GE Infrastructure Sensing
Contents
1. 4 7 Installing an OptionCard 4 8 Installing a PCMCIA MemoryCard 4 9 Assembling Installing the Circuit Board Assembly 4 9 November 2004 Introduction The Model XGS868 has been designed to permit easy on site upgrades and parts replacement See Figure 4 1 on page 4 13 for details of the standard XGS868 electronics enclosure assembly The instructions in this chapter along with a few common tools are all that is reguired to perform the following tasks removing the circuit board assembly replacing the LCD display replacing the fuse replacing the User Program installing a fast response board installing an option card installing a PCMCIA memory card assembling installing the circuit board assembly IWARNING Prior to performing any maintenance procedures be sure to disconnect the main power from the unit If the XGS868 is installed in a hazardous environment the electronics enclosure must be moved to a safe area prior to removing the covers Note For compliance with the European Union s Low Voltage Directive 73 23 EEC this unit reguires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model XGS868 Use Figure 4 1 on page 4 13 to locate the relevant compone2. 4 6 Amplitude Error E5 2 3 Equation Limit Error E15 2 5 Analog Inputs Option Card Error Code Calibrating 1 5 Elis as 2 2 Analog Output Error E7 2 3 El KA acral aor ei 2 2 Analog Outputs o Le RD else Seta 2 4 Calibrating 1 2 Ellas ae 2 4 Linearity ses asas ner 1 2 ER ee ern sn ans 2 4 Resolution 1 2 Elia ia ee 2 5 Analog Outputs Slot 0 ET KAA ee ee 2 5 Ammeter Readings 1 4 EIS haB AER na nn 2 5 As Calibrated Current Source 1 5 Eu ren sel 2 2 Analog Outputs Option Card BI dee 2 2 Calibrating 1 2 EA er te ln dead a 2 3 Eme tityaa aguada pentes nome 1 2 Eat ges os A etna E Anak 2 3 Resolution 1 2 EG io hante ek oS he beer ee WS 2 3 A een 2 3 B ERE R EE 2 4 Bracket Option Card 4 8 E9 DAS A E aa Error Message Display Screen 2 1 C Expansion Slots 1 1 Calibrating F See Parameter Name Calibration Flowcell Problems Menu Map ee 1 11 Gas A LR LET 3 4 Contamination Gas 3 4 Pipe REN N TT A 3 5 Corrosion Transducers 3 6 Frequency Option Card POSTING IA EA 1 10 D Fuse y Replacing a santa o Ass asa es 4 5 Diagnostic Parameters Table msn 3 2 G Table of Values A 3 Diagnostics Gas a
3. only i data logging option card installed ration Signal Array Upload Memory Hardware Test Analog Outputs A B ANALOG OUTPUT Option Card A press EXIT key 20 mA Numer EST EXIT Reading CALIBRATING DOWN Full Scale Slot 1 Analog Outputs A B ANALOG OUTPUT 4 mA 20 mA CALIBRATING ANALOG INPUT CALIBRATING ABORT RTD Inputs B TEST EXIT DOWN mA Reading Full Scale Set SET POINT TEMP PE TEMP ING Alarm Relays 3 EN Totalizer Outputs 3 PULSES Frequency Outputs B FREQUENCY NOTE Plain text represents prompt area messages and boxed text represents option bar choices Fx represent function keys to select option bar choices Calibration Menu Map Fi
4. November 2004 Calibrating to 4 mA E NU N H Calibrating to 20 mA 1 2 3 Select 4 milliamps to calibrate the low end of the input range Set the calibrated current source to 4 mA Select 4 MA STORE or 4 MA ABORT Proceed to the next section to calibrate to 20 mA or go to Procedure Options below Select 20 milliamps to calibrate the high end of the input range Set the calibrated current source to 20 mA Select 20 MA STORE or 20 MA ABORT Procedure Options This completes calibration of the Slot 1 analog input Do one of the following To calibrate or test another output press Next Item Enter and return to Step 4 in Accessing the Calibration Test Menu on the previous page To calibrate test additional inputs outputs press Next Item Enter and proceed to the appropriate section To leave the User Program press EXIT PAGE three times 1 6 Calibration November 2004 Calibrating the RTD Inputs Preparing for Calibration Accessing the Calibration Test Menu Entering the Set Point Entering the Slope Procedure Options RTD analog inputs may be added to the Model XGS868 by installing an appropriate option card in Slot 1 This option card contains two or four RTD inputs which are designated as A B C and D Both the set point and slope point values for each input must be specified prior to use Prepare for the calibration procedure by connecting the RTD temperature transmitter to t
5. See Chapter 3 Diagnostics for further instructions The signal amplitude exceeds the limits programmed in the SETUP SIGNL submenu of the User Program Excessive levels of an attenuating gas such as CO may be present in the flowcell Solid or liguid particulates may be present in the flowcell Refer to Chapter 3 Diagnostics to correct any flowcell problems The acceleration exceeds the limits programmed in the SETUP SIGNL submenu of the User Program This condition is usually caused by poor flow conditions or improper transducer alignment Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems The current in the analog output circuit exceeds the limits for the analog output port The output load exceeds the specified limits for the analog output port Make sure the output load is lt 600 ohms for the Slot 0 analog outputs or is lt 1000 ohms for an analog outputs option card in Slot 1 Error Codes 2 3 November 2004 E8 Temp In E9 Press In E10 Special Input E11 Super Saturated E12 Low Pressure Problem Cause Action Problem Cause Action Problem Cause Action Problem Cause Action Problem Cause Action This message indicates a temperature input error The temperature exceeds the specified limits for the analog RTD inputs option card or no input device is connected Check the temperature transmitter and the
6. Error Message CH1 MASS Exx 4500 LB HR x XGS868 LCD Display Figure 2 1 Error Message Location If an error message appears during normal operation of the Model XGS868 refer to the appropriate section of this chapter for instructions on how to proceed Error Codes 2 1 November 2004 EO No Error E1 Low Signal E2 Sound Speed Error E3 Velocity Range Problem Cause Action Problem Cause Action Problem Cause Action Problem Cause Action No error condition currently exists This message appears briefly to confirm that the response to another error message has corrected the problem No action is required Poor ultrasonic signal strength or the signal exceeds the limits entered via the User Program Poor signal strength may be caused by a defective cable a flowcell problem a defective transducer or a problem in the electronics console A signal that exceeds the programmed limits is probably caused by the entry of an improper value in the SETUP SIGNL submenu of the User Program Using the procedures in Chapter 3 Diagnostics check the components listed above Also check the value entered into the SETUP SIGNL submenu as described in Chapter 1 Programming Site Data of the Programming Manual The sound speed exceeds the limits programmed in the SETUP SIGNL submenu of the User Program The error may be caused by incorrect programming poor flow
7. This error code message indicates that the present measurement exceeds the range of the meter A internal mathematical overflow has occurred in either the volumetric or mass flow calculations Select larger measurement units or a shorter time interval for the current measurement parameter For example choose KSCF M instead of SCF M in the CHx SYSTM menu See Chapter 2 Initial Setup of the Startup Guide for instructions The totalizers are unable to keep up with the total accumulated flow signals The programmed units pulse value is too small Select a larger number of units pulse value The current temperature or pressure exceeds the valid range for the built in steam density equations The temperature and pressure range of the XGS868 has been extended through the use of the optional BWT transducers However the built in steam density equations are not valid at these extended values and the calculated steam density may be inaccurate Select YES at the Mass Flow Static static prompt in the CHx PIPE menu and enter the correct steam density for the current temperature and pressure values Error Codes 2 5 Chapter 3 Diagnostics Introduction PA er 3 1 Displaying Diagnostic Parameters 3 1 Flowcelli Problems a ae 3 4 Transducer Problems 3 6 November 2004 Introduction Displaying Diagnostic Parameters This chapter explains
8. must be replaced Contact the factory for information on transducers in materials suitable for the application INTERNAL DAMAGE An ultrasonic transducer consists of a ceramic crystal bonded to the transducer case The bond between the crystal and the case or the crystal itself may be damaged by extreme mechanical shock and or temperature extremes Also the internal wiring can be corroded or shorted if contaminants enter the transducer housing PHYSICAL DAMAGE Transducers may be physically damaged by dropping them onto a hard surface or striking them against another object The transducer connector is the most fragile part and is most subject to damage Minor damage may be repaired by carefully bending the connector back into shape If the connector can not be repaired the transducer must be replaced IMPORTANT Transducers must be replaced in pairs Refer to Chapter 2 Initial Setup of the Startup Guide to program the new transducer data into the meter If the instructions in this section fail to resolve the problem contact the factory for assistance 3 6 Diagnostics Chapter 4 Parts Replacement Introduction sense en ab 4 1 Removing the Circuit Board Assembly 4 2 Replacing the LCD Display 4 4 REPIGCING the FUSO ss er Esel 4 5 Replacing the User Program 4 6 Installing a Fast Response Board
9. Service Record A 1 Signal Quality Error E4 2 3 Soundspeed Err r B2 44 2 Nun see 2 2 Gas nn PE 3 4 Special Input Error E10 2 4 Super Saturated Error E11 2 4 T Temperature Input Error E8 2 4 Testing Alarm Relay 1 8 Testing Frequency Outputs 1 10 Testing Totalizer Outputs 1 9 Totalizer Option Card Testing 2 Daio cano pode anes Sa 1 9 Totals Overflow Error E14 2 5 Transducers Corrosion 3 6 Internal Damage 3 6 Leaks 2e tent de engen 3 6 Physical Damage 3 6 Pl cement cui pi er o emas Gees 3 5 Problems cus estro rta ne 3 6 Replacement 3 6 U User Program EPROM mia rs Senne net 4 6 Upgrading 4 6 V Velocity Range Error E3 2 2 W Warranty 111 Index DECLARATION Sensing OF CONFORMITY we Panametrics Limited Shannon Industrial Estate Shannon County Clare Ireland declare under our sole responsibility that the IGM878 Industrial Gas Ultrasonic Flow Transmitter XGF868 Flare Gas Ultrasonic Flow Transmitter XGM868 Multi Purpose Gas Ultrasonic Flow Transmitter XGN868 Natural Gas Ultrasonic Flow Transmitter XGS868 Steam Mass Ultrasonic Flow Transmitter XMT868 Liquid Ultrasonic Flow Transmitter to whic
10. Startup Guide for detailed wiring instruction 5 Install the front and rear covers on the electronics enclosure and secure them in place with the set screws provided The Model XGS868 is now ready to be placed back into service Before taking measurements with the Model XGS868 refer to Chapter 2 Initial Setup of the Startup Guide and Chapter 1 Calibration of this manual for instructions on properly setting up the meter for accurate flow rate measurements Note Be sure to enter a complete and detailed account of any parts replacement performed on the Model XGS8668 in Appendix A Service Record To purchase the parts mentioned in this chapter or any items not specifically discussed contact the factory for assistance To make sure the proper components are obtained be sure to specify the serial number of the Model XGS868 at the time of purchase Parts Replacement 4 11 PCMCIA Slot TA REAR VIEW FRONT VIEW wo Display Interconnect Board E Mounting Screw Mounting Holes UMA Connector Angle Bracket AIN BOA Connector WA Terminal Board BOARD FRONT 1 FRONT VIEW w Display Mounting Screw Mounting Screw Contrast Adjustment Mounting Screw LCD Display Board Power Tab
11. conditions or poor transducer orientation Compare the measured sound speed to tabulated nominal values for the gas being used and correct any programming errors Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems The velocity exceeds the limits programmed in the SETUP SIGNL submenu of the User Program This error may be caused by the entry of improper programming data or by poor flow conditions and or excessive turbulence Make sure the actual flow rate is within 75 ft sec 23 m sec See Chapter 1 Programming Site Data in the Programming Manual for details Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems 2 2 Error Codes November 2004 E4 Signal Quality Problem Cause Action E5 Amplitude Error Problem Cause Action E6 Cycle Skip Accel Problem Cause Action E7 Analog Out Error Problem Cause Action The signal quality is outside the limits programmed in the SETUP SIGNL submenu of the User Program The peak of the upstream or downstream correlation signals has fallen below the correlation peak limit as set in the SETUP SIGNL submenu This may be caused by a flowcell or electrical problem Check for sources of electrical interference and verify the integrity of the electronics console by temporarily substituting a test flowcell that is known to be good Check the transducers and relocate them if necessary
12. connecting cable Refer to Chapter 1 Calibration and recalibrate the analog RTD inputs option card This message indicates a pressure input error The pressure exceeds the specified limits for the analog inputs option card or no input device is connected Check the pressure transmitter and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs option card This message indicates a special input error The special input exceeds the specified limits for the analog inputs option card Check the special input device and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs option card This message indicates that based on the temperature and pressure readings the steam is super saturated and may become two phase Low temperature in the system Raise the system temperature or lower the system pressure until all of the water vaporizes If the low pressure switch is active this message indicates that the pressure reading has dropped below the programmed PRESSURE LIMIT System shutdown or a faulty pressure transmitter Bring the steam system back online or check and recalibrate the pressure transmitter If it is not required turn off the low pressure switch 2 4 Error Codes November 2004 E13 Over Range E14 Totals Overflow E15 Eqn Limit Problem Cause Action Problem Cause Action Problem Cause Action
13. how to troubleshoot the Model XGS868 if problems arise with the electronics enclosure the flowcell or the transducers Indications of a possible problem include display of an error message on the LCD display screen erratic flow readings readings of doubtful accuracy i e readings that are not consistent with readings from another flow measuring device connected to the same process If any of the above conditions occurs proceed with the instructions presented in this chapter The Model XGS868 has built in Diagnostic Parameters to aid in the troubleshooting of flowcell transducer and or electrical problems To access these parameters use the Instrument Data Manager IDM to establish communications with the XGS868 Then complete the following instructions to display the desired diagnostic parameter Use the following steps to set up the display Open the SITE EDIT MENU from the Edit Functions menu Select Global Select Input Output Select Display Select LCD Gn Uu W N e Use the pull down menu to select the desired number of parameters to be sequentially displayed and press Next Item Enter 7 Do one of the following e If you are using a 1 Channel meter proceed to Step 8 e If you are using a 2 Channel meter proceed to the next step 8 Use the pull down menu to select the desired channel option and press Next Item Enter 9 Use the pull down menu to select the desired diagnostic paramete
14. installation of the system meets the recommended specifications it is possible that the gas itself may be preventing accurate flow rate measurements The gas being measured must meet the following requirements 1 The gas must be homogeneous single phase and relatively clean Although a low level of entrained particles may have little effect on the operation of the Model XGS868 excessive amounts of solid or liquid particles will absorb or disperse the ultrasound signals This interference with the ultrasound transmissions through the gas will cause inaccurate flow rate measurements In addition temperature gradients in the gas flow may result in erratic or inaccurate flow rate readings 2 The gas must not excessively attenuate ultrasound signals Some gases i e high purity carbon dioxide hydrogen nitrogen etc readily absorb ultrasound energy In such a case an E1 error code message will appear on the display screen to indicate that the ultrasonic signal strength is insufficient for reliable measurements 3 The gas sound speed must not vary excessively The Model XGS868 will tolerate relatively large changes in the gas sound speed as may be caused by variations in gas composition and or temperature However such changes must occur slowly Rapid fluctuations in the gas sound speed to a value that is considerably different from that programmed into the XGS868 will result in erratic or inaccurate flow rate readings Refer to Chapte
15. m Connectors Connectors Mounting Hole Terminal Board gt Fuse Cover gt Fuse Connectors LY BOARD Fuse Cover Mounting Screw Mounting Screw W Connector I Mounting Screw Connector Main Board Connector Interconnect Board il Option Card Connector Interconnect N Connector Power Tab Connector Main Board Fast Response Board SIDE V EW wo Option LC D Cards H SIDE VIEW w Option LCD Cards LCD Display Board A gt Power Supply Board SIDE VIEW w O ption LCD Cards November 2004 Figure 4 1 Model XGS868 Electronics Console Assembly Parts Replacement 4 13 Appendix A Service Record Introduction Data Entry Diagnostic Parameters November 2003 EEE EE EEE Introduction Whenever any service procedure is performed on the Model XGS868 flow transmitter 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 Data Entry Record co
16. pry the EPROM up a little at a time at each notch until it comes free Caution The EPROM is easily damaged by static electricity Before handling the new chip touch a grounded metal object to discharge any built up static electricity and avoid touching the leads on the side of the chip 8 Make sure that the beveled corner on the new EPROM is aligned with the beveled corner of the socket and place the EPROM into the socket 9 By applying egual pressure on all four corners gently press the EPROM into the socket until it is fully seated Do not strike the EPROM or apply excessive force during this procedure Complete the User Program replacement by proceeding to Assembling the Circuit Board Assembly on page 4 9 An optional fast response board may be added to the XGS868 by mounting it on the rear of the power supply board To do so complete the following steps Note Presently the XGS868 software does not utilize the features added by the fast response board 1 Complete Steps 1 6 in Replacing the User Program on the previous page 2 Remove the three standoffs from the rear of the power supply board and save the three sets of screws and washers 3 Using the screws and washers from Step 2 mount the fast response board to the bottom of the power supply board with the three short standoffs Complete the Fast Response Board installation by proceeding to Assembling the Circuit Board Assembly on page 4 9 Parts Repla
17. these components and refer page 2 1 in the Programming Manual for instructions Complete the LCD display board replacement by proceeding to Installing the Circuit Board Assembly on page 4 11 4 4 Parts Replacement November 2004 Replacing the Fuse If it has been determined that the fuse in the XGS868 has been blown complete the following steps to install a new fuse 1 Complete the steps in Removing the Circuit Board Assembly on page 4 2 2 Place the circuit board assembly on its side with the terminal board on the left and the interconnect board on the right Rotate the assembly until the power supply board is facing upward 3 Locate the fuse along the left side of the power supply board just below the terminal board see the lower right SIDE VIEW and the POWER SUPPLY BOARD in Figure 4 1 on page 4 13 4 Pullthe plastic cover off the fuse holder and remove the old fuse 5 Obtain a new fuse ofthe same rating and type Use only atype 3AG 1 1 4 x 1 4 Slo Blo fuse having a rating as indicated in Table 4 1 below Table 4 1 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 100 130 VAC 0 25 A Slo Blo 200 240 VAC 0 25 A Slo Blo 12 28 VDC 2 0 A Slo Blo 6 Press the new fuse into the fuse holder and reinstall the plastic fuse cover To complete the fuse replacement proceed to Installing the Circuit Board Assembly on page 4 11 Note Be sure to record the fuse replacement in Ap
18. 4 MA NUMERIC cal to adjust the ammeter reading until a4 mA reading is achieved If you select 4 mA NUMERIC cal enter a milliamp value and press Next Item Enter Note fthe ammeter reading cannot be adjusted within 5 0 yA of the 4 mA setting contact the factory for assistance 3 Select 4 mA STORE or 4 MA ABORT 1 Select 20 milliamps to calibrate the high end of the output range 2 Select 20 mA UP 20 MA DOWN or 20 mA NUMERIC cal to adjust the ammeter reading until a 20 mA reading is achieved If you select 20 MA NUMERIC cal enter a milliamp value and press Next Item Enter Note Ifthe ammeter reading cannot be adjusted within 5 0 yA of the 20 mA setting contact the factory for assistance 3 Select 20 mA STORE or 20 mA ABORT Note Skip the next section if the linearity test will not be performed at this time Go to Procedure Options on the next page Calibration 1 3 November 2004 Testing the Analog Output Note If you exited this menu and are returning follow steps Linearity 1 through 4 in Accessing the Calibration Test Menu on page 1 3 Select Test Check the ammeter reading at 50 output Enter a different output 0 100 and press Next Item Enter E NU N KA Check the ammeter reading at this setting and press Next Item Enter when done Table 1 1 below lists the expected ammeter readings at various Full Scale settings for both 4 20 mA and 0 20 mA scales Refer to this table to verify
19. 8 Flare Gas Ultrasonic Flow Transmitter XGM868 Multi Purpose Gas Ultrasonic Flow Transmitter XGN868 Natural Gas Ultrasonic Flow Transmitter XGS868 Steam Mass Ultrasonic Flow Transmitter XMT868 Liquid Ultrasonic Flow Transmitter folgende Normen erf llen e EN 50014 1997 A1 A2 1999 e EN 50018 2000 e EN50281 1 1 1998 e 2 GD EExd IIC T5 ISSePO2ATEX008 ISSeP B7340 Colfontaine Belgium e EN 61326 1998 Class A Annex A Continuous Unmonitored Operation e EN61010 1 1993 A2 1995 Overvoltage Category II Pollution Degree 2 e EN 60529 1991 A1 2000 IP66 gem den Europ ischen Richtlinien Niederspannungsrichtlinie Nr 73 23 EG und EMV Richtlinie Nr 89 336 EG und ATEX Richtlinie Nr 94 9 EG Die oben aufgef hrten Ger te und zugeh rige mitgelieferte Schallwandler Messrohre werden in einer separaten Konformit tserkl rung behandelt tragen keine CE Kennzeichnung gem der Druckger te Richtlinie da sie in bereinstimmung mit Artikel 3 Absatz 3 gute Ingenieurpraxis der Druckger te Richtlinie 97 23 EG f r DN lt 25 geliefert werden Shannon July 1 2003 woes EM Mr James Gibson GENERALDIREKTOR NSAI LS ENISO9002 T V ESSEN Shannon ISO 9001 U S CERT DOC H4 August 2004 ATEX COMPLIANCE Sensing We GE Infrastructure Sensing Inc 1100 Technology Park Drive Billerica MA 01821 4111 U S A as the manufacturer declare under our sole responsibility that the product KGS868 Steam Mass Ultraso
20. CD display normally provides years of dependable service but it is easily field replaceable when necessary To replace the LCD display see Figure 4 1 on page 4 13 for the component locations and complete the following steps 1 Complete the steps in Removing the Circuit Board Assembly on page 4 2 2 Place the circuit board assembly on a flat surface with the LCD display board facing upward Refer to the FRONT VIEW upper right in Figure 4 1 on page 4 13 and remove the three mounting screws with flat washers and lock washers indicated 3 Grasp the LCD display board at the top and bottom edges and carefully pull it straight upward until it comes free from the interconnect board Note The two circuit boards are attached by a connector located beneath the top edge ofthe LCD display board see the top middle view in Figure 4 I on page 4 13 4 Place the new LCD display board directly over the interconnect board and align the electrical connector on the rear of the LCD display board with the P3 pins on the interconnect board Firmly push the two boards together until the LCD display board contacts the three standoffs on the interconnect board 5 Secure the LCD display board to the interconnect board with the three screws flat washers and lock washers previously removed Note The display contrast and backlight brightness are adjustable via two potentiometers located on the LCD display board See Figure 4 1 on page 4 13 to locate
21. Displaying 3 1 Contamination lA a 3 4 Display Physical Requirements 3 4 A NE s 4 4 Problems UU Ma 3 4 Replacing 4 4 Soundspeed 3 4 Display Screen Error Message 2 1 Illustration 2 1 Displaying Diagnostics 3 1 Index November 2004 Index cont L ECD Display ss segu ag aie ncaa i 4 4 Leaks Iransducers 3 6 Low Pressure Error E12 2 4 Low Signal Error E1 2 2 EVD Statement 4 1 M Menu Map Calibration 1 11 N NO Error EO uva cs ne 2 2 O Option Card Alarm Relay 1 8 Analog Inputs 1 5 Analog Outputs 1 2 Bracket ice vitae E 4 8 Expansion Slots 1 1 Frequency Outputs 1 10 Installing 4 8 RTD Inp ts u seen 1 7 Totalizer Outputs 1 9 Over Range Error E13 2 5 p Pipe Measurements 3 5 Problems di 3 5 Pressure Input Error E9 2 4 Printed Circuit Board EPROM oes ans rendue ee te 4 6 Problems Transducers 3 6 R Replacing See Part Name Return Policy 111 RTD Inputs Option Card Calibrating site iai ete 1 7 S
22. GE Infrastructure Sensing Model XGS868 Steam Ultrasonic Mass Flow Transmitter 1 amp 2 Channel Service Manual GE Infrastructure Sensing Model XGS868 Steam Ultrasonic Mass Flow Transmitter 1 2 Channel Service Manual 910 196SC November 2004 Model XGS868 is a GE Panametrics product GE Panametrics has joined other GE high technology sensing businesses under a new name GE Infrastructure Sensing November 2004 Warranty Return Policy Each instrument manufactured by GE Infrastructure Sensing Inc is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument at the sole discretion of GE Infrastructure Sensing Inc Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Infrastructure Sensing Inc determines that the eguipment was defective the warranty period is oneyearfor general electronic failures of the instrument oneyearfor mechanical failures of the sensor If GE Infrastructure Sensing Inc determines that the eguipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Infrastructure Sensing Inc the repairs are not covered under this warranty The warranties set
23. Replacement November 2004 Installing the Circuit Board Assembly Be sure that the circuit board assembly is completely assembled as described in the previous section Then refer to Figure 4 1 on page 4 13 and install the circuit board assembly into the electronics enclosure as follows 1 Slide the terminal board end of the circuit board assembly into the front of the electronics enclosure By aligning the slots around the circumference of the terminal board with the bosses inside the enclosure guide the circuit board assembly into the enclosure until the terminal board just clears the bosses at the rear of the enclosure 2 From the rear of the enclosure rotate the circuit board assembly about 20 clockwise so that the mounting holes in the terminal board are positioned over the tapped holes in the bosses Secure the circuit board assembly to the enclosure with the four mounting screws flat washers and lock washers previously removed IMPORTANT If the circuit board assembly is inserted too far into the enclosure it cannot be rotated properly 3 Attach the loose end of the grounding jumper to the enclosure with the mounting screw flat washer and lock washer previously removed Be sure to install the metal label plate under this screw 4 From the rear of the enclosure connect the power line leads to terminal block TB5 Plug the connectors back into terminal blocks J1 J4 If necessary see Chapter 1 Installation of the
24. c Flow Transmitter XMT868 Liquid Ultrasonic Flow Transmitter r latif cette declaration sont en conformit avec les documents suivants e EN 50014 1997 A1 A2 1999 e EN 50018 2000 e EN50281 1 1 1998 e 2 GD EExd IIC T5 ISSePO2ATEX008 ISSeP B7340 Colfontaine Belgium e EN 61326 1998 Class A Annex A Continuous Unmonitored Operation e EN61010 1 1993 A2 1995 Overvoltage Category II Pollution Degree 2 e EN 60529 1991 A1 2000 IP66 suivant les r gles de la Directive de Compatibilit Electromagn tique 89 336 EEC d ATEX 94 9 EC et de la Directive Basse Tension 73 23 EEC Les materiels list s ci dessus ainsi que les transducteurs pouvant tre livres avec les manchettes faisant l objet d une declaration de conformit s par e ne portent pas le marguage CE de la directive des eguipements sous pression car ils sont fournis en accord avec la directive 97 23 EC des quipements sous pression pour les DN lt 25 Article 3 section 3 qui concerne les pratiques et les codes de bonne fabrication pour l ing nierie du son Shannon July 1 2003 whee yoo Mr James Gibson DIRECTEUR GENERAL NSAI LS ENISO9002 T V ESSEN Shannon ISO 9001 U S CERT DOC H4 August 2004 Sensing KONFORMIT TS ERKL RUNG Wir Panametrics Limited Shannon Industrial Estate Shannon County Clare Ireland erkl ren in alleiniger Verantwortung da die Produkte IGM878 Industrial Gas Ultrasonic Flow Transmitter XGF86
25. cement 4 7 November 2004 zz o A Installing an Option Card The Model XGS868 flowmeter can accommodate up to two option cards A data logging or RS485 card may be installed in Slot 2 and a variety of 1 O option cards are available for installation in Slot 1 To install an option card refer to the SIDE VIEW in Figure 4 1 on page 4 13 and complete the following steps 1 Complete the steps in the Removing the Circuit Board Assembly on page 4 2 2 Remove the main board power supply board terminal board sub assembly by completing Steps 1 6 in Replacing the User Program on page 4 6 3 There is a 36 pin connector P2 and a 30 pin connector P1 on the rear of the interconnect board The option cards must be plugged into these connectors a To install a data logging or RS485 option card into Slot 2 orient the option card so that its 36 pin connector is positioned over connector P2 on the interconnect board Then firmly seat the card into its connector When properly installed the side of the option card with the 36 pin connector must face the center of the interconnect board and the edge of the option card must not overhang the edge of the interconnect board b To install an V O option card into Slot 1 orient the option card so that its 30 pin connector is positioned over connector P1 on the interconnect board Then firmly seat the card into its connector When properly installed the side of the option card with the 30 pin co
26. d de dd ta 1 10 Chapter 2 Error Codes A ee ee u ee 2 1 EOS NO EFFOF E er de a AAA AAE 2 2 EI LOW SIGN a ES a er ES 2 2 Bui IA a De A a E RE ee est 2 2 ES VEIOCIU RANGE carrer Aids eo 2 2 ESO ee ee NN 2 3 ESSAMPIEUGEEFOR AE al da 2 3 EG COS SKID a AA se ee ab 2 3 EKA la leo OIKENI ON omaa AA a re a Eee 2 3 ES TEMP A Renee a Re rd e A e pei KUA baa 2 4 EN PIESS Nase ee a da Lee ee 2 4 ELO Specials esca toto ee eigens 2 4 SAN O AAA A A ne IN 2 4 E12 OW PEU mami A Re Ene 2 4 ETS OVER RONDES do ito ds 2 5 E AS AAA A O 2 5 EA o Nee te e ee e Teamin kea 2 5 November 2004 EEE Table of Contents cont Chapter 3 Diagnostics Introduction er AN 3 1 Displaying Diagnostic Parameters aus ast e net a del al de tid 3 1 Eloweell Problems ms animes reliant Re E oe ee Md OG eee See 3 4 Gas Problems nanu nunane wanan 3 4 Pipe Problems username RS a A ba ma 3 5 Transdueer Problems zu sapata n es mots hic Lits Miks ESTE TR 3 6 Chapter 4 Parts Replacement IRKLOAUEHON e nn SAT Asta tei A 4 1 Removing the Credit Board Assembly Aare Elis idas 4 2 Replacing The HED Dispo a ee ein 4 4 Replacing the US seele 4 5 Replacing the User da fie ni 4 6 Installing a Fast Response Board erp a ee ls De et ca hs sd be 4 7 ASIAN GAMA PU Card ci kuta Tre nt sin E 4 8 Installing a PCMCIA Memory Card ac aaa 4 9 Assembling Installing the Circuit Board Assembly 4 9 Assembling the Circuit Board Assemb
27. ed to the appropriate section To leave the User Program press EXIT PAGE three times Calibration 1 7 November 2004 Testing the Alarm Relays Preparing for Testing Testing the Relay Procedure Options Alarm relays may be added to the Model XGS868 by installing an appropriate option card in Slot 1 This option card contains two or four alarm relays which are designated A B C and D Prepare for the testing procedure by connecting an ohmmeter to the NO and COM pins of the desired alarm on the option card See Figure 1 3 on page 1 12 to identify the NO NC and COM pins for the desired alarm on terminal block J2 1 Open the Calibration Test from the Edit Functions menu 2 Select Calibration 3 Select Slot 1 Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 4 Select the desired output IMPORTANT The procedure for testing all the alarms is the same However when testing a different output be sure to reconnect the ohmmeter at terminal block J2 See Figure 1 3 on page 1 12 for the correct pin numbers 5 Do one of the following Select Close Alarm The ohmmeter should yield a reading of about zero e Select Open Alarm The ohmmeter should yield an infinite reading Note To test the NC relay position move the ohmmeter lead from the NO pin to the NC pin and repeat the above test In this case the ohmmeter readings will be infinite when Close Alarm
28. for the upstream transducer 400 to 400 DN Signal Q Displays the signal quality for the downstream transducer 400 to 400 UP Amp Discrim Displays the value for the signal amplitude of the upstream transducer lt 19 or gt 29 DN Amp Discrim Displays the value for the signal amplitude of the downstream transducer lt 19 or gt 29 UP Peak Displays signal peaks for the upstream transducer 100 2300 lt 100 or gt 2300 DN Peak Displays signal peaks for the downstream transducer 100 2300 lt 100 or gt 2300 UP DAC COUNTS DN DAC COUNTS Displays the AGC DAC count for the upstream gain setting Displays the AGC DAC count for the downstream gain setting N A N A 3 2 Diagnostics November 2004 Option Bar Table 3 1 Available Diagnostic Parameters Continued Description Temperature Displays the gas temperature from 0 4 20 mA input Pressure Displays the gas pressure from 0 4 20 mA input Compress Displays the compressibility factor Act Vol Displays actual volumetric flow Std Vol Displays standard volumetric flow UP Transit S Displays Skan transit time upstream DN Transit S Displays Skan transit time downstream DeltaT s Displays Skan Delta T UP Transit M Displays Measure transit time upstream DN Transit M Displays Measure transit time downst
29. forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties of merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade If a GE Infrastructure Sensing Inc instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Infrastructure Sensing Inc giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory service GE Infrastructure Sensing Inc will issue a RETURN AUTHORIZATION number RA and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Infrastructure Sensing Inc 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 3 Upon receipt GE Infrastructure Sensing Inc will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken e If the damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e f GE Infrastructure Sensing Inc determines that the damage is not covered under the terms of the warranty or if the warranty has expired an estimate for the cost of the re
30. gure 1 2 Calibration 1 11 November 2004 SUO 29UUOD 0 I p409 UONdO T aunbiy 1 12 Calibration Chapter 2 Error Codes Introduction sauer A 2 1 EO NO EOR SN ues nr ne nn 2 2 ETS EOWSTOnaAl uses vasaa Vaasa N Taa Dana aa 2 2 E2 Sound Speed sis a neun 2 2 E3 Velocity RANJE su ern 2 2 EA Signal Quality sus ae ee ee 2 3 ES Amplitude Error uta 2 3 E6 Cycle Skip Accel u es matin 2 3 E7 Analog OUT Error a0 an 2 3 ESTONIA AAA AAA ee MA 2 4 E9 Press I it E AAA da 2 4 E10 Special Opt cion sure ran 2 4 E11 Super Saturated rra sos rr a u 2 4 E12 LOW Pressure 2 rer are 2 4 E13 Over Range eines A AAA A 2 5 E14 Totals Overflow 2 5 EISEAN RT sax sy u EBERLE 2 5 November 2004 Introduction The Model XGS868 ultrasonic flow transmitter 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 However if a problem should arise with the electronics enclosure the transducers or the flowcell a built in error code message system greatly simplifies the troubleshooting process All of the possible Model XGS868 error code messages are discussed in this chapter along with the possible causes and the recommended actions When an error code is generated it will appear on the LCD as shown in Figure 2 1 below
31. h this declaration relates are in conformity with the following standards e EN 50014 1997 A1 A2 1999 e EN 50018 2000 e EN50281 1 1 1998 e 2 GD EExd IIC T5 ISSePO2ATEX008 ISSeP B7340 Colfontaine Belgium e EN 61326 1998 Class A Annex A Continuous Unmonitored Operation e EN61010 1 1993 A2 1995 Overvoltage Category II Pollution Degree 2 e EN 60529 1991 A1 2000 IP66 following the provisions of the 89 336 EEC EMC Directive the 94 9 EC ATEX Directive and the 73 23 EEC Low Voltage Directive The units listed above and any transducers supplied with them spoolpieces are addressed under a separate declaration of conformity do not bear CE marking for the Pressure Eguipment Directive as they are supplied in accordance with Article 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Eguipment Directive 97 23 EC for DN lt 25 Shannon July 1 2003 As LES Mr James Gibson GENERAL MANAGER NSAI LS ENISO9002 T V ESSEN Shannon ISO 9001 U S CERT DOC H4 August 2004 DECLARATION Sensing DE CONFORMITE Nous Panametrics Limited Shannon Industrial Estate Shannon County Clare Ireland d clarons sous notre propre responsabilit que les IGM878 Industrial Gas Ultrasonic Flow Transmitter XGF868 Flare Gas Ultrasonic Flow Transmitter XGM868 Multi Purpose Gas Ultrasonic Flow Transmitter XGN868 Natural Gas Ultrasonic Flow Transmitter XGS868 Steam Mass Ultrasoni
32. he desired input A B C or D on the option card See Figure 1 3 on page 1 12 to identify the RTD and COMI pins for the desired input on terminal block J2 1 Open the Calibration Test from the Edit Functions menu 2 Select Calibration 3 Select Slot 1 Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 4 Select the desired input IMPORTANT The procedure for calibrating all the inputs is the same However when calibrating a different input be sure to reconnect the current source at terminal block J2 See Figure 1 3 on page 1 12 for the correct pin numbers 1 Before proceeding place the RTD in a temperature bath and allow it to stabilize at the desired set point temperature 2 Select RTD Set Point to program the RTD set point 3 Enter the desired set point temperature and press Next Item Enter 4 Press Store to accept the new set point value or Abort to cancel the entry 1 Select RTD Slope Point to program the RTD slope point 2 Enter the desired slope point temperature and press Next Item Enter 3 Press Store to accept the new slope point value or Abort to cancel the entry This completes calibration of the Slot 1 RTD input Do one of the following e To calibrate or test another input press Next Item Enter and return to Step 4 in Accessing the Calibration Test Menu above To calibrate test additional inputs outputs press Next Item Enter and proce
33. in the Programming Manual To program the meter with PanaView see Appendix D PanaView for IDM Compatible Meters in the Programming Manual and or the PanaView User s Manual 910 211 e calibrating the Slot O and Slot 1 analog outputs page 1 2 calibrating option card analog inputs page 1 5 calibrating option card RTD inputs page 1 7 testing option card alarm relays page 1 8 testing option card totalizer outputs page 1 9 testing option card freguency outputs page 1 10 Note Convention in this manual identifies any expansion slot as Slot x where X is a number from 0 2 Slot 2 is used only for data logging or Modbus option cards See Chapter 1 Installation and Appendix B Data Records in the Startup Guide for a complete description of the available option cards and the procedures for wiring them Calibration 1 1 November 2004 Calibrating and Testing the Analog Outputs Preparing for Calibration Every Model XGS868 flowmeter includes two built in analog outputs A and B at terminal block J1 which is designated as Slot 0 Additional analog outputs may be added to the Model XGS868 by installing an appropriate option card in Slot 1 This option card contains two analog outputs which are also designated as A and B Before beginning calibration an ammeter must be connected to the desired analog output Both the zero point and full scale values for all of these outputs must be calibrated Afte
34. ing 2 Loosen the set screw on the rear cover Place a rod or long screwdriver across the cover in the slots provided and rotate the cover counterclockwise until it comes free from the enclosure 3 Repeat Step 2 to remove the front cover 4 2 Parts Replacement November 2004 Removing the Circuit Board Assembly cont 4 From the rear of the enclosure disconnect the power line leads from terminal block TB5 Unplug the connectors from terminal blocks J1 J4 Refer to the REAR VIEW upper left in Figure 4 1 on page 4 13 and remove the five terminal board mounting screws This will disconnect one end of the green grounding jumper and the label plate with the ground symbol will come loose from beneath it IMPORTANT Each screw will have a flat washer and a lock washer over it Be careful not to lose these washers Carefully rotate the circuit board assembly counterclockwise about 20 until the five bosses in the enclosure are visible through the slots along the circumference of the terminal board Then slowly push the circuit board assembly through the enclosure and remove it from the front of the enclosure Bring the circuit board assembly to a clean safe work area and proceed to the appropriate section of this chapter to perform the desired service procedure Parts Replacement 4 3 November 2004 Replacing the LCD Display An optional LCD display may be included with the Model XGS868 The L
35. ircuit board assembly has been disassembled to any degree complete the steps below Otherwise proceed directly to Installing the Circuit Board Assembly on page 4 11 See Figure 4 1 on page 4 13 and complete the following steps 1 Face the User Program side of the main board toward the rear of the power supply board Orient the boards so that the pins along the bottom of the main board align with connectors J2 and J6 on the power supply board and push the two boards firmly together Note Jf the optional fast response board is mounted on the power supply board there are three connectors on the fast response board that must also engage connectors on the main board 2 Secure the power supply board to the main board by installing the single screw flat washer and lock washer previously removed from the lower left corner of the power supply board 3 Place the terminal board on a flat surface with the back side facing upward Plug the main board power supply board sub assembly onto the terminal board so that the large three pin connector plugs onto the power tab on the top edge of the power supply board and the four smaller connectors engage the pins on the upper edge of the main board Parts Replacement 4 9 November 2004 Assembling the Circuit Board Assembly cont IMPORTANT The small angle bracket on the terminal board must be positioned on the outside of the main board with the previously removed nylon washer between the
36. is selected and zero when Open Alarm is selected This completes testing of the Slot 1 alarm relays Do one of the following e To test the normally open and normally closed contacts for another alarm relays return to Step 4 in Testing the Relay above e To calibrate test additional inputs outputs proceed to the appropriate section To leave the User Program press EXIT PAGE twice 1 8 Calibration November 2004 Testing the Totalizer Outputs Preparing for Testing Testing the Output Procedure Options Totalizer outputs may be added to the Model XGS868 by installing an appropriate option card in Slot 1 This option card contains two or four totalizer outputs which are designated A B C and D Prepare for the testing procedure by connecting a freguency counter to the desired output of the option card See Figure 1 3 on page 1 12 to identify the OUT and RTNI pins for Output A on terminal block J2 1 Open the Calibration Test from the Edit Functions menu 2 Select Calibration 3 Select Slot 1 Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 4 Select the desired output IMPORTANT The procedure for testing all the outputs is the same However when testing another output be sure to reconnect the frequency counter at terminal block J2 See Figure 1 3 on page 1 12 for the correct pin numbers 5 Enter a value for the minimum pulse on time bet
37. lock J2 1 Open the Calibration Test from the Edit Functions menu 2 Select Calibration 3 Select Slot 1 Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 4 Select the desired output IMPORTANT The procedure for testing all the outputs is the same However when testing another output be sure to reconnect the frequency counter at terminal block J2 See Figure 1 3 on page 1 12 for the correct pin numbers 5 Enter a frequency between 1 and 10 000 Hz and press Next Item Enter 6 Verify that the freguency counter reads the correct value This completes testing of the Slot 1 freguency outputs Do one of the following e To test another of the available frequency outputs return to Step 4 in Testing the Output above If any of the frequency outputs fails the test contact the factory for assistance To calibrate test additional inputs outputs proceed to the appropriate section To leave the User Program press EXIT PAGE twice Calibration November 2004 IDM Main Menu Meter Window Menu Global Data Help Connect to a New Instrument Select an Existing Instrument 4 Scan Network for Instruments Preferences Dial Modem Hang Up Modem Exit Upload Download Edit Functions Real Time SITE EDIT MENU CALIBRATION TEST PAUSE MEASUREMENT LOG EDIT MENU FILE MENU
38. ly u as assa ee ee 4 9 Installing the Circuit Board Assembler 4 11 Appendix A Service Record MELDE e o ae A 1 Data Ets at a A ads A 1 Diagnostic Parameters ii A cach rein anr A 3 vi Chapter 1 Calibration Introduction aus een 1 1 Calibrating and Testing the Analog Outputs 1 2 Calibrating the Analog Inputs 1 5 Calibrating the RTD Inputs 1 7 Testing the Alarm Relays 1 8 Testing the Totalizer Outputs 1 9 Testing the Frequency Outputs 1 10 November 2004 Introduction The Model XGS868 electronics enclosure includes one slot for installation of an input output option card This slot is designated as Slot 1 and a variety of option cards is available In addition every Model XGS868 flowmeter includes two built in analog outputs A and B at terminal block J1 which is designated as Slot 0 Proceed to the appropriate section s of this chapter to calibrate and or test any of the installed inputs and or outputs Refer to the Menu Map in Figure 1 2 on page 1 11 as a guide in following the calibration instructions in this chapter Note The instructions in this chapter assume the use of IDM for programming the meter To program the meter with the optional RCCU refer to Appendix C Remote Control Communications Unit
39. m Secure the sub assembly together by installing the three mounting screws flat washers and lock washers previously removed from the main board The longer screw should be used at the angle bracket location Place the interconnect board LCD display board sub assembly on a flat surface with the three long standoffs facing upward Make sure that any required option cards are plugged into the rear of the interconnect board as described in Installing an Option Card on page 4 8 Carefully align the pins along the bottom of the main board with the connector on the back of the interconnect board and the pins on the top edge of any installed option cards with the connectors on the back of the terminal board Firmly press the terminal board and the interconnect board toward each other until all of the connectors are completely seated IMPORTANT With two option cards installed it may require some patience to get all of the connectors properly aligned Do not force the assembly together or some of the pins may not enter the sockets properly Secure the assembly together by installing the three PCB screws flat washers and lock washers previously removed from the terminal board Be sure to install one end of the grounding jumper under the screw indicated in Figure 4 1 on page 4 13 Proceed to the next section for instructions on installing the reassembled circuit board assembly in the electronics enclosure 4 10 Parts
40. mplete and detailed service data for the Model XGS868 in Table A 1 below Make additional copies of the table as needed Table A 1 Service Record Description of Service Performed By Service Record A 1 November 2003 RES TG Tea Table A 1 Service Record cont Description of Service Performed By A 2 Service Record November 2003 A gt en rel Diagnostic Parameters After a successful initial installation of the Model XGS868 and whenever any system malfunction is noticed the values for the diagnostic parameters should be entered in Table A 2 below Table A 2 Diagnostic Parameters Parameter Initial Current Parameter Initial Current UP Sig Strength Pressure DN Sig Strength Compress Soundspeed Act Vol UP Transit Std Vol DN Transit UP Transit S DeltaT DN Transit s Multi K Factor DeltaT s PEAK UP Transit M UP Signal O DN Transit M DN Signal Q DeltaT M UP Amp Discrim Vinst DN Amp Discrim T Saturat UP DAC COUNTS T Superht DN DAC COUNTS Fluid Dens UP Peak T Kelvin DN Peak kiloPascal Temperature Steam Quality 1 available only if Multi K factors ON available only if Burst Mode S M Service Record A 3 November 2004 Index A E Acceleration Error E6 2 3 EPROM Alarm Option Card Replacing 4 44 esse heure 4 6 TESTIIN D rn nee 1 8 User Program
41. nic Flow Transmitter to which this document relates in accordance with the provisions of ATEX Directive 94 9 EC Annex II meets the following specifications C ex Il 2 GD EEx d IIC T5 20 C to 65 C 1180 ISSePO2ATEX008 T95 C IP66 Furthermore the following additional requirements and specifications apply to the product e Having been designed in accordance with EN 50014 EN 50018 and EN 50281 the product meets the fault tolerance requirements of electrical apparatus for category d e The product is an electrical apparatus and must be installed in the hazardous area in accordance with the requirements of the EC Type Examination Certificate The installation must be carried out in accordance with all appropriate international national and local standard codes and practices and site regulations for flameproof apparatus and in accordance with the instructions contained in the manual Access to the circuitry must not be made during operation Only trained competent personnel may install operate and maintain the equipment e The product has been designed so that the protection afforded will not be reduced due to the effects of corrosion of materials electrical conductivity impact strength aging resistance or the effects of temperature variations s The product cannot be repaired by the user it must be replaced by an equivalent certified product Repairs should only be carried out by the manufacturer or by an approved repaire
42. nnector must face away from the center of the interconnect board and the edge of the option card must not overhang the edge of the interconnect board Complete the option card installation by proceeding to Assembling the Circuit Board Assembly on the next page 4 8 Parts Replacement November 2004 Installing a PCMCIA Memory Card Assembling Installing the Circuit Board Assembly Assembling the Circuit Board Assembly If the XGS868 is equipped with a data logging option card in Slot 2 additional memory expansion may be achieved by installing an industry standard PCMCIA memory card To do so complete the following steps 1 Refer to Figure 4 1 on page 4 13 to locate the slot for the PCMCIA card next to terminal block J2 on the terminal board 2 Install the PCMCIA card through the slot in the terminal board and into the connector located on the rear of the data logging option card in Slot 2 Complete the option card installation by proceeding to Step 5 in Installing the Circuit Board Assembly on page 4 11 Most of the parts replacement procedures described in this chapter require removal of the circuit board assembly from the electronics enclosure Furthermore most of the procedures require varying degrees of disassembly of the circuit board assembly See Figure 4 1 on page 4 13 and follow the instructions in this section to assemble the circuit board assembly and or to install 1t in the electronics enclosure If the c
43. nts while completing the service procedures discussed in this chapter IMPORTANT Keep a detailed record of all parts installations and replacements performed on the XGS868 in the Appendix A Service Record This service history may prove very helpful in diagnosing any future problems Parts Replacement 4 1 November 2004 Removing the Circuit Board Assembly All parts replacement procedures for the Model XGS868 require the removal of the circuit board assembly from the electronics enclosure Therefore complete the instructions in this section before attempting any other service tasks The Model XGS868 circuit board assembly consists of circular front and rear circuit boards with several rectangular circuit boards sandwiched between the circular end boards and oriented perpendicular to them Specifically some or all of the following circuit boards may be included in the assembly FRONT BOARDS LCD Display Board optional e Interconnect Board REAR BOARD Terminal Board MIDDLE BOARDS Main Board e Power Supply Board e Fast Response Board optional e Slot 1 Input Output Card optional Slot 2 Logging RS485 Card optional To disassemble the circuit board assembly refer to Figure 4 1 on page 4 13 and complete the following steps 1 Disconnect the power to the XGS868 and move the electronics enclosure to a safe area IWARNING The main power to the Model XGS868 must be disconnected before proceed
44. pairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned lii November 2004 E m ee Table of Contents Chapter 1 Calibration INES SCHON ee ae E or ee 1 1 Calibrating and Testing the Analog OUtpUtS 1 2 Preparing TORE ANDI Mss a rs e pela 1 2 Accessing the Calibration Test Menu 1 3 Calibrating the Low End ofthe Output Ronge rr aa 1 3 Calibrating the High End of the OutputRange 1 3 Testing the Analog Output Linearity 1 4 Calpratina the Anal gili AA o sia is De 1 5 Preparo ION AND Nee 1 5 Accessing the Calibration Test Menu ccc nee erkennen 1 5 Calibrating er ee A 1 6 Calibrating to 20 MA seen asiatischen 1 6 Calibrating the BREDIRBUS ee ee aaah 1 7 Preparing for Calibration 1 7 Accessing the Calibration Test MEN ao A A A 1 7 BANANA AA 1 7 A A AH ee T 1 7 Testing the Alarm Relais ea ads ee see AA 1 8 PEPO NAGU ee ee ee ae 1 8 Testing the Bela nn fa a ee ee ee el 1 8 Testing the Totalizer Outputs ss a datan ansehe 1 9 Pre peniano Testing esse er ne E aa er IA 1 9 Testing the Qutp t RS ue a ot RE 1 9 TeSting the Frequene O Bans nern 1 10 Preparing TOR TS SIRO apassit avas ts OO 1 10 Testing atm das la res lee A
45. pendix A Service Record Parts Replacement 4 5 November 2004 Replacing the User Program The Model XGS868 s User Program is stored on an erasable programmable read only memory EPROM chip The EPROM which is designated as component U6 is mounted in a socket on the front of the main circuit board EPROM replacement may be required to replace a defective chip or to upgrade to a newer software version To replace the User Program refer to Figure 4 1 on page 4 13 and complete the following steps 1 Complete the steps in Removing the Circuit Board Assembly on page 422 2 Place the circuit board assembly on a flat surface with the terminal board facing upward Refer to the REAR VIEW upper left in Figure 4 1 on page 4 13 and remove the three PCB screws with flat washers and lock washers indicated This will also remove the green grounding jumper 3 The main board is attached to the interconnect board by a large connector Grasp the edges of the interconnect board with one hand and the edges of the main board with the other hand Then with a slight rocking motion carefully pull the main board straight up until it comes free The main board power supply board and terminal board will remain attached to each other IMPORTANT Do not pull on the terminal board to extract the main board from the assembly 4 See the SIDE VIEW lower left in Figure 4 1 on page 4 13 and remove the three mounting screws with flat washer
46. r e The product must not be subjected to mechanical or thermal stresses in excess of those permitted in the certification documentation and the instruction manual e The product contains no exposed parts which produce surface temperature infrared electromagnetic ionizing or non electrical dangers CE amp CERT ATEX D Rev August 2004 USA 1100 Technology Park Drive Billerica MA 01821 4111 Web www gesensing com Ireland Shannon Industrial Estate Shannon County Clare Ireland
47. r and press Next Item Enter Table 3 1 on the next page lists the available diagnostic parameters for the Model XGS868 Diagnostics 3 1 November 2004 Displaying Diagnostic Parameters cont Option Bar UP Sig Strength have been set up 10 Repeat Steps 8 and 9 until all of the specified OF LCD PARAMS Press Exit Page three times to leave the User Program the XGS868 will reset itself and will begin to display the parameters specified in this section If more than one parameter was set up each of the parameters will be displayed in sequence with a pause of several seconds between display changes Table 3 1 Available Diagnostic Parameters Description Displays the signal strength for the upstream transducer lt 50 or gt 75 DN Sig Strength Displays the signal strength for the downstream transducer lt 50 or gt 75 Soundspeed Displays the measured speed of sound in the gas N A UP Transit Displays the upstream ultrasonic signal transit time N A DN Transit Displays the downstream ultrasonic signal transit time N A DeltaT Displays transit time difference between the upstream and downstream signals gt 1 usec Multi K Factor Displays the K Factor interpolated from the table for the current velocity lt lor gt 20 PEAK Displays the percentage of peak set to 50 by default N A UP Signal Q Displays the signal quality
48. r 2 Initial Setup of the Startup Guide and make sure that the appropriate sound speed is programmed into the meter 3 4 Diagnostics November 2004 Pipe Problems Pipe related problems may result either from a failure to observe the installation instructions as described in the Startup Guide or from improper programming of the meter By far the most common pipe problems are the following 1 The collection of material at the transducer location s Accumulated debris at the transducer location s will interfere with transmission of the ultrasound signals As a result accurate flow rate measurements are not possible Realignment of the flowcell or transducers often cures such problems and in some cases transducers that protrude into the flow stream may be used Refer to Chapter 1 Installation of the Startup Guide for more details on proper installation practices 2 Inaccurate pipe measurements The accuracy of the flow rate measurements is no better than the accuracy of the programmed pipe dimensions For a flowcell supplied by GE Infrastructure Sensing 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 Also check the pipe for dents eccentricity weld deformity straightness and other factors that may cause inaccurate readings Refer to Chapter 2 Initial Setup of the Startup Guide for instruction
49. r calibrating the outputs which have a resolution of 5 0 uA 0 03 full scale their linearity should be tested Note The zero point of the analog output may be set at either O mA or 4 mA However the calibration always uses the 4 mA point as the meter extrapolates this value to obtain the 0 mA point Prepare for calibration by inserting an ammeter in series with the load on the desired output DO NOT connect the ammeter directly across the terminals Refer to Figure 1 1 below and Figure 1 3 on page 1 12 to identify the OUT and RTN pins for the desired output Terminal Block J1 Slot 0 B B A A RTN SIG RTN SIG Loa d Ammeter Figure 1 1 Ammeter Connection Output A 1 2 Calibration November 2004 Accessing the Calibration 1 Open Calibration Test from the Edit Functions menu Test Menu Calibrating the Low End of the Output Range Calibrating the High End of the Output Range 2 Select Calibration 3 Select Slot O or Slot 1 Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 4 Select the desired output IMPORTANT The procedure for calibrating all the outputs is the same However when calibrating a different output be sure to reconnect the ammeter at terminal block J1 See Figure 1 1 on the previous page for the correct pin numbers H Select 4 milliamps to calibrate the low end of the output range 2 Select 4 MA UP 4 mA DOWN or
50. ream DeltaT M Vinst Displays Measure Delta T Displays the instantaneous velocity T Saturat Displays the saturation temperature for steam at the current pressure T Superht Displays actual temperature minus the saturation temperature Tactual Tsat Fluid Dens Displays fluid density N A T Kelvin Displays the current process temperature in K N A kiloPascals Displays the current process pressure in kPa N A Steam Quality Displays the steam quality from a live input or a static programmed value 1 available only if Multi K factors ON available only if Burst Mode S M lt 0 0 or gt 1 0 Diagnostics 3 3 November 2004 EEE Flowcell Problems If preliminary troubleshooting with the Error Code Messages and or the Diagnostic Parameters indicates a possible flowcell problem proceed with this section Flowcell problems fall into two categories gas problems pipe problems Read the following sections carefully to determine if the problem is indeed related to the flowcell If the instructions in this section fail to resolve the problem contact the factory for assistance Gas Problems Most gas related problems result from a failure to observe the flowmeter system installation instructions as described in the Startup Guide Refer to Chapter 1 Installation of the Startup Guide to correct any installation problems If the physical
51. s and lock washers from the main board Then carefully pull the terminal board away from the main board power supply board assembly Note Do not lose the nylon washer located between the small angle bracket on the terminal board and the main board 5 Turn the assembly over and remove the single mounting screw flat washer and lock washer in the lower left corner of the power supply board see POWER SUPPLY BOARD in Figure 4 1 on page 4 13 6 Grasp the edges the main board with one hand and the edges of the power supply board with the other hand Then with a slight rocking motion carefully pull the two boards apart The main board and power supply board are attached along the bottom edge by two connectors In addition if an optional fast response board is mounted on the power supply board it will be attached to the main board by three smaller connectors 4 6 Parts Replacement November 2004 Replacing the User Program cont Installing a Fast Response Board The U6 EPROM is located along the upper edge of the main board on the side that was facing the power supply board see the MAIN BOARD FRONT view in Figure 4 1 on page 4 13 It is the only socketed chip on this board and it has a white identification label 7 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 the upper right and lower left corners of the socket Gently
52. s on programming the pipe data In addition to the actual pipe dimensions the path length P and the axial dimension L based on the actual transducer mounting locations must be accurately programmed into the flowmeter For a GE Infrastructure Sensing flowcell this data will be included with the documentation for the system If the transducers are mounted onto an existing pipe these dimensions must be precisely measured See Appendix C Measuring P and L Dimensions of the Startup Guide for a thorough discussion of this topic Diagnostics 3 5 November 2004 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 1 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 CORROSION DAMAGE If the transducer material was not properly chosen for the intended application the transducers may suffer corrosion damage The damage usually occurs either at the electrical connector or on the transducer face If corrosion is suspected remove the transducer from the flowcell and carefully inspect the electrical connector and the transducer face for roughness and or pitting Any transducer damaged in this manner
53. the Slot O analog outputs may be used for the calibration During the analog input calibration the Slot O analog output will supply the low reference high reference 4 mA and 20 mA signals at the appropriate times IMPORTANT fa Slot O analog output will be used to calibrate the analog inputs the Slot O analog output calibration procedure must be completed first Prepare for the calibration procedure by connecting a Slot O analog output or an independent calibrated current source to the desired input on the option card See Figure 1 3 on page 1 12 to identify the IN and RTN pins for the desired input on terminal block J2 Note The zero point of the analog input may be set for either O mA or 4 mA However the calibration always uses the 4 mA point as the meter extrapolates this value to obtain the 0 mA point 1 Open the Calibration Test from the Edit Functions menu 2 Select Calibration 3 Select Slot 1 Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 4 Select the desired input IMPORTANT The procedure for calibrating all the inputs is the same However when calibrating a different input be sure to reconnect the current source at terminal block J2 See Figure 1 3 on page 1 12 for the correct pin numbers 5 Do one of the following e Proceed to Calibrating to 4 mA on the next page S Proceed to Calibrating to 20 mA on the next page Calibration 1 5
54. the accuracy of the ammeter readings taken above Table 1 1 Expected Ammeter Readings Full Scale 4 20 mA Scale 0 20 mA Scale all ammeter readings should be 0 005 mA If the linearity test readings are not within 5 UA of the values listed in Table 1 1 above check the accuracy and wiring of the ammeter Then repeat the low and high end calibrations If the analog output still does not pass the linearity test contact the factory for assistance Procedure Options This completes calibration of the analog output Do one of the following e To calibrate or test another output press Next Item Enter and return to Step 4 in Accessing the Calibration Test Menu on the previous page To calibrate test additional inputs outputs press Next Item Enter and proceed to the appropriate section To leave the User Program press EXIT PAGE three times 1 4 Calibration November 2004 Calibrating the Analog Inputs Preparing for Calibration Accessing the Calibration Test Menu Analog inputs may be added to the Model XGS868 by installing an appropriate option card in Slot 1 This option card contains two or four analog inputs which are designated as A B C and D Both the zero point and full scale values for each input must be calibrated Calibration of the analog inputs reguires the use of a calibrated current source If an independent calibrated current source is not available one of
55. ween 1 usec and 10 000 usec for the frequency of the totalizer pulses and press Next Item Enter Note A complete pulse consists of equal amounts of ON and OFF times Choose a value that is compatible with the frequency counter to be used 6 Verify that the frequency counter reads the correct value 7 Enter a value for the number of measurement units represented by each pulse between 1 and 10 000 and press Next Item Enter That number of pulses will then be output at the specified frequency This completes testing of the Slot 1 totalizer outputs Do one of the following e To test another of the available totalizer outputs return to Step 4 in Testing the Output above If any of the totalizer outputs fails the test contact the factory for assistance To calibrate test additional inputs outputs proceed to the appropriate section To leave the User Program press EXIT PAGE twice Calibration 1 9 November 2004 Testing the Frequency Outputs Preparing for Testing Testing the Output Procedure Options Frequency outputs may be added to the Model XGS868 by installing an appropriate option card in Slot 1 This option card contains two or four freguency outputs which are designated A B C and D Prepare for the testing procedure by connecting a freguency counter to the desired output on the option card See Figure 1 3 on page 1 12 to identify the OUT and RTN pins for the desired output on terminal b
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