Fluid Components International GF90, GF92 User Manual
Installation, Operation and Maintenance
GF90 and GF92
[
Model GF92 In-Line
Model GF90 Insertion
]
Doc 06EN003229
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1. General Information
2. Quick Start Guide
3. Installation
Description ............................................................................................................ 1
Flow Element ........................................................................................................ 1
Flow Transmitter ................................................................................................... 1
Technical Specifications ....................................................................................... 2
Pre-Installation ...................................................................................................... 5
Flow Element Installation ...................................................................................... 5
Wiring Preparation ................................................................................................ 6
Wiring the Instrument ............................................................................................ 6
Instrument Operation ............................................................................................. 8
Receiving/Inspection ............................................................................................. 11
Packing/Shipping/Returns..................................................................................... 11
Factory Calibration Note ....................................................................................... 11
Pre-Installation Procedure .................................................................................... 11
Install Flow Element .............................................................................................. 13
Install Flow Transmitter ......................................................................................... 16
Customer Wiring ................................................................................................... 20
Serial Communication Option ............................................................................... 20
HART Option Installation ...................................................................................... 21
Foundation Field Bus ............................................................................................ 24
Isolated Output Option and 4-20 mA Adjustment ................................................. 25
LT81 Series Upgrade Information......................................................................... 26
Apply Power .......................................................................................................... 26
4. Operation
5. Maintenance
6. Troubleshooting
Introduction ............................................................................................................. 27
Start-Up Procedure ................................................................................................. 27
Operation ................................................................................................................ 27
Advanced Features ................................................................................................. 41
External Input Auto-Select Procedure ................................................................... 53
Optional Veri-Cal In-Situ Calibration Verfication .................................................... 54
Optional Purge System ........................................................................................ 59
Two Point Averaging System Option ..................................................................... 60
Maintenance ........................................................................................................... 65
Introduction ............................................................................................................. 67
Troubleshooting Equipment ..................................................................................... 67
Quick Troubleshooting ............................................................................................ 67
In-Depth Troubleshooting - Standard GF90/GF92 Flow Element .............................. 68
In-Depth Troubleshooting - GF90 with VeriCal Flow Element ................................... 69
In-Depth Troubleshooting - The Flow Transmitter ..................................................... 71
In-Depth Troubleshooting - The Installation .............................................................. 72
In-Depth Troubleshooting - The Process ................................................................. 72
Other Troubleshooting ............................................................................................. 73
Verifying Delta R's .................................................................................................. 74
Repair ..................................................................................................................... 75
Defective Parts ....................................................................................................... 75
Customer Service ................................................................................................... 75
7. Appendices
Appendix A. Outline Drawings and Wiring Diagrams ............................................... 77
Appendix B. Glossary of Terms .............................................................................. 83
Appendix C. Declaration of Conformity .................................................................... 87
Appendix D. Customer Service ............................................................................... 93
Doc. No. 06EN003229 Rev. H GF Series Flow Meter Models GF90/GF92
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GF Series Flow Meter Models GF90/GF92 Doc. No. 06EN003229 Rev. H
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1. General Information
Description
Flow Element
This document describes the procedures required to install, operate, maintain, and troubleshoot the
Model GF90 and GF92 Flowmeters. 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
device (flow element) interconnected to a microprocessor-based electronics control and display package
(flow transmitter). The flow element can be attached directly to the flow transmitter (local instrument)
or it can be connected to the flow transmitter with a cable of up to 1000 feet or 300 meters (remote
instrument).
The instrument is designed to operate in gaseous mass flow metering environments. The flowmeter is
factory calibrated to handle a range of flows.
The flow element consists of 4 thermowells. The thermowells are hollow metal tubes that are braised
together to make 2 pairs of thermowells. One thermowell pair contains the active Resistance
Temperature Detector (RTD) and a heater. The other thermowell pair contains the reference RTD and
an empty thermowell for thermal mass equalization. Figure 1 shows the flow element.
Figure 1. Cut-Away View of the Flow Element
Flow
Transmitter
Doc. No. 06EN003229 Rev. H 1
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 input signal and to provide an output signal.
This output signal is calibrated to the flow rate as a function of velocity, standard volume or mass flow.
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 operation with a menudriven selection of control, monitoring, display and driver options.
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The flow element consists of two pairs of thermowells of the same size, shape and mass. One pair contains
a platinum RTD and a heater element. The other pair contains one RTD. The RTD located next to the heater
element is called the active RTD. The other RTD is referred to as the reference RTD. Since the active RTD
is adjacent to the heater, the temperature at the walls of the thermowell are 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 exists
between the two pairs of thermowells and a proportional ∆R exists between the active and the reference
RTDs. The ∆R is measured by the flow transmitter. The relationship of ∆T to the mass flow rate is
calculated by the flow transmitter and is converted into a signal or is sent to the flow transmitter's display.
Technical Specifications
Gas Mass Flow Measurement:
GF90: In ducts or pipes sizes with a minimum 2.0 inch (5.1 cm) nominal inside diameter.
GF92: In pipe lines or tubing sizes from 0.125 to 3 inches (0.3175 to 7.62 centimeters).
Flow Elements
Process Connection:
GF90: 1 inch male NPT standard. Flange connections and field retractable packing gland assemblies
available.
GF92: 3/4 inch female NPT standard. 1.0, 1.5, 2.0 and 3.0 inch male or female NPT, flange
connections available.
Insertion Length — GF90: Variable length. Specify insertion “U” length (dimension from the
process connection to the tip of the flow element) to extend the tip of the flow element 1 inch (2.5cm)
past the centerline of the process pipe.
Body Length — GF92: 7.25 inches (18.4cm) for 1 inch flow tubes; 12.0 inches (30.5 cm) for 1.5 to
3 inch (3.81 to7.62 cm) pipe spool pieces. Variable A-lengths available.
Flow Element Material: All wetted surfaces are 316 stainless steel with nickel braze. Corrosionresistant alloys are available with factory specified all welded construction or compatible brazes.
Flow Element Range:
GF90: 0.25 to 1600 SFPS for most gases (ft/sec at a standard temperature of 70° F and pressure of
14.7 psia) or 0.08 to 487.7 NMPS [m/sec at a normal temperature of 21.1°C and
pressure of 1.013 bar (absolute)].
GF92: 0.006 to 2000 SCFM for most gases (ft3/min at a standard temperature of 70°F and pressure
of 14.7 psia) or 0.01 to 3398 Nm3/h [m3/ hr at a normal temperature of 21.1°C and
pressure of 1.013 bar (absolute)].
Actual velocity for both the GF90 and GF92 must be limited to a maximum of 200 feet per second
(60.96 meters per second).
Temperature Range: -50° F to +350°F (-45° C to +176.7°C) with the standard temperature flow
element. The GF90 is available in a High Temperature Flow Element configuration for service
in process temperatures from -100° F to +850° F (-73.3° C to +454.4°C).
Operation Pressure: Up to 1000 psig [68.9 bar (gauge)].
Transmitter
Signal Output:
Analog: Two independent signal outputs available that may be field set from the following listed
selection:
4-20 mA, 600 ohms maximum load
0-10 Vdc, 5000 ohms minimum load
0-5 Vdc, 2500 ohms minimum load
1-5 Vdc, 2500 ohms minimum load
Digital: RS-232C (EIA-232) serial port.
Switch Points (Dual Alarms): The switch points may be field set by programming the GF90 or
GF92 to alarm at high, low or windowed flow or at high, low or windowed process temperature.
GF Series Flow Meter Models GF90/GF92 2 No. 06EN003229 Rev. H
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Technical
Specifications
(Cont’d)
Relays: Two Relays independently adjustable: 2 amps bifurcated gold plated DPDT contacts, 0-2.0
amps at 28 Vdc or 115 Vac resistive, 0.1 volts at 230 Vac resistive. 0 amps (or Dry) rating is good if load
is kept below 30mA.
Slave Relay Energization Terminals: Customer provided relay may be energized at programmable
values connecting to points on the output terminal strip.
+Ext Relay: 20 Vdc, sourcing up to 100 mA total both relay outputs.
-Ext Relay: Open/Ground (switching).
Power Input: 115 Vac, ±15 Vac, 16 watts maximum or 230 Vac, ±30 Vac, 50/60Hz, 16 watts
maximum; or 24 Vdc, -2 and +6 Vdc, 16 watts maximum as selected by the power input switch and
terminal selection.
Indicator Display & Built-In Keypad: 4 lines by 20 character liquid crystal display that may be
programmed to indicate flow rate, total flow, temperature, and switch point status in customer
determined English or Metric (SI) values. Keypad permits easy touch programming to change zero,
span, switch points, and units of measurement and for instrument verification, trouble shooting and
other critical instrument functions.
Electrical Enclosures
Fiberglass NEMA/CSA Type 4X is standard. All aluminum and stainless steel enclosures are rated for
hazardous location use (Class I and II, Division 1 and 2, Groups B, C, D, E, F and G; and EEx d IIC)
and resists the effect of weather and corrosion (NEMA/CSA Type 4X and equivalent to IP66).
Electrical Connection: 1 inch female NPT.
Temperature Range: 0°F to +150°F (-18°C to +65.6°C).
Flow
Accuracy: ±1% reading + 0.5% full scale.
Repeatability: ±0.5% reading or better.
Turndown Ratio: Field set to within specified flow range from 2:1 to 1000:1. Turndown ratios up to
1000:1 are possible in some applications. Signal output may be field set to be zero or non-zero based.
Up to three independent calibrations may be stored in the GF Series transmitter and selected via the
built-in keypad, RS-232C Serial Port or Auxiliary Input Terminal (4-20 mA).
Calibration Adjustment: Up to three independent calibration groups are available. Each group is
precisely calibrated at the factory in accordance with the submitted Application Data Sheet to
turndown ratios as high as 1000:1. Most calibrations are performed in the actual process fluid and
process conditions described by the customer’s specification. Adjustment to zero and span are made
easily in the field by using the keypad to input revised flow or temperature range information.
Temperature
Accuracy: ±2°F (±1.1°C ). Valid only above minimum flowing conditions of 5 SFPS (1.5 NMPS).
Repeatability: ±1°F (±0.55°C).
System Approvals
Factory Mutual Research (FM), CSA, CE Mark, CENELEC, CRN and ATEX.
Doc. No. 06EN003229 Rev. H 3
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F Series Flow Meter Models GF90/GF92
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2. Quick Start Guide
Pre-Installation
To get the best results from the instrument, the sensor should be located 20 pipe diameters down
stream from any flow disturbance (valve, pipe elbow, etc.) and 10 pipe diameters upstream from
any disturbance.
The outside of the instrument has tags which show the model number, tag number (if noted on the
customer’s order) and serial number along with other important safety information. Compare this
information with the appropriate pipe installation drawings and calibration sheets to verify the
instrument is the correct configuration.
Verify that the serial numbers on the enclosure(s) tag(s), flow element and electronics match. The
instrument may not work if the serial numbers are miss-matched.
The recommended installation/troubleshooting tools are:
1 ea. Open-ended wrench to fit the NPT connection
1 ea. Open-ended wrench to fit the flanged fitting nuts and bolts
1 ea. Small flat blade screw driver for manipulating potentiometers
1 ea. Medium flat blade screwdriver for tightening connections
1 ea. Medium phillips head screwdriver for tightening connections
1 ea. 3 mm Allen wrench
1 ea. Measuring tape for proper flow element placement
1 ea. DVM for Ohm/Voltage measurements
Flow Element
Installation
Example of GF90 Flow Meter (See Appendix A for Specific Diagrams)
Install the flow element, with the flow arrow pointing in the direction of media flow. The element
should be in the center line of the process pipe or rectangular duct as shown above.
If the NPT option is used, see Page 13 for installation instructions.
If the flanged option is used, see Page 13 for installation instructions.
If the GF92 in-line option is used, see Page 14 for installation instructions.
NOTE: ST98 type flow element only inserts 0.50 inches past centerline. See VeriCal System
Diagram on page 54.
Doc. No. 06EN003229 Rev. H 5 GF Series Flow Meter Models GF90/GF92
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Wiring Preparation
Wiring the
Instrument
CAUTION:
Only qualified personnel are to wire or test this instrument. The operator assumes
all responsibilities for safe practices while wiring or troubleshooting.
ALERT:
The instrument contains electrostatic discharge (ESD) sensitive devices. Use standard
ESD precautions when handling the flow transmitter.
Before the instrument is opened to install the wiring, FCI recommends that ESD precautions be
observed. See Page 11 for ESD instructions.
This section wires the transmitter inputs, outputs and interconnection cabling for the instrument.
Route the output wiring through the opposite port from the power wiring. The maximum gauge of
wire to use is 16 AWG. See Table 1 on Page 16 and Table 2 on Page 17 for the maximum
distance that wires can be run.
Wiring the Flow Element
Connect a shielded, 8 wire cable between the transmitter and the local enclosure terminal strip as
shown below. Be sure the shield (ground wire) is connected to JP3 GND along with the wire from
terminal block terminal 2. Do not connect the shield to the local enclosure (leave it floating).
Alternate 8 wire, ST98 Type Flow Element wiring shown in VeriCal and 2 point Averaging System
sections, see Operations Section 4.0.
Local Enclosure Wiring Diagram
Flow Element Transmitter
Terminal Block JP3 (Terminal No.)
Terminal 5 (ACT) ACT SEN (4)
Terminal 5 (ACT) ACT EXC (6)
Terminal 4 (GND SEN) GND SEN (2)
Terminal 3 (REF) REF SEN (3)
Terminal 3 (REF) REF EXC (5)
Terminal 2 (GND) GND (1)
Terminal 1 (HTR) HTR EXC (7)
Terminal 1 (HTR) HTR SEN (8)
Flow Element Wiring Table
Flow Element Terminal Block
Connector JP3
(Be sure the jumper is in place
Terminal 2 to terminal 4.)
GF Series Flow Meter Models GF90/GF92 6 Doc. No. 06EN003229 Rev. H
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Wiring the Instrument’s Signal Output to the Customer Application:
For Current Output: 4 - 20 mA; connect a positive wire to + I OUT and a negative wire
to OUT COM.
For Voltage Output: 0 - 5, 0 - 10 or 1 -5 Vdc; connect a positive wire to + E OUT
and a negative wire to OUT COM.
Analog Output 2 is connected in a similar manor as Analog Output 1. ( For Voltage Output:
0 - 5, 0 - 10 or 1 -5 Vdc; connect a positive wire to + E OUT2 and a negative wire to
OUT 2 COM. For Current Output: 4 - 20 mA; connect a positive wire to + I OUT2 and a
negative wire to OUT 2 COM.)
Customer Connections Analog Output Diagram
Analog Output
Plug Location
Alert:
Either voltage or current from the Analog Outputs can be connected to the customer
application, not both. (Example: Voltage and current from analog output 1 cannot be
connected.) However, one Analog Output can be wired for current and the other
Analog Output can be wired for Voltage.
Wiring the Output Relays:
The instrument contains two sets of alarm output relays (connectors JP4 Relay Output 1, and JP5
Relay Output 2). They can be wired by the customer. (NO = Normally Open, NC = Normally
Closed, Pole = Common)
Output Relay Wiring Diagram
Doc. No. 06EN003229 Rev. H 7 GF Series Flow Meter Models GF90/GF92
Connectors JP5 and JP4
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y
Wiring the Input Power:
Caution: FCI recommends placing an ON/OFF switch in line with the power source. When
JP1 is connected to the power source the instrument is ON.
AC or DC power can be used to operate this instrument. For best results route the output signal
wiring through the left port of the instrument enclosure and the power input wiring thorough the
right port. See the wiring table on Page 16 to determine the minimum size of wiring to be used
versus the length of the wire run to the power source.
115 or 230 VAC Power Option
The input power can be switched from 115 Vac to 230 Vac by moving switch S1 to the correct
setting. (The instrument requires only AC or DC to be connected, not both.) Connect the hot side
of the AC Line to AC Line, the neutral side to AC NEUT, and ground to EARTH GND. (Do not
connect the local enclosure shield wire to the EARTH GND on this plug.)
24 VDC Power Option
If DC power is used, the AC Input and switch S1 are not pertinent. Wire the positive 24 volt input
to +24V. Connect the negative wire to DC GND.
Instrument Operation
Switch S1
Connector JP1
Input Power Location
Input Power Wiring Diagram
The instrument has been configured and calibrated to custom specifications. In-depth programming
of the instrument in the field should not be necessary.
Apply power to the instrument. Wait 10 minutes for the instrument to stabilize. During this period
the instrument may indicate a high flow condition. When the instrument is powered up, the
instrument will display an initialization sequence. Then the instrument will display the normal
operation information. Shown below is the normal operation window.
Output Channel #
Calibration Group #
Flow Rate
CH1: 5056.3 SCFM
CH2: 71.2 °F
Σ =
435226 SCF
(grp1)(ed)(norm)(m)
Rela
Status
Mode
Flow Units
Process Temperature
Totalizer (If Enabled)
Sample (Flashes) Rate
Normal Operation Window
GF Series Flow Meter Models GF90/GF92 8 Doc. No. 06EN003229 Rev. H
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Menu Control
The prompt line displays appropriate key strokes for the required 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 and key
assignments are shown below:
Title
Menu Level
Available Selections
3.1.2 STD VOLUME
1=Cu feet
3=Liters
(CF)?
Current Selection
Display Characteristics
3=Cu meter
Prompt Line
KEY KEY NAME ACTION
0-9 Numeric
Selects options and enters
numbers.
Y Yes Enter a yes response
•
NNo or (N)ext
Enter a no response or
scroll to next screen
- Minus Enter a minus sign
Decimal Point Enter a decimal point
1 2 3 Y N
Back Space Moves cursor back one space
P (P)revious Scrolls to the previous screen
4 5 6
7 8 9 P
_
.
ENTR Enter
HOME Home
Enters a numeric value or
response
Returns to the Main Menu or
escapes from routines
UP Up Move current menu up on level
ENTR
0 #
HOME
UP
Key Assignments
Key Pad
At any time, the HOME key can be pressed and the main menu will display. HOME can be used to escape
from most routines, or restart a progression into the menu structure.
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.
The quick operation menu is shown below:
0.0 MAIN MENU
1 = Normal Operation
2 = Port Setup
3 = Display Setup
4 = Miscellaneous
CH1: 5056.3 SCFM
CH2: 71.2
Σ
(gr p1) ( dd) (mode N) (m)
F
= 435226 SCF
Normal Operation
2.0 PORT SETUP
1 = Analog Output
2 = Relays
3 = Comm Output
4 = Aux Input
Doc. No. 06EN003229 Rev. H 9 GF Series Flow Meter Models GF90/GF92
3.0 DISPLAY SETUP
1 = Flow Setup
2 = Temperature Setup
3 = Totalizer Setup
4 = Sample Rate
QUICK
OPERATION
MENU
4.0 MISCELLANEOUS
1 = Set Group
2 = Corrector Setup
3 = Password Setup
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GF Series Flow Meter Models GF90/GF92 10 Doc. No. 06EN003229 Rev. H
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3. Installation
Receiving/
Inspection
Packing/
Shipping/
Returns
Factory
Calibration
Note
Pre-Installation Procedure
• Unpack carefully.
• Verify that all items in the packing list are received and are correct.
• Inspect all instruments for damage or contaminants prior to installation.
If the above three items are satisfactory, proceed with the installation. If not, then stop and contact a
customer service representative.
These issues are addressed in Appendix D - Customer Service.
The instrument 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 instrument in service.
CAUTION: Only qualified personnel should install this instrument. Install and follow safety
procedures in accordance with the current National Electrical Code. Ensure that power
is off during installation. Any instances where power is 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.
ALERT: The instrument is not designed for weld-in-place applications. Never weld to process
connection or a structural support.
Damage resulting from moisture penetration of the enclosure(s) is not covered by
product warranty.
The flow transmitter contains electrostatic discharge (ESD) sensitive devices. Use
standard ESD precautions when handling the circuit board assemblies. See below for
ESD details.
Use Standard ESD Precautions
When opening an instrument enclosure or handling the flow transmitter use standard ESD precautions.
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 approved plastic, tape and packing
foam.
The above precautions are minimum requirements to be used. The complete use of ESD precautions
can be found in the U.S. Department of Defense Handbook 263.
Prepare or Verify the Flow Element Location
Prepare the process pipe for installation or inspect the already prepared location to ensure that the
instrument will fit into the system.
Mount the flow element at least 20 diameters downstream and 10 diameters upstream from any bends
or interference in the process pipe or duct to achieve the greatest accuracy.
Doc. No. 06EN003229 Rev. H 11 GF Series Flowmeter Models GF90/GF92
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Verify Dimensions
The GF90 Insertion Models have an adjustable insertion length ferrule until it is locked into position.
Verify all dimensions before locking the fitting in place. See the appropriate figures in Appendix A.
NOTE: Two types of ferrules are available. One type of ferrule is made from Teflon. This can be
tightened and loosened repeatedly at different places on the flow element. The other type of ferrule is
made from Stainless Steel. This ferrule can only be tightened in one place on the flow element. The
Stainless Steel Ferrule makes an indentation into the flow element for a more firm fit.
The GF92 In-Line Model's flow element has a tube or pipe length and diameter that is specified at the
time of order. This dimension should be double checked with the process line.
Verify Flow Direction
Verify the flow direction and orientation of the flow element before placing it into the flow media.
The GF90’s flow element has flat areas machined on the flow element near the enclosure end of the
flow element. Etched on the flow element is a flow arrow indicating the direction of flow. See
Figure 2. Align the GF90’s flow element during installation so the flat areas are parallel to the
direction of the process media flow, and the flow arrow points in the direction of process media flow.
A flow direction arrow is etched on the in-line GF92’s tube or pipe and should be pointing in the
direction of flow. Failing to install the flow element correctly will reduce the accuracy of the flow
meter.
Verify Serial Numbers
Verify the serial number of the flow element and electronics. The instrument’s flow element has a
serial number near the flat machined area or flow arrow. The same number is on the main electronics
circuit board, and on the tag of the electronics enclosure. These numbers have to match because the
flow element and the electronics are a matched set. Failure to observe serial numbers will cause
inaccurate readings.
Figure 2. Model GF90 Insertion Flanged Flow Element Showing Orientation
GF Series Flowmeter Models GF90/GF92 12 Doc. No. 06EN003229 Rev. H
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Install Flow Element
ALERT: Do not overtighten the flow element. The RTD's can be damaged if the flow element is
forced into the far wall of the pipe or vessel.
Cable Glands and Conduit Fittings
All cable glands and conduit fittings, including conduit plugs, must meet or exceed the area
approval where unit is being installed.
NOTE: The instrument accuracy will be reduced if the media flow is reversed from the flow
direction of the flow arrow machined on the flow element or if the flats are not parallel,
within ±1° of the flow direction.
Select one of the following installation procedures which is applicable to the unit being installed.
GF90 Flange Mount
The flange mount flow element is shown in Figure 2. Attach the process mating flange with care. The
correct orientation of the flow element must be maintained to ensure the calibrated accuracy.
• Verify that the process media flow is in the same direction as the arrow on the FLAT.
• Apply the appropriate gasket and/or sealant to flange mount as required.
• Mate flow element flange to process mount keeping flat oriented properly.
• 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.
GF90 NPT Pipe Thread Mount
ALERT: DO NOT change the orientation of the flow element in the enclosure as the
interconnecting RTD and heater wiring could be stressed and damaged. DO NOT apply
any torque to the flow element enclosure - only apply to NPT pipe surface itself.
NOTE: When mounting the flow element to the process pipe, it is important that a lubricant/
sealant is applied to the male threads of all connections. A lubricant/sealant compatible
with the process environment should be used. All connections should be tightened firmly.
To avoid leaks do not overtighten or cross-thread connections.
The pipe thread configuration is shown in Figure 3. Apply sealant compatible with the process media
to male threads. Carefully insert into process mount. Threads are right-handed. Tighten with an openend wrench on the hexagonal surface provided. Rotate until snug and continue to turn until flat is
horizontal to process flow.
Figure 3. Model GF90 Insertion NPT Flow Element
Doc. No. 06EN003229 Rev. H 13 GF Series Flowmeter Models GF90/GF92
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GF90 Adjustable / Retractable Flow Element Assembly
Applications involving the use of a packing gland (low, medium or high pressure) should refer to
the drawings located in Appendix A for additional detail.
• NPT and flange packing gland mounts are available. The valve assembly with appropriate
connections are customer supplied. Follow the pipe thread procedure or the flange procedure
as shown on the previous page.
• Then 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.
• 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.
• 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).
• 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.
• Reverse these steps for removal.
GF90 2 Inch (50 mm) Pipe Mount (Inside Diameter)
Use a tee-pipe configuration for applications where the inside diameter of the process pipe is
2 inches (50 mm). See Figure 4 for an illustration. The flow element active area is approximately
1 inch (25.4 mm) long, (the inactive area is also approximately 1 inch long), so it is impractical to
place the flow element in a line of less than 2 inches (50 mm) inside diameter without loss of
accuracy and reliability. Install the flow element per connection procedure for pipe thread, flange,
or packing gland assembly as applicable.
Figure 4. 2 Inch (51 mm) Pipe Mount
GF90/GF92 Pigtail
Insert the instrument into the process and connect the flow element per the wiring diagram in
Figure 50. Be sure to the correct diagram for either the cable or wire configuration.
GF Series Flowmeter Models GF90/GF92 14 Doc. No. 06EN003229 Rev. H
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GF92 In-line Body Length Verification
The GF92 flow element's mounting shape is a cylindrical pipe, with a customer specified "A" length
(see Figures 5 and 6) with process connections as ordered. The minimum recommended clearance
length in the process media pipe is 7.25 inches (184 mm).
Figure 5. Correct Orientation
GF92 Flange Mount
For flange mount flow element, attach the process mating flange with care. The correct orientation of
the flow element must be maintained to ensure the calibrated accuracy.
Figure 6. Flange Connections
GF92 Butt Weld
When welding the butt weld option into the process line, be sure the flow arrow with the machined flat
is facing up and the arrow is in the direction of flow. Also, be sure the wires to the remote enclosure are
disconnected from the integral enclosure. Ground the flow element before welding. Do not weld
anything to either the remote or local enclosures.
GF92 NPT Connection (Threaded Male or Female)
Apply sealant to male threads. Carefully place in the process media line with the machined flat facing
up, flat and level within ±2° for best results. The instruments threads are right-handed, tighten the
process connections.
Doc. No. 06EN003229 Rev. H 15 GF Series Flowmeter Models GF90/GF92
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Remote Hardware Location (GF90 and GF92)
The outline dimensions shown in Appendix A show the physical dimensions for the proper mounting
of the flow element and transmitter electronics enclosure. Select a location for the flow transmitter
within 1000 feet (310 M) of the flow element. Pigtail flow elements can not be located more than
10 feet (3 M) from the flow transmitter. This location should be easily accessible with enough room to
unscrew the enclosure top at any time. Secure the enclosure to a surface capable of providing support.
Use appropriate hardware to secure the enclosure.
Install Flow Transmitter
CAUTION: Ensure that all power is off before wiring any circuit.
ALERT: 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.
Cable Glands and Conduit Fittings
All cable glands and conduit fittings, including conduit plugs, must meet or exceed the
area approval where unit is being installed.
NOTE: FCI recommends installing an input power disconnect switch and fuse near the flow
transmitter to interrupt power during installation, maintenance, calibration, and
troubleshooting procedures.
Make all electrical connections through the 3/4 inch NPT ports in the enclosure. Run all electrical
cables through appropriate conduit or protective sheathing.
Minimum Wire Size
If the instrument is used in a remote configuration, a shielded, 8 conductor cable is to be used between
the local and remote enclosures. Table 1 shows the smallest (maximum AWG number) copper wire
that should be used in the cable and in other wiring. Use a lower gauge of wire (larger diameter) for
less of a voltage drop. Contact FCI concerning greater distances than those listed in the table. The
sensing element cable for the remote option must be shielded. The maximum wire size of the nonpower connectors in the instrument is 16 AWG (1.47 mm). The maximum wire size of the power
connectors in the instrument is 12 AWG (2.36 mm). Table 2 shows the AWG to millimeter
conversions.
Table 1. Maximum AWG Number
Connection
Power 2222222018 16
Relay (2A at
220 VAC)
Relay (10A at 120
VAC or 24 VDC)
Flow Element
Wires*
Maximum Distance for AWG
10 FT.
(3M)
50 FT.
(15 M)
24 22 20 16 12 N/R
22 16 12
24 24 24 22 22 18
100 FT.
(31 M)
250 FT.
(76 M)
500 FT.
(152 M)
Not Recommended
1000 FT.
(305 M)
* Requires a an 8 conductor shielded cable. 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).
GF Series Flowmeter Models GF90/GF92 16 Doc. No. 06EN003229 Rev. H
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Table 2. Wire Conversion
WIRE GAGE CONVERSION TABLE
Minimum O.D. of Wire
Gage Stranding
Strands/Gage
24 10/34 0.0063 0.024 0.584
22 7/30 0.010 0.030 0.762
20 10/30 0.010 0.037 0.890
18 16/30 0.100 0.047 1.20
16 19/29 0.113 0.058 1.47
14 19/27 0.0142 0.071 1.85
Nominal O.D.
of Strand (in)
Inches mm
Input Power
CAUTION: If 24 VDC is used as a power source, the terminals are not power isolated.
The flow transmitter is powered by 115 VAC, 230 VAC or 24 VDC (only one power source is needed).
If 115 VAC is used, wire it directly to JP1 and position switch S1 to be in the 115 V position. See
Figure 8 for details. If 230 VAC is used, position switch S1 to be in the 230 V position and then wire
the power directly to JP1. See Figure 8 for details. If 24 VDC is used, it is wired directly to JP1 as
shown in Figure 8.
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
Feed the flow element cable and the two voltage/current output cables through the left access port in the
remote enclosure. Similarly, feed the AC power line and the two relay cables through the right port.
This separates the I/O signal and low voltage DC lines from the high voltage AC and relay lines. See
wiring diagram, Figure 8 for the flow element wiring to JP3. Customer connections needing to be made
are to JP4 and JP5 (relay logic), and also to JP6 (current or voltage).
Doc. No. 06EN003229 Rev. H 17 GF Series Flowmeter Models GF90/GF92
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Figure 8. GF90 or GF92 Wiring Diagram
GF Series Flowmeter Models GF90/GF92 18 Doc. No. 06EN003229 Rev. H
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Figure 52. ST98 or ST98L Remote Wiring Diagram
Doc. No. 06EN003229 Rev. H 19 GF Series Flowmeter Models GF90/GF92
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Customer
Wiring
Jacks JP3 (top circuit board), JP4, JP5, JP6 and JP7 are for customer use and are described in Table 3.
Table 3. Customer Wiring
JACK / NOMENCLATURE DESCRIP TION
JP3 (Top Circuit Board)
RS-232 (EIA-232) Serial Port
Used in conjunction with equipment compatible
with an RS 232 (EIA-232) serial port. See
Chapter 4 for more details.
Factory pre-programmable relay contacts. Two
JP4
Relay Output 1
and
JP5
Relay Output 2
normally open and 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 18 Vdc, 0.
There are two factory pre-programmable signals
JP6
Analog Output
which are voltage and/or current. The 1AUX and
+20 V pin is a customer option for the use as a
dynamic correction factor. See Chapter 4 for
more information
JP7
RS485 (EIA-485) Serial Port
Used in conjunction with equipment compatible
with an RS 485 (EIA-485) serial port.
Serial
Communication
Option
(Hyper
Terminal Hook
Up)
The RJ-12 (P3) connector on the top circuit board ( near the right side of the key pad) provides RS-232
communication with the user. An FC88 Communicator can be plugged in for periodic re-configuration
and/or diagnostics, or personal computer can be plugged in instead of the FC88 Communicator. This
connection is a RJ-12 communication (phone) jack. Figure 7 shows the connection between the serial
port and a host device. Figure 56 shows the wiring of the DB-9 connector.
Serial Port
RJ-12 Phone Jack
6
5
4
3
2
1
+5V
NC
DTR
TXD
RXD
GND
+5V
NC
DTR
TXD
RXD
GND
RJ-12 Pin
Description
1
2
3
4
5
6
RJ-12 Pin
Description
1
2
3
4
5
6
IBM PC
DB-9 Connector
DCD
DTR
TXD
RXD
GND
JUMPER
JUMPER
IBM PC
DB-25 Connector
JUMPER
JUMPER
DCD
DTR
TXD
RXD
GND
1
Data Carrier Detect
4
Data Terminal Ready
3
Transmit Data
2
Receive Data
5
Ground
7
Jumper
8
Jumper
4
5
8
20
2
3
7
Jumper
Jumper
Data Carrier Detect
Data Terminal Ready
Transmit Data
Receive Data
Ground
C00251-1
Figure 7. Wiring Diagram, DB-9 and DB-25 PC Connectors
GF Series Flowmeter Models GF90/GF92 20 Doc. No. 06EN003229 Rev. H
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Figure 56. Wiring of DB-9 Connector
FCI recommends using the PC Interface Kit P/N: 014108-02 to connect the flow transmitter to a personal
computer. The kit includes operation instructions and an adaptor for the RJ-12 to serial connection. Connect
one end of the interface kit to the RJ-12 port and the other end to a DB pin connector. Plug the connector
into the COM1 or COM2 port in the back of the computer terminal.
See instructions on how to use the serial communications in the next chapter.
HART Option Installation
Use the following steps to install the Hart Option for GF90/GF92:
1. All the FCI transmitters that incorporate the HART protocol are set at the factory to polling address “0”.
Users should reset the polling address to match the needs of their network.
2. At polling address “0”, the GF90/GF92 outputs a current of 4-20 mA; at any other polling address, the
GF90/GF92 outputs a fixed 4 mA current; in compliance with the HART standard. A digital signal is
provided with all polling addresses.
3. If the GF90/GF92 is going to be used as a HART network transmitter, the polling address needs to be
changed to other than “0”.
4. When the GF90/GF92 is connected in a HART Network, the instrument is configured for an external
current source. The polling address must be changed to other than “0”. The power supply feeding the
network must provide sufficient current to support the instruments in the network.
Figure 9. Hart Module
Wiring the Hart Instrument
INPUT POWER - Follow the GF90/GF92 manual to connect power.
OUTPUT SIGNAL - The GF90/GF92 analog outputs are factory connected to the hart modules. The two
diagrams below shows recommended methods of connecting the HART modules to the customer’s system.
Doc. No. 06EN003229 Rev. H 21 GF Series Flowmeter Models GF90/GF92
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Ω
Ω
Ω
Figure 10. Hart Module Wiring Option 1
Ω
Ω
Ω
Ω
Figure 11. Hart Module Wiring Option 2
GF Series Flowmeter Models GF90/GF92 22 Doc. No. 06EN003229 Rev. H
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MAIN MENU
1 DEVI CE SETUP
2 VOLT (Displays actual process value, i.e. flow)
3 LRV (Displays configured lower range value)
4 URV (Displ ays configured upper range value)
5 I OUT (Displays actual out put curr ent in mA)
6 % RANGE (Shows output current in % output span)
7 DATALOGGER
GF90/GF92 HART
MENU TREE
1 DEVICE SETUP MENU
1 INPUT SETUP
2 OUTPUT SETUP
3 DEVI CE INFO.
4 DIAG/SERVICE
7 DATALOGGER MENU
1 MAX. VALUE (Displ ays highest process
value since reset)
2 MIN. VALUE (Displays l owest process
value since reset)
3 RESET MIN/MAX (Reset the memory
holding min/max data)
*This is a sub menu, where the out-of-range and
3 DEVICE INFO
1 DISTRIBUTOR (Displays name Kamstr up)
2 MODEL (Displays name FlexTop HRT)
3 DEV ID (Displays devi ce serial number)
4 TAG (Enter tag number (identify FlexTop HRT))
5 DATE (Enter date of choice, i.e. date of event)
6 WRITE PROT. (Displays write protect status, NONE)
7 DESCRIPTOR (Enter description, ie a location code)
8 MESSAGE (Enter message, i. e. a warni ng)
9 FINAL ASMBLY NUM (Enter 8 digits, i.e. ref #
identifying sensor and transmitter during a
calibration session)
10 REVISION #'s (Displays the rev #'s of command set
(5), the FlexTop HRT(2) and the DD soft ware (3))
11 HART OUTPUT
4.1
1 INPUT SETUP 1 Signal Condition
1 SIGNAL CONDITI ON
2 SENSOR TYPE (Enter Sensor type
i.e. RTD, T/C, mV, Ohm, Pot)
3 LRV (Enter lower range value)
4 URV (Enter upper range val ue)
5 DAMP (Enter dampi ng value)
1 SENSOR (mV Hi)
2 USL (Upper sense level
i.e. 1000 mV)
3 LSL (Lower sense level
i.e. 0 mV)
4 MIN SPAN (20 mV)
2 OUTPUT SETUP*
1 UNDER LIM (Ent er t he out put current f or measurements LOWER
t han configured range, i.e. if temp. falls below 0°C)
2 OVER LIM (Enter the out put curr ent for measurements HIGHER
than configured range, i.e. if temp. goes above 100°C)
3 SENS ERR (Enter the output current in case sensor fails.
sensor- burn-out can be entered.
2.1
11 HART Output
1 POLL ADR (Enter the polling adr. for the FlexTop
2 NUM PREAMS (Displ ays number of preamble
characters sent by master to ensure
HRT. Observe that poll adr = 0
automatically sets the FlexTop HRT in
analog mode, resulting in a mixed-signal
setup. If intent is to connect several
FlexTop's in Multi-drop mode, pol l
addresses 1 to 15 must be used.
sync with the slave device.
1 Loop Test
1 4 mA FIXED OUTPUT
2 20 mA FIXED OUTPUT
3 OTHER (Inter value of fixed current out put)
4 END (Leave the menu)
4 DIAG/SERVICE**
1 LOOP TEST (Enter /Change loop
current to fixed value)
2 D/A TRIM (Connect a reference meter
(5 di git). Compensate for
the inaccuracy in output
D/A converter)
3 SENSOR TRIM
**WARNING:
To enter this menu, remove the loop from automatic
control. All trim adjustments can be carried out f rom
the configurator only - not from the FlexProgrammer.
3 Sensor Trim
1 FACTORY TRIM (Offset and gain values are
reset to factory settings)
2 ONE POINT TRIM (Enter reference temp. value for a
non-cal ibrated sensor. Displays measured
temperature. If ref temperatures are different,
enter t his value.
3 TWO POINT TRIM (Enter 2 reference temperature
values. Displays actual measured temp. If
reference temps are different, enter the
values. The gain is #1, the function curve will
change the slope and not start in the zero
point)
4 VOLT. (Not used by FCI)
5 S. OFF. (This is the differ ence between the measured
and the reference value. Enter this value)
6 S. GAIN (Enter this value. This adjustment
corresponds to the 2-point trim. However
the f uncti on curve wil l start in the zero poi nt.
Figure 12. HART Module Menu Tree
Doc. No. 06EN003229 Rev. H 23 GF Series Flowmeter Models GF90/GF92
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Foundation Field Bus
Foundation Fieldbus access to the GF90/GF92 signals is accomplished through the SMAR IF302
Current to Fieldbus Converter. Two GF90/GF92 parameters are available through the IF302; Process
Flow in Channel 1 and Process Temperature in Channel 2.
The SMAR IF302 contains 18 functional blocks, and the GF90/GF92 flow and temperature signals are
presented at the output of the corresponding “Analog Input” blocks in mA.
For complete details on the IF302 please go to the SMAR web site at www.smar.com and register to
recieve the “Operation and Maintenance Instruction Manual”.
Installation GF90/GF92 and IF302
Connect the GF90/GF92 Flow current output to the Channel 1 input of the IF302, and then connect the
GF90/GF92 Temperature current output to Channel 2 of the IF302.
Figure 13. Foundation Field Bus Module Wiring Diagram
GF Series Flowmeter Models GF90/GF92 24 Doc. No. 06EN003229 Rev. H
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Factory Setup of IF302
FCI sets the tags on the AI blocks that contain the signal connection to the Flow channel and the Temperature
channel identifying them as shown below.
Other configuration and tag definitions are left to the system integrator.
Isolated Output Option and 4-20 mA Adjustment
An isolated 4 to 20 milliampere (mA) output is an available option. The isolated output is available by
connecting a loop powered isolator module to the transmitter output. The modules have their own set of
output terminals which provide an isolated 4 to 20 mA output equal to the non-isolated instrument output.
This one-to-one current isolation is used to prevent instrumentation ground loops. See
Figure 14 for the wiring diagram to install the isolated output module.
Use of the isolator module will add a small signal conversion error to the instrument output and limit the
output load to 350 ohms.
Doc. No. 06EN003229 Rev. H 25 GF Series Flowmeter Models GF90/GF92
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LT81 Series Upgrade Information
Apply
Power
NOTE:
The LT analog series flowmeters can be fully upgraded to the GF series flowmeters by replacing the LT
series transmitter with a properly calibrated GF series transmitter. The flow elements are the same except
for wiring differences at the flow element. The analog outputs also change locations. Jumper wire is
added from terminal 2 to terminal 4 of the flow element head terminal block. New connectors will need to
be installed on the transmitter for power, relays, flow element and analog output.
The input power should not be turned on until the installation has been completed with all connections
verified, power and signal connection board assembly screwed down and the instrument ready to
operate. Be sure any external circuit breakers are on.
Follow the wiring diagrams in Appendix A to reconnect the existing flow element to the
replacement GF series flow transmitter, and to install a jumper on the flow element terminal
board if applicable.
Figure 14. Isolated Output Option Wiring Diagram
GF Series Flowmeter Models GF90/GF92 26 Doc. No. 06EN003229 Rev. H
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