Panametrics DigitalFlow GF868 Service Manual
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Panametrics DigitalFlow GF868 Service Manual

Ultrasonic flowmeter for flare gas
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DigitalFlow™ GF868
Ultrasonic Flowmeter for Flare Gas
Service Manual (1 and 2-Channel)
910-194S Rev. F
panametrics.com
Jul 2021

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  • Page 1 Flow DigitalFlow™ GF868 Ultrasonic Flowmeter for Flare Gas Service Manual (1 and 2-Channel) 910-194S Rev. F panametrics.com Jul 2021...
  • Page 3 Service Manual (1 and 2-Channel) 910-194S Rev. F Jul 2021 panametrics.com Copyright 2021 Baker Hughes company. This material contains one or more registered trademarks of Baker Hughes Company and its subsidiaries in one or more countries. All third-party product and company names are trademarks of their respective...
  • Page 4 [no content intended for this page]...
  • Page 5 Information Paragraphs Note: These paragraphs provide information that provides a deeper understanding of the situation, but is not essential to the proper completion of the instructions. IMPORTANT: These paragraphs provide information emphasizing instructions which are essential to proper setup of the equipment.
  • Page 6 Environmental Compliance Waste Electrical and Electronic Equipment (WEEE) Directive Panametrics Solutions is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-back initiative, directive 2012/19/EU. The equipment that you bought has required the extraction and use of natural resources for its production. It may contain hazardous substances that could impact health and the environment.

  • Page 7: Table Of Contents

    Contents Chapter 1. Calibration Introduction ..................... .1 Menu Map .
  • Page 8 Contents Replacing the EPROM ................... 32 Installing an Option Card .

  • Page 9: Chapter 1. Calibration

    Chapter 1. Calibration Chapter 1. Calibration Introduction Calibrating the Model GF868’s analog outputs and inputs is explained in this chapter. In addition, testing the optional totalizer/frequency and alarm relay outputs is discussed. The following specific topics are included: • calibrating Slot 0-6 analog outputs •...

  • Page 10: Calibrating The Analog Outputs

    Chapter 1. Calibration Calibrating the Analog Outputs Every Model GF868 flowmeter includes two built-in analog outputs (A and B) at terminal block I/O, which is designated as Slot 0. Additional analog outputs may be added to the Model GF868 by installing an Analog Outputs Option Card in one (or more) of the six expansion slots.

  • Page 11: Accessing The Calibration Menu

    Chapter 1. Calibration Calibrating the Analog Outputs (cont.) Terminal Block (Option Card) Ammeter Figure 2: Ammeter Connection for Slots 1-6 (Output A) 1.3.1 Accessing the Calibration Menu Press the [CAL] key to enter the Calibration Program . Press [Fx] to calibrate the desired slot. (The option bar will include a slot listing for each installed option card.) Press [Fx] to select the desired output.

  • Page 12: Calibrating The Low End Of The Output Range

    Chapter 1. Calibration 1.3.2 Calibrating the Low End of the Output Range Press [F1] to calibrate the low end of the output range. Press [F1] or [F2] to adjust the ammeter reading UP or DOWN, until a 4 mA reading is achieved. If you press [F3], Numer, enter a numeric value for the calibration point and press [ENT].

  • Page 13: Testing The Analog Output Linearity

    Chapter 1. Calibration 1.3.4 Testing the Analog Output Linearity If you exited this menu and are returning, follow steps 1 through 3 in Accessing the Calibration Menu on Note: page 3. Press [F3] to TEST the linearity of the currently selected analog output. Check the ammeter reading at the 50% output level.

  • Page 14: Calibrating The Analog Inputs

    Chapter 1. Calibration Calibrating the Analog Inputs Analog inputs may be added to the Model GF868 flowmeter by installing an Analog Inputs Option Card in one (or more) of the six expansion slots. The option card contains two analog inputs, which are designated as A and B. Each of the inputs, which may be either a 0/4-20 mA input or an RTD input, must be calibrated at both the zero-point and full-scale values.

  • Page 15: Accessing The Calibration Menu

    Chapter 1. Calibration Calibrating the Analog Inputs (cont.) For this discussion, assume that the option card has been installed in Slot x. Note: The zero point of the analog input may be set for either 0 mA or 4 mA. However, the calibration procedure always uses the 4 mA point, as the meter will extrapolate this value to obtain the 0 mA point.

  • Page 16: Alow Option = [F1]

    Chapter 1. Calibration 1.4.2 aLOW Option = [F1] Enter the low reference value and press the [ENT] key. Press [F1] to store the current low reference value or press [F2] to cancel the entry. In either case, the ANALOG INPUT prompt will reappear. Press [F2] to proceed to the next section.

  • Page 17: Calibrating The Rtd Inputs

    Chapter 1. Calibration Calibrating the RTD Inputs Calibrating an RTD option card involves a different procedure than for other analog input cards. However, you access the card in the same manner as other cards. 1.5.1 Accessing the Calibration Menu Press the [CAL] key to enter the Calibration Program . Press [Fx] to calibrate the desired slot.

  • Page 18: Numer Option = [F2]

    Chapter 1. Calibration 1.5.3 Numer Option = [F2] The Numer option forces the user to calculate the temperature vs. resistance information. To do this, the user must first collect data using the RTDs option in the PRINT menu (discussed in Chapter 5 of the Programming Guide ). The RTDs option allows you to know what point value the GF868 is reading at a given temperature.

  • Page 19: Testing The Alarm Relays

    Chapter 1. Calibration Testing the Alarm Relays Alarm relays may be added to the Model GF868 by installing an Alarms Option Card in one (or more) of the six expansion slots. Each option card includes three alarm relays, which are designated as A, B, and C. To test the alarm relays, connect an ohmmeter to the option card terminal block as shown in Figure 4.

  • Page 20: Accessing The Calibration Menu

    Chapter 1. Calibration Testing the Alarm Relays (cont.) 1.6.1 Accessing the Calibration Menu Press the [CAL] key to enter the Calibration Program . Press [Fx] to calibrate the desired slot. (The option bar will include a slot listing for each installed option card.) Press [F1]-[F3] to select alarm relay A, B or C, respectively.

  • Page 21: Testing The Totalizer/Frequency Outputs

    Chapter 1. Calibration Testing the Totalizer/Frequency Outputs Totalizer/Frequency outputs may be added to the Model GF868 by installing a Totalizer/Frequency Option Card in one (or more) of the six expansion slots. Each option card includes four outputs, which are designated as A, B, C and D.

  • Page 22: Accessing The Calibration Menu

    Chapter 1. Calibration 1.7.1 Accessing the Calibration Menu Press the [CAL] key to enter the Calibration Program . Press [Fx] to calibrate the desired slot. (The option bar will include a slot listing for each installed option card.) Press [F1]-[F4] to select output A, B, C or D, respectively. 1.7.2 Entering Frequency Enter a new frequency in the range of 1-10,000 Hz and press the [ENT] key.
  • Page 23 Chapter 1. Calibration SLOT0 SLOT1 SLOT2 SLOT3 SLOT4 SLOT5 SLOT6 Slot x (Option Card) Slot 0 Outputs (TB I/O) Slot x Inputs (Analog Inputs) Slot x Outputs (Alarms) ANALOG OUTPUT ANALOG INPUT ALARMS 4 mA 20 mA TEST EXIT aLOW aHIGH 4 mA 20 mA...
  • Page 24 Chapter 1. Calibration DigitalFlow™ GF868 Service Manual (1 and 2-Channel)

  • Page 25: Chapter 2. Error Codes And Screen Messages

    Chapter 2. Error Codes and Screen Messages Chapter 2. Error Codes and Screen Messages Introduction The Model GF868 ultrasonic flowmeter is a reliable, easy to maintain instrument. When properly installed and operated, as described in the Startup Guide , the meter provides accurate flow rate measurements with minimal user intervention.

  • Page 26: E0: No Error

    Chapter 2. Error Codes and Screen Messages 2.1.1 E0: No Error Problem: No error condition currently exists. Cause: This message appears briefly to confirm that the response to another error message has corrected the problem. Action: No action is required. 2.1.2 E1: Low Signal Poor ultrasonic signal strength or the signal exceeds the limits entered via the User Program .

  • Page 27: E5: Amplitude Error

    Chapter 2. Error Codes and Screen Messages 2.1.6 E5: Amplitude Error The signal amplitude exceeds the limits programmed in the SETUP submenu of the User Program . Problem: Cause: Excessive levels of an attenuating gas, such as CO , are present in the flowcell. Solid or liquid particulates may be present in the flowcell.

  • Page 28: E10: Special Input

    Chapter 2. Error Codes and Screen Messages 2.1.11 E10: Special Input Problem: This message indicates a special input error. Cause: The special input exceeds the specified limits for the analog inputs option card. Action: Check the special transmitter and the connecting cable. Refer to Chapter 1, Calibration , and recalibrate the analog inputs on the option card.

  • Page 29: Screen Messages

    Chapter 2. Error Codes and Screen Messages Screen Messages A variety of messages may appear on the display screen during the performance of a task. Since the error codes have already been discussed in this chapter and the locator bar messages are discussed in detail in Chapter 3, Operation , of the Startup Guide , they will not be repeated here.
  • Page 30 Chapter 2. Error Codes and Screen Messages Table 2: Screen Messages Message Meaning When in the CAL menu, this message indicates that the calibration of the analog output is invalid. Hit any key to clear the message, and the GF868 will default to the Outside limits, value rejected.

  • Page 31: Chapter 3. Diagnostics

    Chapter 3. Diagnostics Chapter 3. Diagnostics Introduction This chapter explains how to troubleshoot the Model GF868 if problems arise with the electronics console, the flowcell, or the transducers. Indications of a possible problem include: • display of an error message on the active display screen •...
  • Page 32 Chapter 3. Diagnostics Displaying Diagnostic Parameters (cont.)   Ch1 label gSITE  keys and the appropriate [Fx] key to display a different Press the [ and [ diagnostic parameter or to EXIT the Diagnostics Menu . Ch1 DN Transit usec 519.7 (error codes appear here) Tdow...

  • Page 33: Diagnostic Record

    Chapter 3. Diagnostics Table 3: Available Diagnostic Parameters Option Bar Screen Display Description Good ToffS* Skan T Offset usec Displays dynamically calculated signal timing offset in N.A. N.A. skan signal measurement Tu S* UP Transit S usec Displays Skan Tup. N.A.

  • Page 34: Gas Problems

    The accuracy of the flow rate measurements is no better than the accuracy of the programmed pipe dimensions. For a flowcell supplied by Panametrics, the correct data will be included in the documentation. For other flowcells, measure the pipe wall thickness and diameter with the same accuracy desired in the flow rate readings.

  • Page 35: Transducer Problems

    Chapter 3. Diagnostics Transducer Problems Ultrasonic transducers are rugged, reliable devices. However, they are subject to physical damage from mishandling and chemical attack. The most common transducer problems are listed below: LEAKS: Leaks may occur around the transducer and/or the flowcell fittings. Repair such leaks immediately. If the leaking gas is corrosive, carefully check the transducer and cables for damage, after the leak has been repaired.
  • Page 36 Chapter 3. Diagnostics [no content intended for this page] DigitalFlow™ GF868 Service Manual (1 and 2-Channel)

  • Page 37: Chapter 4. Parts Replacement

    Chapter 4. Parts Replacement Chapter 4. Parts Replacement Introduction The electronics console of the Model GF868 has been designed to permit easy on-site upgrades and parts replacement. See Figure 8 on page 37 and Figure 9 on page 38 for details of the standard GF868 electronics console assembly.

  • Page 38: Fuse Replacement

    Chapter 4. Parts Replacement Fuse Replacement If it has been determined that the fuse in the Model GF868 requires replacement, complete the following steps: WARNING! The main power to the Model GF868 must be disconnected before proceeding. Open the cover on the electronics console. For LVD compliant units, remove the two mounting screws and lift the clear plastic shroud out of the electronics console.

  • Page 39: Removing The Printed Circuit Board

    Chapter 4. Parts Replacement Removing the Printed Circuit Board All of the remaining maintenance procedures discussed in this chapter require removal of the printed circuit board. To accomplish this task, see Figure 8 on page 37 and Figure 9 on page 38 while completing the following: Remove the main power to the electronics console.

  • Page 40: Replacing The Eprom

    Chapter 4. Parts Replacement Replacing the EPROM The Model GF868’s User Program is stored on an erasable programmable read only memory (EPROM) chip. The EPROM, which is designated as component U4, is located in the top left corner of the rear of the printed circuit board. See Figure 9 on page 38 for a rear view of the printed circuit board.

  • Page 41: Installing An Option Card

    Chapter 4. Parts Replacement Installing an Option Card The Model GF868 flowmeter can accommodate up to six option cards. The option cards are installed into sockets on the rear of the printed circuit board, and they are held in place with a metal bracket. A single metal bracket is used to secure all the installed option cards.

  • Page 42: Replacing The Lcd Display

    Chapter 4. Parts Replacement Replacing the LCD Display The Model GF868’s measurements are displayed on a a two-pane LCD graphic display panel. The LCD display normally provides years of dependable service, but it is easily field-replaceable when necessary. To replace the LCD display, see Figure 8 on page 37 for the component locations, and complete the following steps: Remove the printed circuit board, as described in a previous section of this chapter.
  • Page 43 Chapter 4. Parts Replacement Installing the Printed Circuit Board (cont.) Position the printed circuit board within the electronics console with the top edge tilted forward. Insert the display ribbon cable and keypad ribbon cable connectors into their sockets on the rear of the printed circuit board. See Figure 8 on page 37 and Figure 9 on page 38 to identify the cables and sockets.

  • Page 44: Spare Parts

    Spare Parts All of the necessary components to upgrade or repair the Model GF868 flowmeter are readily available from Panametrics. As a convenient reference, some of the more common spare parts are listed in Table 5. Table 5: Spare Parts List...
  • Page 45 Chapter 4. Parts Replacement Front View Mounting Screw Keypad Cable Main Shroud Main Shroud 8 places Display Cable Nuts & Washers Nuts & Washers WARNING 4 places Display Shroud Option Card Socket GATE DRTN TWIND RWIND ALARMS ANALOG OUT ANALOG IN TOTL/FREQ RTD IN LCD Display...
  • Page 46 Chapter 4. Parts Replacement Keypad Cable Vertical Components Short Standoff 3 places Backlight Cable Long Standoff EPROM (U4) 3 places LCD Display Beveled BLACK Corner Keypad Connector (J50) Display Connector (J52) Display Cable – G N/L2 L1 J2 Connector Fasteners (typ.) Option Card Connectors Metal Bracket Rear View...

  • Page 47: Appendix A. Service Record

    Appendix A. Service Record Appendix A. Service Record Introduction Whenever any service procedure is performed on the Model GF868 flowmeter, the details of the service should be recorded in this appendix. An accurate service history of the meter can prove very helpful in troubleshooting any future problems.
  • Page 48 Appendix A. Service Record Table 6: Service Record Date Description of Service Performed By DigitalFlow™ GF868 Service Manual (1 and 2-Channel)

  • Page 49: Appendix B. Optional Enclosures

    Appendix B. Optional Enclosures Appendix B. Optional Enclosures Introduction The Model GF868 is available in optional enclosure types, each of which has been designed to permit easy on-site upgrades and parts replacement. See the foldout drawings at the end of this appendix for details of the applicable GF868 electronics console assembly.

  • Page 50: Rack Mount Fuse Replacement

    Appendix B. Optional Enclosures Rack Mount Fuse Replacement If it has been determined that the fuse in the Model GF868 requires replacement, refer to Figure 10 on page 49 and Figure 11 on page 50, and complete the following steps: On the rear panel of the meter, set the power switch to the OFF position and pull the power cord out of its recep- tacle.

  • Page 51: Rack Mount Option Card Installation

    Appendix B. Optional Enclosures Rack Mount Option Card Installation The Model GF868 flowmeter can accommodate up to six option cards in a manner similar to that used in a PC. The option cards are installed into sockets on the printed circuit board, and they are held in place with a metal bracket. A single metal bracket is used to secure all the installed option cards.
  • Page 52 Appendix B. Optional Enclosures After disconnecting the main power to the meter, remove the top panel from the enclosure by removing the four screws indicated. WARNING! The main power to the Model GF868 must be disconnected before proceeding. Using a chip puller, remove the EPROM from its socket. If a chip puller is unavailable, a straightened paper clip may be used in the notches at opposite corners of the socket.

  • Page 53: Rack Mount Lcd Display Replacement

    Appendix B. Optional Enclosures Rack Mount LCD Display Replacement The Model GF868 measurements are displayed on a two-pane LCD graphic display panel. The LCD display normally provides years of dependable service, but it is field-replaceable when necessary. To replace the LCD display, refer to Figure 11 on page 50 and complete the following steps: After disconnecting the main power to the meter, remove the top panel from the enclosure by removing the four screws indicated.

  • Page 54: Rack Mount Printed Circuit Board Replacement

    Appendix B. Optional Enclosures Rack Mount Printed Circuit Board Replacement If troubleshooting procedures have indicated a defective printed circuit board, follow the instructions in this section to replace the defective board with a new one. B.7.1 Circuit Board Removal Refer to Figure 11 on page 50 and complete the following steps: After disconnecting the main power to the meter, remove the top panel from the enclosure by removing the four screws indicated.

  • Page 55: B.7.2 Circuit Board Installation

    Appendix B. Optional Enclosures B.7.2 Circuit Board Installation Refer to Figure 11 on page 50 and complete the following steps: Position the new printed circuit board within the electronics console so that it rests on the six standoffs in the base of the enclosure and the option card sockets are located near the rear of the enclosure.
  • Page 56 Appendix B. Optional Enclosures [no content intended for this page] DigitalFlow™ GF868 Service Manual (1 and 2-Channel)
  • Page 57 Appendix B. Optional Enclosures Fuse 14.83 (377) 16.99 (432) 4.19 (106) 11.82 11.37 13.13 (300) (289) (333) 15.70 (399) 3.31 (84) 5.22 2.25 (57) (133)     18.25 (464) 19.00 (483) DigitalFlow™ GF868 Service Manual (1 and 2-Channel)
  • Page 58 Appendix B. Optional Enclosures Option Card Slot Cover Line Lead (Black) Option Card Socket Analog Output Connector Neutral Lead (White) (typ.) CH1 Transducer Connector Fuse RS232 Connector CH2 Transducer Connector Ground Lead (Green) Top Panel Mounting Hole Power Terminal Block 4 places Printed Circuit Board Display Cable...
  • Page 59 Index Fuse Acceleration Error - E6 ........19 Holder .
  • Page 60 Index Shroud Aluminum ......... . 29, 35 LCD Display .
  • Page 61 RETURN AUTHORIZATION NUMBER (RAN), and shipping instructions for the return of the instrument to a service center will be provided. If Panametrics Sensing instructs you to send your instrument to a service center, it must be shipped prepaid to the authorized repair station indicated in the shipping instructions.
  • Page 62 Warranty DigitalFlow™ GF868 Service Manual (1 and 2-Channel)
  • Page 63 Cable glands of an approved flameproof design are required for Ex d rated equipment. These must be installed • according to the manufacturer’s instructions. Where the cable glands are provided by Panametrics, the manufacturer’s instructions, as supplied to Panametrics, will be included in the documentation.
  • Page 64 Special Conditions for Safe Use Consult the manufacturer if dimensional information on any flameproof joint is necessary. Follow the manufacturer’s instructions to reduce the potential of an electrostatic charging hazard. Consult the manufacturer for genuine replacement flange fasteners. M10x35 hexagon socket cap screws of ISO 12.9 DIN912 grade steel (zinc-plated) or better with a minimum yield strength of 135,000 psi are acceptable alternatives.
  • Page 65 Panametrics Sensing 1100 Technology Park Drive Billerica, MA 01821 declare under our sole responsibility that the DigitalFlow™ DF8688 Liquid Ultrasonic Flowmeter DigitalFlow™ GC868 Clamp-On Gas Ultrasonic Flowmeter DigitalFlow™ GF868 Flare Gas Mass Ultrasonic Flowmeter DigitalFlow™ GM868 General-Purpose Gas Ultrasonic Flowmeter DigitalFlow™...
  • Page 66 [no content intended for this page] DigitalFlow™ GF868 Service Manual (1 and 2-Channel)
  • Page 68 Customer Support Centers U.S.A. The Boston Center 1100 Technology Park Drive Billerica, MA 01821 U.S.A. Tel: 800 833 9438 (toll-free) 978 437 1000 E-mail: mstechsupport@bakerhughes.com Ireland Sensing House Shannon Free Zone East Shannon, County Clare Ireland Tel: +353 (0)61 470200 E-mail: mstechsupport@bakerhughes.com Copyright 2021 Baker Hughes company.

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