24 Hour Factory Service Hot Line: 1 (800) 854-1993

Document 06EN003321 Rev. -

GF92 Installation, Operation and

Troubleshooting Guide
A.

To get the best results from the instrument, the sensor should be located 20 pipe diameters downstream from any
flow disturbance (valve, pipe elbow, etc.) and 10 pipe diameters upstream from any disturbance.
The instrument tags show the model number, tag number (if noted on the customers order), 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.

Tag Location - Top Side of

Tag Location - Between Conduit Ports
Remote Enclosure
On Local Enclosure
If the instrument is a remote configuration, the serial number on the enclosure tags must match. The recommended tag
number on the local enclosure will have an FT in the tag number. The recommended tag number on the remote enclosure
will have an FE in the tag number. (Tags are specified by the customer, FE/FT is a recommended naming convention .)
B.

Verify the serial numbers on the enclosure(s), flow element and electronics match. The instrument may not work if the
serial numbers do not match. (The instrument has a remote transmitter enclosure (FT) and a local flow element
enclosure (FE).)

Flow Element Serial Number

Also Showing Flow Arrow
(Located near the FE enclosure.
It is also on the enclosure tag.)
C.

Electronics Serial Number

(Top circuit board, lower left corner. It is also on
the transmitters (FT) enclosure tag.

Recommended installation/troubleshooting tools are an open-ended wrench to fit the NPT connection, an openended wrench to fit the flanged fitting nuts and bolts, a small flat blade screw driver for manipulating potentiometers,
both a medium flat blade screwdriver and a medium phillips head screwdriver for tightening connections, 3 mm allen
wrench for CENELEC approved instruments, a measuring tape for proper flow element placement, and a DVM for
Ohm/Voltage measurements.

INSTALLATION, OPERATION AND TROUBLESHOOTING GUIDE

Step 2.

FLUID COMPONENTS INTL

Flow Element Installation

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 the pipe surface itself.

Install the flow element, with the flow arrow (shown on Page 1) in the direction of media flow. The remote enclosure,
local enclosure, flow element and electronic transmitter serial numbers must all match.
For flange mount flow elements, 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 machined area.

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.

For NPT pipe thread installations, apply sealant to the male threads. Carefully place in the process media line with the
machined flat facing up. Tighten the process connections. To avoid leaks do not overtighten or cross-thread
connections.
Shown below is the NPT mounting option. Other options are flange mount and butt weld mount. See the Installation
Section in the GF Series Manual, Document Number 06EN003229 for more details.

In-Line GF92 Flow Element and Enclosure

Local NEMA 4 &7 Enclosure Dimensions

Remote Enclosure NEMA TYPE 4X Dimensions (Option)

Model GF92 Flowmeter

Remote Explosion Proof Enclosure Dimensions (Option)

2

Doc. No. 06EN003321 Rev.-

INSTALLATION, OPERATION AND TROUBLESHOOTING GUIDE

FLUID COMPONENTS INTL

Step 3. Wiring Preparation

Before the instrument is opened to install the wiring, FCI recommends that the following ESD precautions be observed:
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 such as Static Free made by Chemtronics (or equivalent) 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.
Open the instrument enclosure to expose the terminal strips. The orientation of the connectors are shown below:
JP5
RELAY 2

JP4
RELAY 1

JP3 - CUSTOMER
JP6
WIRING TO FLOW
AUXILIARY &
ELEMENT
SIGNAL
OUTPUT

JP1
AC OR DC
POWER

SWITCH S1
( 115VAC
230VAC)

FUSES
GF92 Terminal Strip, Power Option Switch and Fuse Orientation

Step 4. Wiring the Instrument

Alert:

Caution:

The instrument contains electrostatic discharge (ESD)

sensitive devices. Use standard ESD precautions when
handling the flow transmitter.

Only qualified personnel are to wire or test this instrument.

The operator assumes all responsibilities for safe practices
while wiring or troubleshooting.

Wiring the Instrument into the Customer Application:

This section describes wiring to the transmitter inputs, outputs and interconnection cabling for the remote enclosure. For best
results route the output wiring through the opposite port from the power wiring. See the table on the next page to determine
the size of wiring to be used versus the length of the wire.
Doc. No. 06EN003321 Rev. -

Model GF92 Flowmeter

INSTALLATION, OPERATION AND TROUBLESHOOTING GUIDE

FLUID COMPONENTS INTL

Maximum Distance for AWG

Connection

10 ft.
(3m)

50 ft.
(15m)

100 ft.
(31m)

250 ft.
(76m)

500 ft.
152m)

1000 ft.
(305m)

AC Power

22

22

22

20

18

16

Relay (2A, at
220VAC)

24

22

20

16

12

Not
Recommended

Relay (10A, at
120VAC or 24VDC)

22

16

12

Flow Element Wires

for Remote Option*

24

24

24

Not Recommended
22

22

18

Wire Gauge Versus Distance Of Wire To Run

Wiring the Instruments 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.) See GF Series manual 06EN003229 for details.

Customer Connections, Analog Output Diagram

Alert:

Model GF92 Flowmeter

Analog Output Plug Location

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.

Doc. No. 06EN003321 Rev.-

INSTALLATION, OPERATION AND TROUBLESHOOTING GUIDE

FLUID COMPONENTS INTL

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).

Local Enclosure Wiring Diagram

Flow Ele m e nt
Te rm ina l Block
Terminal 5 (ACT)
Terminal 5 (ACT)
Terminal 4 (GND SEN)
Terminal 3 (REF)
Terminal 3 (REF)
Terminal 2 (GND)
Terminal 1 (HTR)
Terminal 1 (HTR)

Tra nsm itte r

JP3 (Te rm ina l No.)
ACT SEN (4)
ACT EXC (6)
GND SEN (2)
REF SEN (3)
REF EXC (5)
GND
(1)
HTR EXC (7)
HTR SEN (8)

Flow Element Wiring Table

Flow Element Wiring Diagram
(Be sure the jumper is in place
Terminal 2 to terminal 4.)

Connector JP3

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 as desired. (NO = Normally Open, NC = Normally Closed, Pole = Common)

Connectors JP5.and JP4

Output Relay Wiring Diagram

Doc. No. 06EN003321 Rev. -

Model GF92 Flowmeter

INSTALLATION, OPERATION AND TROUBLESHOOTING GUIDE

FLUID COMPONENTS INTL

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 through the right port. See the wiring table on Page 4 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.

Switch S1
Connector JP1

Input Power Location

Step 5.

Input Power Wiring Diagram

Operation

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.
Flow Rate
Output Channel #

Flow Units

CH1: 5056.3 SCFM

CH2: 71.2 F
S = 435226 SCF
(grp1)(ed)(norm)(m)

Calibration Group #

Relay Status

Process Temperature
Totalizer (If Enabled)
Sample (Flashes) Rate

Mode

Normal Operation Window

Model GF92 Flowmeter

Doc. No. 06EN003321 Rev.-

INSTALLATION, OPERATION AND TROUBLESHOOTING GUIDE

FLUID COMPONENTS INTL

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 Available Selections

Menu Level

Key

Selects options and enters

numbers

Yes

Enter a yes response

No or (N)ext

Enter a no response or scrolls

to the next screen

Minus

Enter a minus sign

Decimal Point

Enter a decimal point

Back Space

Moves cursor back one space

(P)rv or Previous

Scrolls to the previous screen

Enter

Enters a numeric value or

response

Current Selection Prompt Line

Display Characteristics
1

P
ENTR

HOME Home
ENTR

HOME

Action

Numeric

0-9

3.1.2 STD VOLUME

1=Cu feet 3=Cu meter
3=Liters
(CF)?

Key Name

UP

UP

Up

Key Pad

Returns to the Main Menu or

escapes from routines
Move current menu up one
level

Key Assignments

At any time, the HOME key can be pressed and the main menu will display. HOME can be used to escape from most
routines, 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

2.0 PORT SETUP

1 = Analog Output
2 = Relays
3 = Comm Output
4 = Aux Input

Doc. No. 06EN003321 Rev. -

CH1: 5056.3 SCFM

CH2: 71.2F
S = 435226 SCF
(grp1) (dd) (mode N) (m)

QUICK OPERATION
MENU

Normal Operation

3.0 DISPLAY SETUP

1 = Flow Setup
2 = Temperature Setup
3 = Totalizer Setup
4 = Sample Rate

4.0 MISCELLANEOUS
1 = Set Group
2 = Corrector Setup
3 = Password Setup

Model GF92 Flowmeter

INSTALLATION, OPERATION AND TROUBLESHOOTING GUIDE

FLUID COMPONENTS INTL

Step 6. Troubleshooting
In the event that the instrument does not operate as expected use the table below:
Proble m
No Display

Solution
Check Fuses (below JP1).
Verify S1 is switched to the correct input voltage for AC applications.
Verify correct power is applied
Verify the ribbon cable between the upper and lower circuit boards is
solidly connected and the red stripe is on pin 1.
No Display or Dim Display Adjust pot R1 on the upper left of the top circuit board. If there is no
change in the display return the pot to the original setting.
Display is Locked Up
Press HOME and then 1 to return to normal operation.
Reset the instrument by cycling the power.
Readings Seem Incorrect Verify the serial number of the flow element and the flow transmitter
are the same serial number.
Verify the flat on the flow element is parallel to the pipe and the flow
flow arrow is pointed in the direction of the flow stream.
Verify the sensor is mounted in the center of the pipe.
Verify the calibration data sheet matches the process configuration.
Verify all jacks and plugs are all firmly seated and the wiring to them
is correct and secure.

If there are still problems with the instrument, see the Troubleshooting Section in the GF Series Manual,
Document Number 06EN003229. To acquire a manual call your local FCI sales representative.

Notice of Proprietary Rights

This document contains confidential technical data, including trade secrets and proprietary information which are the property of Fluid Components Intl
(FCI). Disclosure of this data to you is expressly conditioned upon your assent that its use is limited to use within your company only (and does not include
manufacture or processing uses). Any other use is strictly prohibited without the prior written consent of FCI.
Visit FCI on the Worldwide Web: www.fluidcomponents.com
1755 La Costa Meadows Drive, San Marcos, California 92069 USA - 760-744-6950 - 800-854-1993 - Fax 760-736-6250
European Office: Persephonestraat 3-01 5047 TT Tilburg - The Netherlands - Phone 31-13-5159989 - Fax 31-13-5799036
Copyright 2001 Fluid Components Intl a limited liability company All Rights Reserved

Model GF92 Flowmeter

Doc. No. 06EN003321 Rev.-