Aalborg GFM User Manual

Technical Data Sheet No. TD9411M Rev. L Date of Issue: April 2013

OPERATING MANUAL

GFM MASS

FLOW METERS

 CAUTION:

This product is not intended to be used in life support applications!

TABLE OF CONTENTS

1. UNPACKING THE GFM MASS FLOW METER.........................................

1.1 Inspect Package for External Damage.................................................

1.2 Unpack the Mass Flow Meter...............................................................

1.3 Returning Merchandise for Repair.......................................................

2. INSTALLATION........................................................................................

2.1 Primary Gas Connections.................................................................

2.2 Electrical Connections......................................................................

2.3.1 Remote LCD Readouts.....................................................................

2.3.2 Panel Mounting Readouts................................................................

3. PRINCIPLE OF OPERATION...................................................................

4. SPECIFICATIONS...................................................................................

4.1 CE Compliance.................................................................................

5. OPERATING INSTRUCTIONS..................................................................

5.1 Preparation and Warm Up..................................................................

5.2 Flow Signal Output Readings..........................................................

5.3 Swamping Condition.......................................................................

6. MAINTENANCE.........................................................................................

6.1 Introduction......................................................................................

6.2 Flow Path Cleaning...........................................................................

6.2.1 Restrictor Flow Element (RFE)........................................................

6.2.2 GFM 17 models................................................................................

7. CALIBRATION PROCEDURES.................................................................

7.1 Flow Calibration...............................................................................

7.2 Calibration of GM Mass Flow Meters..............................................

7.2.1 Connections and Initial Warm Up.....................................................

7.2.2 ZERO Adjustment.............................................................................

7.2.3 SPAN Adjustment............................................................................

7.3 Linearity Adjustment..........................................................................

7.3.1 Connections and Initial Warm Up....................................................

7.3.2 ZERO Adjustment.............................................................................

7.3.3 25% Flow Adjustment......................................................................

7.3.4 50% Flow Adjustment......................................................................

7.3.5 75% Flow Adjustment......................................................................

1 1 1 1

1 1 2 4 4

6 7

9 9 9

10 10 10 10 11

11 11 13 13 13 13 14 14 14 14 15 15

7.3.6 50% Flow Adjustment....................................................................

7.3.7 75% Flow Adjustment....................................................................

7.3.8 100% Flow Adjustment....................................................................

7.4 LCD Display Scaling.........................................................................

7.4.1 Access LCD Display Circuit..............................................................

7.4.2 Adjust Scaling..................................................................................

7.4.3 Change Decimal Point......................................................................

8. TROUBLESHOOTING.............................................................................

8.1 Common Conditions........................................................................

8.2 Troubleshooting Guide.....................................................................

8.3 Technical Assistance.......................................................................

9. CALIBRATION CONVERSIONS FROM REFERENCE GASES.......................

APPENDIX 1 COMPONENT DIAGRAM.........................................................

APPENDIX 2 GAS FACTOR TABLE ("K" FACTORS)........................................

APPENDIX 3 DIMENSIONAL DRAWINGS......................................................

PARTS OF THE FLOW METER..............................................

APPENDIX 4 WARRANTY..............................................................................

15 15 15 15 16 16 16

16 16 17 21

28 29

1. UNPACKING THE GFM MASS FLOW METER

1.1 Inspect Package for External Damage

Your GFM Mass Flow Meter was carefully packed in a sturdy cardboard carton, with anti-static cushioning materials to withstand shipping shock. Upon receipt, inspect the package for possible external damage. In case of external damage to the package contact the shipping company immediately.

1.2 Unpack the Mass Flow Meter

Open the carton carefully from the top and inspect for any sign of concealed shipping damage. In addition to contacting the shipping carrier please forward a copy of any damage report to your distributor or Aalborg7 directly.

When unpacking the instrument please make sure that you have all the items indicated on the Packing List. Please report any shortages promptly.

1.3 Returning Merchandise for Repair

Please contact the customer service representative of your distributor or Aalborg7 if you purchased your Mass Flow Meter directly, and request a Return

Authorization Number (RAN). Equipment returned without an RAN will not be accepted. Aalborg7 reserves the right to charge a fee to the customer for

equipment returned under warranty claims if the instruments are tested to be free from warrantied defects.

Shipping charges are borne by the customer. Meters returned “collect” will not be accepted!

It is mandatory that any equipment returned for servicing be purged and neutralized of any dangerous contents including but not limited to toxic, bacterially infectious, corrosive or radioactive substances. No work shall be performed on a returned product unless the customer submits a fully executed, signed SAFETY CERTIFICATE. Please request form from the Service Manager.

2. INSTALLATION

2.1 Primary Gas Connections

Please note that the GFM Mass Flow Meter will not operate with liquids. Only clean gases are allowed to be introduced into the instrument. If gases are contaminated they must be filtered to prevent the introduction of impediments into the sensor.

CAUTION: Some of the IC devices used in the GFM are Electro Static Discharge (ESD) sensitive and may be damaged by improper handling. When wiring interface connector, adjusting or servicing the meter, use of a grounded ESD protection wrist strap is required to prevent inadvertent damage to the CMOS integral solid state circuitry. When 9 pins interface D-connector is not used do not remove factory installed ESD protection cover.

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CAUTION: IT IS THE USERS RESPONSIBILITY TO DETERMINE IF THE INSTRUMENT IS APPROPRIATE FOR THEIR OXYGEN APPLICATION, AND FOR SPECIFYING O2 CLEANING SERVICE IF REQUIRED. AALBORG IS NOT LIABLE FOR ANY DAMAGE OR PERSONAL INJURY, WHATSOEVER, RESULTING FROM THE USE OF THIS INSTRUMENT FOR OXYGEN GAS.

For more information contact your distributor or Aalborg7.

Attitude limit of the Mass Flow Meter is ±15Ffrom calibration position (standard calibration is in horizontal position). This means that the gas flow path of the Flow Meter must be within this limit in order to maintain the original calibration accuracy. Should there be need for a different orientation of the meter, re-calibration may be necessary. It is also preferable to install the GFM transducer in a stable environment, free of frequent and sudden temperature changes, high moisture, and drafts.

Prior to connecting gas lines inspect all parts of the piping system including ferrules and fittings for dust or other contaminant’s.

Be sure to observe the direction of gas flow as indicated by the arrow on the front of the meter when connecting the gas system to be monitored.

Insert tubing into the compression fittings (except GFM77) until the ends of the properly sized tubings home flush against the shoulders of the fittings. Compression fittings are to be tightened according to the manufacturer's instructions to one and one quarter turns. Avoid over tightening which will seriously damage the Restrictor Flow Elements (RFE's)!

Using a Helium Leak Detector or other equivalent method perform a thorough leak test of the entire system

. (All GFM's are checked prior to shipment for leakage

within stated limits. See specifications in this manual.)

2.2 Electrical Connections

All GFM models require power supplies with nominal current rating of at least 200 mA. The operating power input is supplied via the DC power jack or the 9pin “D” connector located at the side of the flow transducer enclosure. On GFM's pur-chased without an LCD readout, a readout panel meter, digital multimeter, or other equivalent device is required to observe the flow signal.

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CAUTION: WIRING THE GFM METER WITH THE POWER ON MAY RESULT IN INTERNAL DAMAGE! PLEASE MAKE ALL WIRING CONNECTIONS BEFORE SWITCHING ON THE POWER.

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Based on the GFM transducer’s serial number it may require a different power sup-ply voltage. GFM flow meters with serial numbers below 340621-1 may require 12 or 24 Vdc power supplies. Before connecting power supply check the meter power supply requirements label located on the flow meter back cover. If the power supply requirements label states that the power supply requirement is 12 Vdc, do not connect power supply with voltage above 15 Vdc. Exceeding specified maximum power supply voltage limit will result in device permanent damage.

The GFM flow meters with serial numbers above 340621-1 have universal power input and can be used with any power supply voltage between +12 and +26 Vdc.

CAUTION: BEFORE CONNECTING POWER SUPPLY CHECK YOUR METER SERIAL NUMBER AND POWER SUPPLY REQUREMENTS LABEL LOCATED ON THE FLOW METER BACK COVER. DO NOT CONNECT 24Vdc POWER SUPPLY UNLESS YOUR GFM METER WAS ORDERED AND CONFIGURED FOR 24Vdc. EXCEEDING SPECIFIED MAXIMUM POWER SUPPLY VOLTAGE LIMIT MAY RESULT IN DEVICE PERMANENT DAMAGE.

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PIN FUNCTION

1 Remote LCD display signal 2 0 to 5 VDC output indication 3 0 to 5 VDC common 4 Power supply, positive 5 Power supply, common 6 Remote LCD display reference 7 (unassigned) 8 4 to 20 mA output indication

self-powered (sourcing type, non-isolated)

9 4 to 20 mA common (return)

FIGURE 2.a - 9-PIN “D” CONNECTOR PINOUTS FOR GFM TRANSDUCER.

IMPORTANT NOTES:

In general, “D” Connector numbering patterns are standardized. There are, however, some connectors with nonconforming patterns and the numbering sequence on your mating connector may or may not coincide with the numbering sequence shown in our pin configuration table above. It is imperative that you match the appropriate wires in accordance with the correct sequence regardless of the particular numbers displayed on your mating connector.

Make sure power is OFF when connecting or disconnecting any cables in the system.

When connecting power to the GFM mass flow meter via the DC power jack, do not connect any power supply to the 9-pin 'D' Connector. The DC power jack has a center positive polarity.

When battery use is required to power the GFM, use only the optional battery and accompanying charger available from Aalborg7.

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Based on the device serial number the power input is protected by a 750mA (12 and 24 Vdc flow meter models with serial numbers below 340621-1) or 300 mA (universal power flow meter models with serial numbers above 340621-1) M (medium time-lag) resettable fuse. If a shorting condition or polarity reversal occurs, the fuse will cut power to the flow transducer circuit. Disconnect the power to the unit, remove the faulty condition, and reconnect the power. The fuse will reset once the faulty condition has been removed.

CAUTION: Resettable fuse will not protect meter if power supply voltage exceeds maximum voltage specified for particular model.

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In order to operate flow meter within the specification the cable length for analog 0-5 Vdc output and remote LCD display may not exceed 9.5 feet (3 meters).

Use of the GFM flow transducer in a manner other than that specified in this manual or in writing from Aalborg7, may impair the protection provided by the equipment.

2.3.1 Remote LCD Readouts

GFM Mass Flow Meters are available with optional remote reading LCD displays supplied with a three foot long wire to accommodate most applications. This configuration includes the upper block element which serves as the LCD readout mounting. Special lengths of remote extension wiring (up to 9.5 feet [3 meters]) are available on request.

2.3.2 Panel Mounting Readouts

Another option for the GFM Mass Flow Meter is the Panel Mounting Remote Readout. In this configuration the LCD readout is supplied with a three foot long extension wire, and no aluminum housing around the LCD. The LCD readout for panel mounting includes a bezel with two plastic screws which conveniently fit into a rectangular cut-out for panel mounting (see Figure 2.b).

FIGURE 2.b - CUTOUT DIMENSIONS FOR LCD PANEL MOUNTING.

3. PRINCIPLE OF OPERATION

The stream of gas entering the Mass Flow transducer is split by shunting a small portion of the flow through a capillary stainless steel sensor tube. The remainder of the gas flows through the primary flow conduit. The geometry of the primary conduit and the sensor tube are designed to ensure laminar flow in each branch. According to principles of fluid dynamics the flow rates of a gas in the two laminar flow conduits are proportional to one another. Therefore, the flow rates measured in the sensor tube are directly proportional to the total flow through the transducer.

In order to sense the flow in the sensor tube, heat flux is introduced at two sections of the sensor tube by means of precision wound heater-sensor coils. Heat is transferred through the thin wall of the sensor tube to the gas flowing inside. As gas flow takes place heat is carried by the gas stream from the upstream coil to the downstream coil windings. The resultant temperature dependent resistance differential is detected by the electronic control circuit. The measured gradient at the sensor windings is linearly proportional to the instantaneous rate of flow taking place.

An output signal is generated that is a function of the amount of heat carried by the gases to indicate mass-molecular based flow rates.

4. SPECIFICATIONS

FLOW MEDIUM: Please note that GFM17/37/47/57/67/77 Mass Flow Meters are designed to work with clean gases only. Never try to meter or control flow rates of liquids with any GFM's.

CALIBRATIONS: Performed at standard conditions [14.7 psia (1.01 bars) and 70

(21.1

C)] unless otherwise requested or stated.

ENVIRONMENTAL (per IEC 664): Installation Level II; Pollution Degree II.

ACCURACY: ±1.5% F.S. (optional enhanced accuracy ±1% F.S.).

REPEATABILITY: ±0.25% of full scale.

TEMPERATURE COEFFICIENT: 0.15% of full scale/

PRESSURE COEFFICIENT: 0.01% of full scale/psi (0.07 bar).

RESPONSE TIME: 800 ms time constant; approximately 2 seconds to within ±2% of set

flow rate for 25% to 100% of full scale flow rate.

GAS PRESSURE: 1000 psig (69 bars) GFM 17, 37 and 47; 500 psig (34.5 bars) GFM 57, 67 and 77; optimum pressure is 20 psig (1.4 bars).

GAS AND AMBIENT TEMPERATURE: 32

F to 122 FF (0 FC to 50 FC).

F to 122 FF (-10 FC to 50 FC) - Dry gases only.

RELATIVE GAS HUMIDITY: Up to 70%.

LEAK INTEGRITY: 1 x 10

- 7

sccs He max. to the outside environment.

ATTITUDE SENSITIVITY: Incremental deviation of up to 1% full scale from stated accuracy, after re-zeroing.

OUTPUT SIGNALS: Linear 0-5 VDC (1000 Ω minimum load impedance) and 4-20 mA self-powered sourcing type, non-isolated (0-500 loop Ω resistance); 20 mV peak to peak max noise.

Contact your distributor or Aalborg7for optional RS232 or RS-485 interfaces.

TRANSDUCER INPUT POWER:

GFM models with 12 VDC power input (serial numbers below 340621-1):

12 VDC, 200 mA maximum;

GFM models with 24 VDC power input (serial numbers below 340621-1):

+24 VDC, 200 mA maximum;

GFM models with universal power input (serial numbers above 340621-1):

any voltage between +12 and +26 VDC, 200 mA maximum;

Power input is protected by a 750 mA (GFM models with serial numbers below 340621-1) or 300 mA (GFM models with serial numbers above 340621-1) M (medium time-lag) resettable fuse, and a rectifier diode for polarity protection.

WETTED MATERIALS:

GFM17/37/47/57/67/77: Anodized aluminum, brass, and 316 stainless steel with

VITON7 O-rings seals; BUNA7, EPR or KALREZ7 O-rings are optional.

GFM17S/37S/47S/57S/67S/77S: 316 stainless steel with VITON7 O-rings seals; BUNA7, EPR or KALREZ7 O-rings are optional.

Aalborg7makes no expressed or implied guarantees of corrosion resistance of mass flow meters as pertains to different flow media reacting with components of meters. It is the customers' sole responsibility to select the model suitable for a particular gas based on the fluid contacting (wetted) materials offered in the different models.

INLET AND OUTLET CONNECTIONS:

GFM 17 and 37: 1/4" compression fittings. Optional: 6mm compression, 1/4" VCR7 ,

3/8" or 1/8" compression fittings (GFM 17).

GFM 47: 3/8" compression fittings. GFM 57: 3/8" compression fittings. GFM 67: 1/2" compression fittings. GFM 77: 3/4" FNPT fittings or 3/4" compression fittings.

LCD DISPLAY: 3½ digit LCD (maximum viewable digits “1999”), 0.5 inch high characters.

On GFM171/371/471/571/671/771 aluminum or stainless steel models the LCD display is built into the upper block element and may be tilted over 90 degrees for optimal viewing comfort. Remote or panel mounting remote reading is optional.

Standard readings are in direct engineering units for the given gas and flow rate (i.e. liters/minute [slpm], standard cubic centimeters/minute [sccm], standard cubic feet/hour [scfh], etc.). 0 to 100% LCD calibration scaling is available upon request at time of order. Contact your distributor or Aalborg7 when non-standard display settings are desired.

TRANSDUCER INTERFACE CABLE: Optional shielded cable is available mating to the GFM transducer 9-pin “D” connector. In order to operate flow meter within the specification the cable length for analog 0-5 Vdc output and remote LCD display may not exceed 9.5 feet (3 meters).

4.1 CE Compliance

Any model GFM bearing a CE marking on it, is in compliance with the below stated test standards currently accepted.

EMC Compliance with 89/336/EEC as amended; Emission Standard: EN 55011:1991, Group 1, Class B Immunity Standard: EN 55082-2:1992.

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