GPI 09 COMPUTER ELECTRONICS User manual

Commercial Grade
09 COMPUTER
ELECTRONICS
Owner’s Manual
Rev. D 920787-01
09/11
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To the owner . .
Congratulations on receiving your
GPI Commercial Grade Computer
Electronics. We are pleased to pro-
vide you with a product designed
to give you maximum reliability and
efciency.
Our business is the design, manu-
facture, and marketing of liquid han-
dling, agricultural, and recreational
products. We succeed because we
provide customers with innovative,
reliable, safe, timely, and compet-
itively-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, depend-
able service.
President
Great Plains Industries, Inc.
General Information .............................2
Installation ...........................................3
Operation .............................................4
Calibration ...........................................5
User Conguration...............................6
Maintenance ........................................7
Troubleshooting ...................................8
Specications ......................................9
Parts ..................................................10
Service...............................................10
2
This manual will assist you in oper-
ating and maintaining the Computer
Electronics of the GPI Commer-
cial Grade Meters. (See Figure 1)
Calibration details are given in this
manual. Information on turbine hous-
ings and accessory modules are
contained in other manuals. Please
reference those as necessary.
Figure 1
Turbine
Housing
Computer
Electronics
Before Getting Started
Take the time to fully acquaint your-
self 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 through-
out the manual to call your
attention to safety messages.
Warnings alert
you to the poten-
tial for personal
injury.
Cautions call
your attention to
practices or pro-
cedures which
may damage your
equipment.
Notes give information that can
improve efciency of operations.
TABLE OF CONTENTS
GENERAL INFORMATION
WARNING
CAUTION
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3
The CMOS, microprocessor-based
electronics have extremely low pow-
er 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 equip-
ment for visible damage. The com-
puter is a precision measuring
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 side of the computer and also
underneath a battery.
If you ordered your computer elec-
tronics with a turbine housing, it is
installed at the factory.
If you ordered your computer sepa-
rately 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.
If you ordered the computer with
turbine and an accessory module,
please review and thoroughly un-
derstand all installation instructions
before proceeding.
It is your responsibility to make sure
that all operators have access to ad-
equate instructions about safe oper-
ating and maintenance procedures.
Read Me!
For your safety, review the major
warnings and cautions below before
operating your equipment.
The apparatus enclosure may
contain aluminum and is consid-
ered 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 con-
structed from plastic. To prevent
the risk of electrostatic sparking
the plastic surface should only
be cleaned with a damp cloth.
WARNING
1. This equipment is approved to
handle only uids that are com-
patible with all wetted materials.
2. When measuring ammable liq-
uids, observe precautions against
re or explosion.
3. When handling hazardous liq-
uids, always follow the liquid
manufacturer’s safety precau-
tions.
4. When working in hazardous
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
Commercial Grade Turbine Hous-
ings.
INSTALLATION
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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 field
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 con-
tinuous measurement and cannot
be manually reset. The Batch Total
can be reset to measure ow during
a single use. The Cumulative Total
is labeled 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 zeros must be added to the
6 digits shown.
4
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 opposite direction is
desired, simply rotate the computer
electronics 180 degrees prior to
installation.
Avoid electronically “noisy”
environments. Install at least 6
inches (15.2 cm) away from motors,
relays, or transformers.
All GPI A1 Series meters are Factory
Mutual Approved and carry a Class
1, Division 1 Approval for hazardous
environments. In addition, GPI meters
have NEMA Type 4 enclosures.
They are tested and calibrated at
the factory using state-of-the-art
calibration procedures and testing
equipment.
To ensure accurate measurement,
remove all air from the system before
use.
1. Ensure some back pressure on
the turbine.
2. Open the discharge valve
or nozzle and allow fluid to
completely ll the system. Make
sure the stream is full and steady.
3. Close the discharge valve or
nozzle.
4. Start normal operations.
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 figure final volume. For best
results, accuracy should be veried
periodically as part of a routine
maintenance schedule.
OPERATION
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5
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 Calibra-
tion Section. Totals derived from the
eld calibration are invoked when the
FAC icon is no longer visible on the
top line of the display.
Verify Accuracy Before
Beginning Field
Calibration
For the most accurate results,
dispense at a owrate which best
simulates your actual operating con-
ditions. 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:
Low Flow meter 0.3 GPM (1 LPM)
1 inch meter 3 GPM (11 LPM)
2 inch meter 30 GPM (113 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, it is strongly
recommended that Field Calibration
of two inch meters be completed with
a combination of volume and weight
using ne resolution scales.
Press the DISPLAY button briey
to switch between the TOTAL 1,
TOTAL 2 BATCH and FLOWRATE
(if applicable). 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.
Flowrate Feature (some models)
To use this feature, press and release
DISPLAY button 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.
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 configured 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 CALI-
BRATE 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).
CALIBRATION
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6
Field Calibration Necessity
Field Calibration and Factory Cali-
bration are dened in the Operation
Section. Factory calibration settings
are programmed into each computer
during manufacturing, using stoddard
text solvent at 70° F (21° C) for Low
Flow and one inch meters and water
at 70° F (21° C) for two inch meters.
Settings are correct for light liquids
such as water, gasoline or diesel.
Readings using the Factory Calibra-
tion (FAC) may not be accurate in
some situations, for example, “heavy”
liquids such as motor oil and 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 but-
tons 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 +/– position appears either
as an “underscore” character for
plus, or as a “hyphen” character
for minus. The DISPLAY but-
ton selects the position and the
CALIBRATE button toggles this
character.
3. The DISPLAY button can then
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 re-
main visible and selectable – the
entered correction will be applied
to all enabled units.
5. To return to factory calibration
(FAC), press and hold both CALI-
BRATE and DISPLAY buttons for
about 3 seconds until FAcCAL is
displayed. Then release buttons.
Unit should return to normal op-
eration and FAC icon is visible.
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 “unneces-
sary” 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 (Minute, Hour,
Day)
USER CONFIGURATION
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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 need to be
replaced. Replacement batteries can
be ordered from your distributor or
the factory. See details in the Parts
Section.
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 com-
puter 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 cor-
rectly, the computer powers on
automatically and the readout
displays information.
5. Make sure the seal is fully seated
before placing the computer elec-
tronics on the turbine. Tighten the
four screws.
6. Do not clean exterior of computer
assembly with Isopropyl Alcohol.
7
• Factory Calibration Curve Units
Enabled – Gallons, Litres, Imperial
Gallons, Quarts, Ounces, Cubic
Feet, Cubic Centimeters, Cubic
Meters or Barrels (42 Gal.)
• Dispense/Display or K-Factor
Entry Calibration
Changing Conguration
Settings
Access to the conguration 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 informa-
tion 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.
The computer electronics is powered
by lithium batteries which provide at
least 5 years of use. Removing the
MAINTENANCE
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8
Symptom Probable Cause Corrective Action
A. METER IS NOT 1. Field Calibration not Field calibrate again or select
ACCURATE performed properly Factory Calibration.
2. Factory Calibration not Perform a Field Calibration accord-
suitable for liquid being ing to Calibration Section.
measured
3. Meter operated below Increase owrate.
minimum owrate
4. Meter partially clogged Remove meter. Clean carefully.
with dried liquid Make sure rotor spins freely.
5. Turbine bearings Remove meter. Clean carefully.
partially clogged with Make sure rotor spins freely.
dried liquid
6. Sealant material Remove meter. Make sure rotor
wrapped around rotor spins 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 Remove computer, check and
FADED OR or not connected replace batteries if necessary.
2. Computer defective Contact the factory.
C. NORMAL 1. Field Calibration not Field Calibrate again or select
FLOWRATE performed correctly Factory Calibration.
2. Rotor stuck or damaged Remove meter. Make sure rotor
spins freely.
3. Sealant material Remove meter. Make sure rotor
wrapped around rotor spins freely.
4. Computer defective Contact the factory.
D. REDUCED 1. Meter clogged with Remove meter. Clean carefully.
FLOWRATE dried liquids Make sure rotor spins freely.
2. Below minimum Increase ow.
owrate
E. CANNOT GET 1. Wrong button sequence Proceed with calibration according
METER INTO to the Calibration Section.
2. Computer circuit board Replace computer. Contact the
defective factory.
3. Button defective Replace computer. Contact the
factory.
TROUBLESHOOTING
BLANK
BUT METER
DOES NOT
COUNT
AND METER
DOES NOT
COUNT
FIELD CALI-
BRATION
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9
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:
Min. Pulse In: DC
Min. Coil Input: 10 Hz
Max. Raw: 1,000 Hz
K-Factor:
Min.: 0.1 pulses/unit
Max.: > 999,999 pulses/
unit
Field Calibration Correction:
Min.: –99.9%
Max. +99.9%
Readout Totals:
Min. Display: 0.01
Max. Display: 999,999 (x 100)
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 of use
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 maxi-
mum 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 volt-
age of 3-30 volts P-P, a maxi-
mum rise/fall rate of 0.01
V/µ second and a maximum
frequency of 750 Hz.
J-5 Power Input
When used with Ground (J1-
6), this has reverse polarity
protection, but no on-board
voltage regulation. Supplied
voltage must be 5.75-volts
DC ±5%.
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 elec-
tronics.
J 1
J 10
Computer Electronics
Terminal Connections
SPECIFICATIONS
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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.
D o n o t r e t u r n c o m p u t e r
electronics or meters without
specic authority from the GPI
Customer Service Department.
Du e to st ri ct reg u l a ti on s
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.
Meters not flushed before
shipment can be refused and
returned to the sender.
10
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. Use for water
based uids. Do not use
with fuel products.
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 pre-
pared with your original sales slip
or other evidence of purchase date.
CAUTION
CAUTION
PARTS
SERVICE
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