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GF03
User Manual
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Fluid Components International GF03 User Manual

Installation, Operation and Maintenance GF03 Flowmeter Series
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Doc 06EN003352
FLUID COMPONENTS INTERNATIONAL LLC http://www.fluidcomponents.com
1. General Information
2. Installation
3. Operation
Description ................................................................................................................................. 1
Theory of Operation ................................................................................................................. 1
Sensing Element ........................................................................................................................ 1
Flow Transmitter ....................................................................................................................... 2
Technical Specification ............................................................................................................ 2
Receiving/Inspection ................................................................................................................ 5
Packing/Shipping/Returns ....................................................................................................... 5
Factory Calibration Note .......................................................................................................... 5
Pre-Installation Procedure ....................................................................................................... 5
Install Flow Element ................................................................................................................. 6
Install Transmitter ..................................................................................................................... 8
Customer Wiring ....................................................................................................................... 9
Introduction ................................................................................................................................13
4. Maintenance
5. Troubleshooting
6. Appendices
NOTICE OF PROPRIETARY RIGHTS: This document contains confidential technical data, including trade secrets and proprietary information which is the property of Fluid Components International LLC (FCI). Disclosure of this data to you is expressly conditioned upon your assent that its use is limited to use within your company only (and does not include manufacture or processing uses). Any other use is stricly prohibited without prior written consent of FCI.
Doc. No. 06EN003352 Rev. B Model GF03 Flow Meter
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Model GF03 Flow Meter Doc. No. 06EN003352 Rev. B
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1. General Information
Description
Theory of Operation
This document describes the procedures required to install, operate, maintain, and troubleshoot the Model GF03 Flowmeter. There are a wide range of possible configurations and information related to the optional features. The flowmeter is composed of a remote thermal dispersion sensing transducer (flow element) connected to a microprocessor-based electronics control and display package (flow transmitter). The flow element is attached to the flow transmitter thru a cable of up to 1000 feet or 300 meters (remote instrument).
The instrument is designed to operate in gaseous flow metering environments. The flowmeter is factory calibrated to handle a range of flows.
The primary flow element consists of two thermowells of the same size, shape and mass. One thermowell contains a platinum RTD and a heater element. The other contains one RTD. The RTD located with the heater element is called the active RTD. The other RTD is referred to as the reference RTD. Since the active RTD is embeded in the heater, the temperature of the active thermowell is always above the temperature of the process media. The temperature at the reference RTD is the temperature of the process media. When the process media is flowing past the active RTD a quantity of heat is carried off into the flow stream. The amount of heat taken from the active RTD is a function of the process media mass flow rate. A ∆T (temperature) exists between the two thermowells and a proportional ∆R (ohms resistance) exists between the active and the reference RTDs. The ∆R is measured by the flow transmitter. The relationship of ∆R to the calibrated flow rate is calculated by the flow transmitter and is converted into both analog and digital outputs.
The Gas Compensation element provides a ∆R value similar to the primary flow element. This value is a no-flow ∆R based on the thermo physical properties of the gas mixture minus any flow component. This value is used to correct gas composition changes in the Transmitter microprocessor.
Sensing Element
The standard sensing element is an all welded 316L stainless steel insertion probe. The element consists of the primary flow element located on the end of the probe and the compensator element located in the insertion pipe. The optional Veri-Cal inlet tube runs the length of the insertion pipe exiting into the base of the primary flow element. This tube allows the Veri-Cal system to distribute a repeatable flow rate on the primary flow element
for calibration verification purposes.
Figure 1 - Flow Element
Doc. No. 06EN003352 Rev. B 1 Model GF03 Flow Meter
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Flow Transmitter
The other component of the flowmeter is the flow transmitter. The basic functions of the flow transmitter are to provide power to the flow element, measure the Differential Temperature (∆T) between the two RTDs as a function of resistance, amplify and linearize the Differential Resistance (∆R) measurement of the flow element and provide a proportional output signal.
This output signal is calibrated to the flow rate as a function of standard velocity or volume. To perform these functions, microprocessor-based electronic circuitry is employed to acquire the analog voltage signals from the RTDs, digitize and interpret the information.
The microprocessor-based electronics provides maximum flexibility and ease of operations with a menu-driven selection of control, monitoring, display and driver options.
Technical Specifications
Figure 2 - Flow Transmitter
INSTRUMENT Flow Range:
Insertion Flow Element: 0.5 to 275 SFPS [0.20 to 84 NMPS] — Air at standard conditions; 70°F [21.1°C] and 14.7 psia [1.01325 bar (a)].
Media: All gases that are compatible with the flow element material. Accuracy:
Flow: ±2% to 5% of reading above 1 SFPS in open stack environments. Temperature: ±2°F (display only, flow rate must be greater than 5 AFPS)
Repeatability:
Flow: ±0.5% reading Temperature: ±1°F (flow rate must be greater than 5 AFPS)
Turndown Ratio:
Standard: Factory set and field adjustable from 2:1 to 600:1 within calibrated flow range.
Temperature Compensation:
Standard: ±30°F [±-1°C] Optional: ±100°F [±38°C]
Agency Approvals (Pending):
FM, CSA, CE MARK, (EMC Directive 89/336/EEC), ATEX, CCE, CRN.
Calibration: Performed on NIST traceable equipment. FLOW ELEMENTS
Material of Construction: All-welded 316L stainless steel. Elements with pressure
transducer have braze and 300 series SST.
Operating Pressure: 0 to 250 psig [0 to 17 bar (g)] Operating Temperature: Process temperature -40°F to 350°F [-40°C to 177°C];
Process Connection: 1” male NPT, Flange (ANSI), Packing Gland 1-1/4” NPT or Flanged.
Model GF03 Flow Meter 2 Doc. No. 06EN003352 Rev. B
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FLOW TRANSMITTER Operating Temperature: 0 to 140°F [-18 to 60°C] Input Power: 115 Vac ± 15 V; 230 Vac ± 30 V; 22 to 30 Vdc; 23 Watts Max.
Output Signal Analog:
Two independent, AC power isolated, which can be set as follows:
4-20 mA, 600 ohm maximum load 0-10 Vdc, 5000 ohm minimum load 0-5 Vdc, 2500 ohm minimum load 1-5 Vdc, 2500 ohm minumum load
One optional pressure output:
4-20 mA, 600 ohm maximum load
One gas compensator output:
4-20 mA, 600 ohm maximum load.
Two programmable 10 amp (115 Vac or 24 Vdc) relay switch points. Communication Port: EIA-232 [RS-232C]
Display: 4 line/20 character per LCD line, indicating flow rate and process temperature
and/or totalized flow.
Communicator(optional): Hand held plug-in interface (model FC88). Remote Enclosure Standard: NEMA/CSA Type 4X (equivalent to IP66) Fiberglass Option: Aluminum rated for hazardous location use Class I and II, Division 1 and 2,
Group B, C, D, E, F, G (previously referred to as NEMA 7 and EEx d IIB) resists the effects of weather and corrosion.
Doc. No. 06EN003352 Rev. B 3 Model GF03 Flow Meter
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2. Installation
Receiving / Inspection
Packing / Shipping and Returns
Factory Calibration Note
Pre-Installation Procedure
w Unpack carefully, observe Electro-Static Discharge (ESD) precautions if handling the
flow transmitter.
w Inspect for damage to the flow element and the flow transmitter. w Verify that all items in the packing list were received and are correct. w Verify the Delta R Data Sheet and the Instrument Information Sheet are present.
If the above items are satisfactory then proceed with installation. If not, then stop and contact the FCI customer service representative for instructions.
These issues are addressed in Appendix C - Customer Service.
The flowmeter is factory calibrated to the flow range specified in the order. There is no need to perform any verification or calibration steps prior to installing and placing the flowmeter in service.
Caution:
The flow transmitter contains electrostatic discharge (ESD) sensitive
devices. Use standard ESD precautions when handling the flow transmitter. See below for ESD details.
The GF Series Flowmeter is not designed for weld-in-place applications. Never
weld into the installation or to a structural support.
Use Standard ESD Precautions
Use standard ESD precautions when opening an instrument enclosure or handling the flow transmitter. FCI recommends the use of the following precautions: Use a wrist band or heel strap with a 1 megohm resistor connected to ground. If the instrument is in a shop setting there should be static conductive mats on the work table and floor with a 1 megohm resistor connected to ground. Connect the instrument to ground. Apply antistatic agents to hand tools to be used on the instrument. Keep high static producing items away from the instrument such as non-ESD aproved plastic, tape and packing foam.
Prepare or Verify Flow Element Location
Prepare the media process pipe for installation or inspect the already prepared location to ensure the instrument will fit into system. Prepare the necessary sealants or gaskets to provide a leak proof installation.
The U-length should be double checked when installing the flow element into the process media. The U-length is determined at the factory order time and is the distance that places the flow element head center line in the center line of process media. See Figure 3. The greatest accuracy is achieved when the flow element is mounted at least 20 diameters downstream and 10 diameters upstream from any bends or interference in the process pipe or duct.
Doc. No. 06EN003352 Rev. B 5 Model GF03 Flow Meter
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Verify Serial Numbers
Verify the flow element and flow transmitter have the same serial number, as they are to be installed as a matched set.
Verify Dimensions
Verify the flow element and flow transmitter dimensions as shown in Appendix A.
Verify Flow Direction for Flow Element Orientation and Placement Note: Correct flow element placement in the measurement stream is vital for obtaining
accurate flow readings. Before mounting the flow element, check the options ordered for correct orientation and insertion length at the planned site of installation.
The flow element thermowells must be positioned in the same orientation to the process flow as they were during calibration (refer to the Instrument Information Sheet). Failing to install the flow element correctly may reduce the accuracy of the flowmeter. Be sure the flow arrow points in the direction of flow.
The flow element thermowells are to be placed as shown in Figure 3, with the end of the shroud 0.6 inches past center line.
There is a flat area machined perpendicular to the thermowell plane. Adjust the flow ele­ment during installation so the flat area is parallel, with in ±2°, to the direction of process media flow.
Adjustable / Retractable Flow Element Assembly
Caution: Do not over-tighten the flow element. The RTD's can be
dammaged if the flow element is forced into the far wall of the pipe or vessel.
Select one of the following installation procedures which is applicable to the unit being installed.
NPT and flange packing gland mounts are available. The valve assembly with appropriate connections are typically customer supplied. Follow the pipe or flange mounting procedure below.
NPT Pipe Mounting
w Apply sealant compatible with the process media to male threads. Carefully insert into
process mount. Threads are right-handed. Tighten with an open-end wrench on the hexagonal surface provided. Rotate until snug.
Figure 3 - NPT Pipe Mount
Model GF03 Flow Meter 6 Doc. No. 06EN003352 Rev. B
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Flange Mounting
w Attach the process mating flange with care. The correct orientation of the flow element
must be maintained to ensure the calibrated accuracy.
w Verify that the process media flow is in the same direction as the arrow on the FLAT. w Apply the appropriate gasket and/or sealant to flange mount as required. w Mate flow element flange to process mount keeping flat oriented properly. w Attach with bolt, two flat washers, lock washer and nut for each bolt hole, apply lubricant/
sealant to male threads and torque. Refer to ANISI B16.5 specifications.
General Mounting
w Tighten packing nut until internal packing is tight enough so that the friction fit on the
shaft is adequate to prevent leakage but not prevent the shaft from sliding. Position the flat horizontal with arrow in direction of process flow.
w Proceed to insert the flow element into process media line. For the medium pressure
packing gland use the adjusting nuts on the all-thread to pull the flow element into proper predetermined depth position.
w Tighten the opposing lock nuts on the all-threads. Tighten the packing nut another 1/2
to 1 turn until tight (approximately 65 to 85 ft-lbs torque).
w Rotate split ring locking collar to line up with connecting strap welded to packing nut.
Tighten the two 1/4-28 hex socket cap screws on the split ring locking collar. Open valve
- check for process media leakage.
w Reverse these steps for removal.
Figure 4 - Flange Mount
Doc. No. 06EN003352 Rev. B 7 Model GF03 Flow Meter
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Install Transmitter
Warning: Installation of an FCI instrument should only be performed by properly trained
personnel in accordance with the current edition of the National Electrical Code. Ensure that all power is off. Any instances where power should be applied to the instrument will be noted in this manual. Where the instructions call for the use of electrical current, the operator assumes all responsibility for conformance to safety standards and practices.
Caution: In applications where the flow element is located in an explosive environment,
isolate the conduit before it leaves the environment. A potting "Y" may be used to provide the isolation.
Remote Hardware
See Appendix A for the remote enclosure along with the physical dimensions so the flow transmitter can be properly mounted.
Note: The factory recommends removal of the transmitter while pulling the necessary
cables; this will prevent damaging the circuit boards or their components. To remove the transmitter unbolt the four outermost screws on the transmitter mounting plate.
Power Connection Information Conduit Routing
All electrical connections are to be made through the female NPT openings in the flow transmitter's enclosure. FCI strongly recommends that all electrical cables be run through an appropriate conduit for the protection of the instrument and personnel. Refer to the appropriate wiring diagram.
Protection of the electronics from moisture is an important consideration. Keep the entry of the conduit into the enclosures in the downward direction so condensed moisture that collects in the conduit will not drain into the enclosure. In addition, FCI recommends sealing off the conduit with a potting Y or other sealing method to prevent moisture from entering the enclosure.
Minimum Wire Size
Table 1 shows the smallest (maximum AWG number) copper wire which should be used in the electrical cables. Use a lower gauge of wire for less of a voltage drop. Contact FCI concerning greater distances than those listed in the chart.
Connection
AC Power 22 22 22 20 18 16 Relay
(2A at 220 VAC) Relay
(10A at 120VAC or 24 VDC) Flow Element Wires for Remote Option *
Pressure Transducer 24 24 24 22 22 18
10 ft. (3 m)
24 22 20 16 12
22 16 12 Not Recommended
24 24 24 22 22 18
50 ft.
(15 m)
Maximum Distance for AWG
100 ft.
(31 m)
250 ft.
(76 m)
500 ft.
(152 m)
1000 ft.
(305 m)
Not
Recommended
Table 1 - Interconnecting Wire Size
* Requires two 8 conductor shielded cables. The shield is connected to the GND pin of
JP3 of the flow transmitter. The other end of the shield is left floating (no connection to the terminal block).
Model GF03 Flow Meter 8 Doc. No. 06EN003352 Rev. B
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Input Power
The flow transmitter is powered by 115 VAC, 230 VAC or 24VDC (only one power source is needed). If 115 VAC is used, wire it directly to JP8 and position switch S1 to be in the 115V position. If 230 VAC is used, position switch S1 to be in the 230V position and then wire the power directly to JP8. If 24 VDC is used, it is wired directly to JP8 as shown on the wiring diagram.
The installation of an AC line disconnect switch (and possibly a fuse) between the power source and the flowmeter is strongly recommended. This facilitates easy power disconnection during calibration and maintenance procedures as well as an added safety feature.
Remote Transmitter
Route all interconnecting wiring into the remote transmitter enclosure. Ensure wires are long enough with sufficient service loops to eliminate excessive strain on the terminal connections. Connect Flow and Analyzer element cables as shown on wiring diagram. The display orientation varies for different transmitter configurations, but the termination block for the element connection remains the same. If the Veri-Cal option was ordered, wire the pressure transducer as shown on the wiring diagram.
Figure 5 - Electronics Assembly
Customer Wiring
Jacks JP3 (top circuit board), JP4, JP5, JP6 and JP7 are for customer use and are described in Table 2.
JACK / NOMENCLATURE DESCRIPTION
JP3 (top circuit board) RS-232 (EIA-232) Serial Port
JP4 Relay Output 1 and JP5 Relay Output 2
JP6 Analog Output
Doc. No. 06EN003352 Rev. B 9 Model GF03 Flow Meter
Table 2 - Customer Wiring
Used in conjunction with equipment compatible with an RS-232 (EIA-232) serial port. See Chapter 3 for more details.
Factory pre -programmable relay contacts. Two normally closed contacts are available (double pole, single throw relay) per jack. External relays can be connected to the +EXT and -EXT pins in each jack. Recommended relays are 18Vdc, 0.1A. max at 180 or more ohms pull i n current.
There are two factory pre -programmable signals which are voltage and/or current. The 1 AUX and +20V pin is a customer option for the use as a dynamic correction factor. See Chapter 3 for more information.
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Figure 6 - Wiring Diagram, Remote with Veri-Cal
Model GF03 Flow Meter 10 Doc. No. 06EN003352 Rev. B
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Figure 7 - Wiring Diagram, Remote
Doc. No. 06EN003352 Rev. B 11 Model GF03 Flow Meter
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3. Operation
Introduction
Start Up Procedure

Operation

The flowmeter has been configured and calibrated to custom specifications. Each flowmeter contains distinct operating limits and units of measurement. This chapter will show how to determine and manipulate the configuration of the flowmeter.
1. After the wiring has been verified, apply power to the flowmeter. (No special instructions for instrument shutdown; turn operating power off.)
2. Then wait 10 minutes for warm-up. During this period the flowmeter may indicate high flow.
3. After power up the instrument automatically enters the flow metering mode and the display sets to normal operation.
Display
The flowmeter contains a 4 x 20 character LCD display. Flow rate, temperature, and system status are all accessible through the display.
Initialization Window
When power is applied to the flowmeter the display will briefly show the initialization window. See Figure 8.
FCI GF03
Initializing
Wait, Please
V1.00 Dec 16, 2003
Version Number and
Revision Date
C00549-1
Figure 8 - Initialization Window
Normal Mode Window
The flowmeter upon power up defaults to the normal mode of operation and begins to display the flow rate, the temperature, the total flow (if enabled ) and the current system status. The Normal Operation display is shown in Figure 9.
Flow Units
Temperature Totalizer
Sample Rate
ModeRelay
C00239-2
Output Channel #
Flow Rate
CH1: 5056.3 SCFM CH2: 71.2 °F
435226 SCF
Σ =
(grp1)(ed)(norm)(m)
Group #
Status
Figure 9 - Normal Operation Display
Doc. No. 06EN003352 Rev. B 13 Model GF03 Flow Meter
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Menu Window
The menu is made up of 4 components. They are the menu level, title, selections, and prompt line. These components are illustrated in Figure 10. The top line displays a menu code and title. Lines 2 and 3 are used to scroll through the available selections. The prompt line indicates which menu commands are appropriate.
Title
Menu Level
2.1 ANALOG SETUP
1=Setup Port 1 2=Setup Port 2
UP HOME
Available Selections
Prompt Line
C00435-1
Figure 10 - Menu Window
The menu code is a numeric reference that identifies each window of the menu structure. The menu code in Figure 10 indicates that the user is two levels deep (Level 2, sublevel 1). The menu structure will be explained further in Menu Organization.
The title gives the user a better idea of where the system is within the menu structure. Some titles are informative enough to completely describe the menu function, while other titles are ambiguous unless there is knowledge of the parent menus.
The middle two lines display the available selection. The number of choices is often more than the two displayed. Pressing the N (next) or P (previous) keys on the keypad will scroll the selections up or down. To choose a function from the available selections press the corresponding number on the keypad.
The prompt line displays appropriate menu control key strokes for that menu level. Pressing N, the (N)ext key, will scroll the display down. Pressing P, the (P)rv or Previous key, will scroll the display up. Pressing the UP key shifts the current menu level up one. Pressing the HOME key goes straight to the 0.0 MAIN MENU.
Other Window Types
Another common window encountered is shown in Figure 11. The window is similar to the Menu Window except that it does not scroll and all choices are contained within the window. The current selection (if there is one) is also contained in the parenthesis to the left of the question mark.
Press the corresponding number in the Available Sections for the choice of display.
Menu Level
Current
Selection
Title
3.1.2 STD VOLUME
1 = Cu feet 2 - Cu meter 3 = Liters (CF)s ?
C00241-1
Available
Selections
Prompt
Line
Figure 11 - Non-Scrolling Menu Window
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Menu Control
The prompt line displays appropriate key strokes for that menu level. If a key is pressed that is not valid for that menu, Invalid Response will flash briefly across the prompt line. The key pad layout is shown in Figure 12.
Key Key Name Action
1 2 3 Y N
4 5 6
7 8 9 P
ENTR
0 #
_
HOME
Figure 12 - Key Pad
See Table 3 for key pad assignments. At any time, the HOME key can be pressed and the main menu will display. HOME can be used to escape from most routines, restart a progression into the menu structure, or quickly change from one area of the menu to another.
When (N)ext is displayed on the prompt line, more than two menu selections are available. Press N to scroll through all the selections.
The UP key, will back-out of a menu level. The menu moves back one level each time the UP key is pressed. The UP key only functions when UP is displayed on the prompt line.
To make a selection, press the numeric key associated with the desired menu selection. The selection does not have to be displayed, but it must be one of the available selections.
Every path through the menu will eventually cause control to pass from the menu structure to a routine that performs a task such as change a parameter value, initiate a test, or calibrate the system hardware. When the system is operating outside the menu structure, there are subtle differences in the user interface. For example, the UP key may have no affect or the prompt line won't appear.
.
UP
C00220-1
0 - 9 Numeric
Y Yes Enter a yes response
N No or (N)ext
- Minus Enter a minus sign Decimal Point Enter a decimal point Back Space Moves cursor back one space
P (P)rv or Previous Scrolls to the previous screen
ENTR Enter
HOME Home
UP Up
Selects options and enters numbers
Enter a no response or scrolls to the next screen
Enters a numeric value or response
Returns to the Main Menu or escapes from routines
Move current menu up one level
Table 3 - Key Assignments for the GF Series Key Pad
Doc. No. 06EN003352 Rev. B 15 Model GF03 Flow Meter
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Menu Organization
The menu structure is divided into 8 major groups. The first menu option places the flow transmitter's display into the Normal Display mode. When the system is in this mode, flow and temperature measurements are displayed. While in the Normal Display mode, pressing any key will cause the main menu to display. Figure 13 shows the entire menu structure.
Menu selections two through eight allow the configuration of the flowmeter to be checked and manipulated. Table 4 summarizes the functions contained in each menu group.
Group Name Function
2.0 Port Setup
Sets analog outputs, set relay switch point and configure the auxiliary input.
Sets the units of measure for the displayed flow
3.0 Display Setup
rate, temperature and total flow. Sets the sample rate.
4.0 Miscellaneous
Sets the current calibration group. Configures the Corrector. Sets the user password.
5.0 Verify Displays system variables to the screen.
6.0 Diagnostics Factory use only.
7.0 Calibration Displays Delta R in ohms.
8.0 Normalize Board Factory use only.
The Port Setup, Display Setup and Miscellaneous groups is where most activity is concentrated. The Verify, Diagnostics, Calibration and Normalize Board groups are used primarily for diagnostics and factory calibration.
Normal Operation
The flowmeter upon power up defaults to this mode. During normal operation the flow rate and the temperature is displayed. The total flow is displayed if it is enabled and few system configuration parameters are shown. Figure 9 is the Normal Operation display.
The first and second lines contain the current flow rate and temperature. The total flow is displayed on the third line only if it is enabled. The last line contains the current Group number (see the Multiple Groups section in Advanced Features), the relay status, the mode of operation and the sample rate.
The relays status shows either e (energized) or d (de-energized). The letters correspond to the first and second relays, respectively. The mode of operation is norm for normal, auto for Auto-Select or link for Link Groups. (See Advanced Features for explanation of these modes). The sample rate is slow (s), medium (m) or fast (f).
Table 4 - Menu Functions
Model GF03 Flow Meter 16 Doc. No. 06EN003352 Rev. B
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