GPI G2 Operating Manual

Industrial Grade
5252 East 36th Street North Wichita, KS USA 67220-3205 TEL: 316-686-7361 FAX: 316-686-6746
1- 888 -99 6-3 837
09 COMPUTER ELECTRONICS
Owner’s Manual
09/11
Rev. F 920709-05
To the owner…
Congratulations on receiving your GPI Industrial Grade Computer Electronics. We are pleased to pro­vide you with a product designed to give you maximum reliability and efciency.
Our business is the design, manu­facture, and marketing of liquid han­dling, agricultural, and recreational products. We succeed because we provide customers with innovative, reliable, safe, timely, and compet­itively-priced products. We pride ourselves in conducting our business with integrity and professionalism.
We are proud to provide you with a quality product and the support you need to obtain years of safe, depend­able service.
President
Great Plains Industries, Inc.
TABLE OF CONTENTS
General Information
Installation
Operation
Calibration
.................................... 3
...................................... 4
.................................... 5
User Conguration........................ 6
Maintenance
Troubleshooting
Specications
Parts
........................................... 10
Service........................................ 10
WEEE Directive
...................... 2
................................. 7
............................ 8
............................... 9
.......................... 10
GENERAL INFORMATION
This manual will assist you in op­erating and maintaining the Com­puter Electronics of the GPI Indus­trial Grade Meters. (See Figure 1) Calibration details are given in this manual. Information on turbine hous­ings and accessory modules are contained in other manuals. Please reference those as necessary.
Figure 1
Turbine Housing
Computer Electronics
(Sold Separately)
2
Before Getting Started
Take the time to fully acquaint your­self with all information about the components of your GPI Electronic Digital Meter. If you need assistance, contact the distributor from whom you purchased your computer.
This symbol is used through­out the manual to call your attention to safety messages.
WARNING
CAUTION
Warnings alert you to the poten­tial for personal injury.
Caut i o n s call your attention to practices or pro­cedure s w h i c h may damage your equipment.
Notes give information that can improve efciency of operations.
It is your responsibility to make sure that all operators have access to ad­equate instructions about safe oper­ating and maintenance procedures.
Read Me!
For your safety, review the major warnings and cautions below before operating your equipment.
WARNING
The apparatus enclosure may contain aluminum and is consid­ered to constitute a potential risk of ignition by impact or friction. Care must be taken into account during installation and use to prevent impact or friction.
WARNING
Part of the enclosure is con­structed from plastic. To prevent the risk of electrostatic sparking the plastic surface should only be cleaned with a damp cloth.
1. This equipment is approved to handle only uids that are com­patible with all wetted materials.
2. Wh en me asur ing fl amma ble liquids, observe precautions against re or explosion.
3. When handling hazardous liq­uids, always follow the liquid manufacturer’s safety precau­tions.
4. Wh en working in haz ardous environments, always exercise appropriate safety precautions.
5. For best results, always verify accuracy before use.
Product Description
These computer electronics are designed specically for use on GPI Industrial Grade Turbine Housings. They are also designed to work with several accessory output modules.
The CMOS, microprocessor-based electronics have extremely low pow­er requirements and data retention capabilities in both RAM and ROM. Information is clearly displayed on a large 6-digit LCD readout with two-point oating decimal for totals from .01 to 999,999. All operations are easily accessed with the two buttons on the front panel.
Liquid flows through the turbine housing causing an internal rotor to spin. As the rotor spins, an electrical signal is generated in the pickup coil. This pulse data is translated from the turbine into calibrated ow units shown on the computer’s readout.
Upon receipt, examine your equip­ment for visible damage. The com­pu ter is a prec isio n meas urin g instrument and should be handled as such. If any items appear damaged or missing, contact your distributor.
Make sure your computer model meets your specic needs. Refer to the Specications Section to conrm required features. The model number of your computer is displayed on the lower front side of the computer and also underneath a battery.
INSTALLATION
If you ordered your computer elec­tronics with a turbine housing, it is installed at the factory.
If you ordered your computer sepa­rately from your turbine, simply mount the computer on the turbine with the four screws at the corners of the faceplate. Make sure the seal is fully seated before tightening the screws.
3
If you ordered the computer with turbine and an accessory module, please review and thoroughly un­derstand all installation instructions before proceeding.
All GPI turbines are designed to measure ow in only one direction. The direction is indicated by the ar­row cast-molded in the turbine outlet. If the computer display is upside down, remove the four screws, turn the display 180 degrees and reinstall the screws. See Diagram 1.
Diagram 1
Avoid electronically “noisy” envi­ronments. Install at least 6 inches (15.2 cm) away from motors, relays, or transformers.
Our computer electronics are Factory Mutual Approved, C-UL Classied and carry a Class 1, Division 1 Ap­proval for hazardous environments. In addition, GPI meters have NEMA Type 4 enclosures.
To ensure accurate measurement, remove all air from the system be­fore use.
It is strongly recommended that ac­curacy be veried prior to use. To do this, remove all air from the system, measure an exact known volume into an accurate container, and verify the volume against the readout or recording equipment. If necessary, use a correction factor to gure nal volume. For best results, accuracy should be veried periodically as part of a routine maintenance schedule.
4
OPERATION
Computer Display
All operations are reected in the LCD readout. The large center digits indicate amounts, where smaller words or “icons” located above and below indicate specic information regarding totals, ow, calibration and units of measure.
Activate the Meter
Computer is on continuously and al­ways ready to perform. The computer is powered by eld replaceable bat­teries. When display becomes dim, faded or the low battery message appears (see below), the batteries need to be replaced. Reference the Maintenance Section for details.
Batch and Cumulative Totals
The computer maintains two totals. The Cumulative Total provides con­tinuous measurement and cannot be manually reset. The Batch Total can be reset to measure ow during a single use. The Cumulative Total is labeled with TOTAL 1, Batch Total is labeled TOTAL 2 BATCH.
When the Cumulative Total reaches a display reading of 999,999 the computer will highlight an X10 icon. This indicates to the operator that a zero must be added to the 6 digits shown. When the next rollover occurs, the computer will highlight an X100 icon. This indicates to the operator that two zeroes must be added to the 6 digits shown.
Press the DISPLAY button briey to switch between the TOTAL 1, TOTAL 2 BATCH and FLOWRATE. Press DISPLAY briey to display the TOTAL 2 BATCH. Hold the DISPLAY button for 3 seconds to reset the Batch Total to zero.
When uid is owing through the meter, a small propeller icon is high­lighted.
NOTE: Totalization counts total units
without differentiating between gallons, litres or eld calibrated units.
Flowrate Feature
(some models)
To use this feature, press and re­lease DISPLAY until FLOWRATE icon appears. The factory set time base will be highlighted to the right of FLOWRATE (M = minutes, H = hours, D = days). When FLOWRATE is in­voked, the display will be indicating rate of ow.
Switching between different units will not corrupt the Total’s contents. For example, in GL mode, the computer totalizes 10.00 gallons, if the user switches to LT mode, the display will read 37.85 litres (the same volume, different unit).
The “eld” calibration may be set by the user, and can be changed or modi­ed at any time using the calibration procedure described in the Calibra­tion Section. Totals or owrate derived from the eld calibration are invoked when the FAC icon is no longer visible on the top line of the display.
CALIBRATION
Factory and Field Calibration
All calibration information is visible to the user as icons on the top line of the display, above the numeric digits.
All units are congured with a “fac­tory” calibration. Both gallons and litres are available (“GL” or “LT” will be displayed). While holding the CALIBRATE button, briey press DISPLAY to toggle between gallons and litres. This factory calibration (indicated with FAC) is permanently programmed into the computer and is not user adjustable.
NOTE: Your computer may have oth-
er units of measure programmed into it. If so, holding the CALI­BRATE button and momentarily pressing the DISPLAY button will toggle through all factory set units. Other possible units are: IGL (imperial gallon), QT (quart), CF (cubic feet), CM (cubic meter), BL (42 gal. barrel), CC (cubic centimeter) or OZ (ounce).
Verify Accuracy Before Beginning Field Calibration
For the most accurate results, dispense at a owrate which best simulates your actual operating con­ditions. Avoid “dribbling” more uid or repeatedly starting and stopping the ow. This can result in less accurate calibrations.
Make sure you meet the meter’s minimum owrate requirements:
1/2 in. meter 1 GPM (3.8 LPM) 3/4 in. meter 2 GPM (7.6 LPM) 1 in. meter 5 GPM (18.9 LPM) 1-1/2 in. meter 10 GPM (37.9 LPM) 2 in. meter 20 GPM (75.7 LPM)
The use of a uniformly dependable, accurate calibration container is recommended for the most accurate results. For best results, the meter should be installed and purged of air before eld calibration.
Due to high owrate on the 2 inch meter, it is strongly recommended that Field Calibration be completed with a combination of volume and weight determined with ne resolu­tion scales.
5
Field Calibration Necessity
Field Calibration and Factory Cali­bration are dened in the Operation Section. Factory calibration settings are programmed into each computer during manufacturing, using stoddard test solvent at 70° F (21° C) for low ow and 1-inch meters and water at 70° F (21° C) for 2-inch meters. Settings are correct for light liquids such as water, gasoline or diesel. Readings using the Factory Calibration (FAC) may not be accurate in some situations, for example, “heavy” liquids such as motor oil, under extreme temperature conditions, non-standard plumbing congurations or with uids other than mentioned above.
For improved accuracy under such conditions, the computer allows for “eld” calibration, that is, user entry of custom calibration parameters. A “single point” calibration may yield acceptable accuracy when used in a non-standard application.
Field Calibration Procedures
(Correction Factor Method)
1. To calibrate, press and hold the CALIBRATE and DISPLAY but­tons for about 3 seconds until you see FLdCAL. Release both buttons and you will see CF - 00.0. You are now in the eld calibration mode and values from -99.9% to +99.9% can be entered.
+
2. The
3. The DISPLAY button can then
/– position appears either as an “underscore” character for plus, or as a “hyphen” character for minus. The DISPLAY but­ton selects the position and the CALIBRATE button toggles this character.
be pushed to select the numeric positions. Press the CALIBRATE button to scroll from 0 to 9. Enter the percentage of change you want the display to correct. When
satised with the value, press both CALIBRATE and DISPLAY buttons simultaneously. CALEnd will be displayed and unit will go back to normal operation, less the FAC (factory calibration) icon.
4. All enabled units-of-measure re­main visible and selectable – the entered correction will be applied to all enabled units.
5. To return to factory calibration (FAC), press and hold both CALI­BRATE and DISPLAY buttons for about 3 seconds until FAcCAL is displayed. Then release buttons. Unit should return to normal op­eration and FAC icon is visible.
USER CONFIGURATION
The “09” series GPI display has been programmed with many new features, most of which can be en­abled by the end user by way of a conguration process. By disabling “unnecessary” features, day-to-day owmeter operation can be greatly simplied, making the unit easier to use. There are several features that GPI disables by default when ship­ping standard meters. (For example, K-Factor Entry Field Calibration, de­scribed below.) For more advanced users, it may be desirable to enable ALL possible features. User congu­rable features include:
• Totalizers/Modes Enabled (Cumu-
lative Total, Batch 2 Total, Flowrate Mode)
• Flowrate Timebase (Units per
Minutes, Hours and Days)
• Factory Calibration Curve Units
Enabled (Gallons, Imperial Gal­lons, Litres, Quarts, Ounces, Cubic Feet, Cubic Centimeters, Cubic Meters or Barrels (42 gal.)
• Dispense/Display or K-Factor En-
try Calibration
6
Changing Conguration Settings
Access to the configuration pro­cess is restricted for security until a “password” is entered. Contact your distributor or GPI to get the password and instructions to unlock and reset conguration settings. This informa­tion is also available on the GPI Web site. Congurations are entered and stored as six-digit “codes” where each digit represents a setting for one of the conguration options. New conguration settings are stored in the computer’s long-term memory and will not be lost either in OFF mode or during battery change.
K-Factor Entry Field Calibration
Presently all GPI computers are programmed with three different eld calibration methods, only one of which is active, the “correction/ factor” calibration procedure de­scribed above. It is possible to ac­tivate “K-Factor entry” or “dispense/ display” eld calibration by changing conguration settings. Contact your distributor or GPI to get the correct password, conguration code, and instructions for this calibration meth­od. This information is also available on the GPI Web site.
MAINTENANCE
When batteries are disconnected or fail, the Batch and Cumulative Totals will maintain the value they had. Factory and Field Calibration Curves are retained in the meter’s computer when power is lost.
It is strongly recommended that battery check and terminal cleaning be a part of a routine maintenance schedule. Battery terminals should be cleaned annually. Batteries can be replaced without removing the meter from the piping system.
Replace Batteries
1. Remove the corner screws from the meter face and lift the com­puter electronics from the turbine.
2. Remove the batteries.
3. Check the battery terminals and remove any corrosion.
4. Install the new batteries and make sure the positive posts are positioned correctly. When the batteries are installed cor­rectly, the computer powers on automatically and the readout displays information.
5. Make sure the seal is fully seated before placing the computer elec­tronics on the turbine. Tighten the four screws.
6. Do not clean exterior of computer assembly with Isopropyl Alcohol.
The computer electronics is powered by lithium batteries. Removing the batteries before storing the meter will extend battery life. If the meter’s readout should become dim, blank or the low battery message appears (see below), the batteries should be replaced. Replacement batteries can be ordered from your distributor or the factory. See details in the Parts Section.
7
TROUBLESHOOTING
Symptom Probable Cause Corrective Action
A. METER IS 1. Field Calibration not per- Field calibrate again or select Factory
NOT
formed properly Calibration.
ACCURATE
2. Factory Calibration not Perform a Field Calibration according suitable for liquid being to Calibration Section. measured
3. Meter operated below Increase owrate. minimum owrate
4. Meter partially clogged Remove meter. Clean carefully. Make with dried liquid sure rotor spins freely.
5. Turbine bearings partially Remove meter. Clean carefully. Make clogged with dried liquid sure rotor spins freely.
6. Sealant material Remove meter. Make sure rotor spins wrapped around rotor freely.
7. Installed too close to Install correctly. ttings
8. Installed too close to Install correctly. motors or electrically “noisy” environment
B. READOUT 1. Batteries weak, dead, or Remove computer, check and replace
FADED OR
not connected batteries if necessary.
BLANK
2. Computer defective Contact the factory.
C. NORMAL 1. Field Calibration not Field Calibrate again or select Factory
FLOWRATE
performed correctly Calibration.
BUT METER DOES NOT
freely.
COUNT
3. Sealant material Remove meter. Make sure rotor spins wrapped around rotor freely.
4. Computer defective Contact the factory.
D. REDUCED 1. Meter clogged with dried Remove meter. Clean carefully. Make
FLOWRATE
liquids sure rotor spins freely.
AND METER
2. Below minimum owrate Increase ow. DOES NOT
COUNT
E. CANNOT GET 1. Wrong button sequence Proceed with calibration according to
METER INTO
the Calibration Section.
FIELD CALI-
2. Computer circuit board Replace computer. Contact the factory. BRATION
defective
3. Button defective Replace computer. Contact the factory.
2. Rotor stuck or damaged Remove meter. Make sure rotor spins
8
SPECIFICATIONS
Standard Features Include:
• 2 Totalizing Registers
• 1 Factory Calibration Curve
• 1 Field Calibration Curve
• Rate of Flow Feature
• Flowrate Time Base in Minutes
Input Pulse Rate:
Minimum Pulse In: DC Minimum Coil Input: 10 Hz Maximum Raw: 1,000 Hz
K-Factor:
Minimum: .01 pulses/unit Maximum: > 999,999 pulses/ unit
Field Calibration Correction:
Minimum: -99.9% Maximum: +99.9%
Readout Totals:
Min. Display: 0.01 Max. Display: 999,999 (x100)
Temperatures:
Operational: +0° to +140° F (-18° to +60° C) Storage: -40° to +158° F (-40° to +70° C)
If wider operating temperature ranges are desired, reference information on GPI Remote Kits.
Power:
Internal Power Supply: 2 Lithium Batteries at 3 volts each Battery Life: 5 years
Optional External Power Module: 7-30-volts DC
Computer Electronics
Terminal Connections
J 1
J 10
J-1 Reset
Programming interfaces. Not
accessible to user.
J-2 Pulse Signal Output
This supplies a high-level am-
plied open collector signal. Output will withstand a maxi­mum open-circuit voltage of 60-volts DC and a maximum closed-circuit of 100 mA.
J-4 Pulse Signal Input
Requires a sine or square
wave with open-circuit volt­age of 3-30 volts P-P, a maxi­mum rise/fall rate of 0.01 V/µ second and a maximum fre­quency of 750 Hz.
J-5 Power Input
Whe n us ed with Gro u nd
(J1-6), this has reverse polar­ity protection, but no on-board voltage regulation. Supplied voltage may be 5-volts to 10-volts DC.
J-6 Ground
J-7, 8, Programming interfaces. Not
accessible to user.
9, 10
NOTE: Safety approvals are void
if any external connections are made to computer elec­tronics.
9
PARTS
The factory, when provided with model number and serial number, can replace your entire Computer Electronics Assembly.
Order replacement kits, parts, and accessories with the part numbers given here.
Part No. Description
113520-1 Battery Replacement Kit 901002-52 Seal 116000-1 Large (5 gal.) Calibration
Container
SERVICE
For warranty consideration, parts, or other service information, please contact your local distributor. If you need further assistance, call the GPI Customer Service Department in Wichita, Kansas, during normal business hours.
1-888-996-3837
To obtain prompt, efcient service, always be prepared with the follow­ing information:
1. The model number of your com-
puter electronics.
2. The serial number or manufactur-
ing date code of your computer electronics.
3. Specic information about part
numbers and descriptions.
For warranty work always be pre­pared with your original sales slip or other evidence of purchase date.
Returning Parts
Please contact the factory before re­turning any parts. It may be possible to diagnose the trouble and identify needed parts in a telephone call. GPI can also inform you of any special handling requirements you will need to follow covering the transportation and handling of equipment which has been used to transfer hazardous or ammable liquids.
CAUTION
Do not return computer electron­ics or meters without specic authority from the GPI Customer Service Department. Due to strict regulations governing transpor­tation, handling, and disposal of hazardous or ammable liquids, GPI will not accept computer electronics or meters for rework unless they are completely free of liquid residue.
CAUTION
Meters not ushed before ship­ment can be refused and re­turned to the sender.
WEEE DIRECTIVE
The Waste Electrical and Electronic Equipment (WEEE) directive (2002/96/EC) was approved by the European Parliament and the Council of the European Union in 2003. This symbol indicates that this product contains electrical and
electronic equipment that may include batteries, printed circuit boards, liquid crystal displays or other components that may be subject to local disposal regulations at your location. Please understand those regulations and dispose of this product in a responsible manner.
10
Declaration of Conformity
Manufacturer’s Name: Great Plains Industries, Inc. Manufacturer’s Address: 5252 East 36th Street North Wichita, KS USA 67220-3205
Declares, that the product:
Product Name: Electronic Digital Meter Model Numbers: 03***** A1*********** A2*********** G2*********
Model numbers include all combinations
of an alpha-numeric series as illustrated above.
Conform to the following Standards:
EMC: EN 50081-1 (Reference EN 55022) EN 50082-1
Energy - Limited Apparatus: EN 50021 I.P. Code: BS EN 60529
Supplementary Information:
“The products comply with the requirements of the EMC Directive 89/336/EEC and the ATEX Directive 94/9/EC (ANNEX VIII).”
I, the undersigned, hereby declare that the equipment specied above conforms to the above Directive(s) and Standard(s).
Signature:
Full Name: Mr. Grant Nutter Position: President Great Plains Industries, Inc. Place: Wichita, KS USA May 2003
11
5252 East 36th Street North Wichita, KS USA 67220-3205 TEL: 316-686-7361 FAX: 316-686-6746
1- 888 -99 6-3 837
Limited Warranty Policy
Great Plains Industries, Inc. 5252 E. 36th Street North, Wichita, KS USA 67220-3205, hereby provides a limited warranty against defects in material and workmanship on all products manufactured by Great Plains Industries, Inc. This product includes a 1 year warranty. Manufacturer’s sole obligation under the foregoing warranties will be limited to either, at Manufacturer ’s option, replacing or repairing defective Goods (subject to limitations hereinafter provided) or refunding the purchase price for such Goods theretofore paid by the Buyer, and Buyer’s exclusive remedy for breach of any such warranties will be enforcement of such obligations of Manufacturer. The warranty shall extend to the purchaser of this product and to any person to whom such product is transferred during the warranty period.
The warranty period shall begin on the date of manufacture or on the date of purchase with an original sales receipt. This warranty shall not apply if:
A. the product has been altered or modied outside the warrantor’s duly appointed
representative;
B. the product has been subjected to neglect, misuse, abuse or damage or has
been installed or operated other than in accordance with the manufacturer’s operating instructions.
To make a claim against this warranty, contact the GPI Customer Service Department at 316-686-7361 or 888-996-3837. Or by mail at:
The company shall, notify the customer to either send the product, transportation prepaid, to the company at its ofce in Wichita, Kansas, or to a duly authorized service center. The company shall perform all obligations imposed on it by the terms of this warranty within 60 days of receipt of the defective product.
GREAT PLAINS INDUSTRIES, INC., EXCLUDES LIABILITY UNDER THIS WAR­RANTY FOR DIRECT, INDIRECT, INCIDENTAL AND CONSEQUENTIAL DAMAGES INCURRED IN THE USE OR LOSS OF USE OF THE PRODUCT WARRANTED HEREUNDER.
The company herewith expressly disclaims any warranty of merchantability or tness for any particular purpose other than for which it was designed.
This warranty gives you specic rights and you may also have other rights which vary from U.S. state to U.S. state.
Note: In compliance with MAGNUSON MOSS CONSUMER WARRANTY ACT – Part 702 (governs the resale availability of the warranty terms).
Great Plains Industries, Inc.
5252 E. 36
th
St. North
Wichita, KS, USA 67220-3205
Factory Mutual Approved Intrinsically Safe for Class I, II, III, Division 1, All Groups.
GPI is a registered trademark of Great Plains Industries, Inc. © 2011 by GREAT PLAINS INDUSTRIES, INC., Wichita, KS.
Printed in U.S.A.
09/11
Rev. F 920709-05
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