrating the Low End of the Output RA a OX e oo ante ae aaa 4 1 3 3 Calibrating the High End of the Output ROO c e Heo Den Eee Ex ei e ee 4 1 3 4 Testing the Analog Output Linearity ses oca tetuer ed etta hod dede He eat aet ett dl ete n 5 Calibrating the Analog AS ava Za c no ca doi
53. n 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 disconnect device DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 35 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
54. nable 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 programmed path and axial length dimensions are correct 20 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 ee A Power Up Messages Backup Battery FAIL 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
55. nostics no content intended for this page 28 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 fuse replacement e printed circuit board PCB removal and installation e EPROM replacement option card installation 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 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 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
56. 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 Ifthe ammeter reading cannot be adjusted within 5 0 yA 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 Ifthe ammeter reading cannot be adjusted within 5 0 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 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 1 Calibration 1 3 4 Testing the Analog Output Linearity Note Ifyou exited this menu and are returning follow steps I 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 ex
57. olves a different procedure than for other analog input cards However you access the card in the same manner as other cards 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 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 method current input selected RTD CALIBRAT last option selected Probe Numer 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 4 2 Probe Option F1 3 Press F1 to select Input A or F2 to select Input B 1 4 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 4 26 Slope Point Temperature
58. or 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 Installing the Printed Circuit Board section of this chapter DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 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 replace 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 standoff
59. ove 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 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 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 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 Complete the EPROM replacement by proceeding to the Installing the Printed Circuit Board section of this chapter page 34 Note If 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 Di
60. pe Meas urements ris AS 10 Problems teks ogres oe oe iaia 10 Pressure Input Error E9 3 Printed Circuit Board EPROM soil bate E Ge DX RR DG 16 Replacing siro is eee ees 15 PROBE Option for RTD Option Card noia 9 Problems Transducers 0000 eee 11 R Reboot Automatic LL 1 Replacing See Part Name Return Policy cad ek ERR nano 39 52 S Safety Auxiliary Equipments dai sO 111 General Issues e a satira UM A aee OS 111 Personal Equipment cs pm 111 Screen Messages Table oooooo 3 Service Record 22 214 boca RES ERE RI Rus 23 Shroud X Trad soo cot Mute CS e eas ed rd 13 19 TOD TSB ou ea CNR E EE 18 IND heads aber das 19 Plastilana Atte 19 Signal Quality Error E4 o ooooo oo 2 Sockets Option Card osi eX cria 17 Soundspeed A Li lille sets 2 QS La RRR restato ketenes HEAT ped 10 Spare Parts List esc a bh dta ee 20 Special Input Error ElO 4 T Temperature Input Error E8 3 Totalizer Frequency Option Card Testing 13 Totals Overflow Error E14 4 Transducers COOSION A eel ee 5 11 Internal Damage aa asa 11 A anak Een ty eR DEEEES 11 Physical Damage ptr hae See AS 11 Placement seta ila See AS 10 Probleitisz 5 9 ee Z KTT ex pre eE perdi 11 U User Program EPROM ey a ts 16 Upgrading tepe ue rei ESENoU RARE EEG EAS 16 V Velocity Range Error E3 eos Seat aes ds 2 W MEA enia S e eee Hm b we gate No Er UE he E 39 WEEE D
61. pected 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 Full Scale 4 20 mA Scale 0 20 mA Scale All ammeter readings should be 0 005 mA If the linearity test readings are not within 5 pA of the values listed in Table 1 above check the accuracy and wiring of 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 To leave the Calibration Menu press F4 EXIT three times DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual 5 Chapter 1 Calibration 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
62. roblem proceed with this section Flowcell problems fall into two categories e 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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 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 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 i e
63. s 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 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
64. s 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 chip 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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
65. 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 white 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 Ultrasonic Flowmeter for Flare Gas Service Manual 47 48 no content intended for this page DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Appendix B Optional Enclosures
66. t 29 42 SPOUSE Replacement Scelba atei 30 4 3 Removing the Printed Circuit Board iero e e Rara 31 44 Replacing the EPROM eat e e EA T we bea afe c ER sa 32 dp Me PAIN amO ption Card ee ch ae aa e ii e nes cick EA a 33 455 Replacing the lED IS a 2 a E 34 4 77 Installing the Printed Gret Boat at SI A E id RUEDA 34 48 Spare eln E E E N ES 36 Appendix A Service Record A 9 12 010 bch lola Eros bo e A een e eee ALLE E E eee ee A 39 AZ DAA EN SERS oa AL LDL a ek pba eU eee PER PME ER OD IN EU 39 vi DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Contents Appendix B Optional Enclosures B 1 B 2 B 3 B 4 B 5 B 6 B 7 O tee e rr die 41 Rack Mount FETA CIS IE Guo Aene ees uci vies nuc uL te E RAIL nc E ID MORET 41 Rack Mo nt PUSS Replacement oo Lance licia o ansi 42 Rack Mo nt Option Cara HFS TCH ARO es coacti Laos eet ioco ic oto zi illo larve 43 Rack Mount ERROMIBSBIGESEBEIES a e diego ERES RER TR acta ES 44 Rack Mount LCD Display Replacement tet te at lettin e e e eu el SE od da 45 Rack Mount Printed Circuit Board Replacement erste ty ite eee RA oat e aloe de tods 46 A IC HIE Board A dein dod Cubic o RT REN IL 46 B Z2 Circ it Board Installation iissa aria 47 DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual vii Contents no content intended for this page viii DigitalFlow GF868 Ultrasonic Flowmeter for Flare Gas Service Manual Chapter 1 Calibration Chap
67. ted 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 to 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 e
68. ted 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 Model 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 Ultrasonic Flowmeter for Flare Gas Service Manual 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
69. ter 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 e calibrating Slot 0 6 analog outputs e calibrating Slot 1 6 analog inputs e calibrating Slot 1 6 RTD inputs testing Slot 1 6 alarm relays 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 addition every Model GF868 flowmeter includes two built in analog outputs A and B at terminal block I O 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 O 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
70. ts listed above Also check the value programmed into the SETUP SIGNL submenu as described in the Operator s 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 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
71. 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 3 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 4 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 fragile 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 Ultrasonic Flowmeter for Flare Gas Service Manual 27 Chapter 3 Diag

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