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DigitalFlow™ XGM868i - GE Measurement & Control

1. PROG RESET CALIB CNTRS See Programming Manual Reset Totals DARKN LTEN O ro J YES bi as STORE ABORT RE J LABORT A SLOTO C sLoT1 L L J Slot 0 Analog Outputs Slot 1 option Card Slot 1 Analog Inputs Slot 1 y Alarm Relays A a EEC EA CANES ANALOG OUTPUT q press EXIT key ALARMS ama zoma Numer TEST exit ANALOG INPUT mA Reading crose OPEN Exr CALIBRATING Full Scale ma 20ma uP pown Numer store oom CALIBRATING store asort Slot 1 y Totalizer Outputs Slot 1 y Analog Outputs CajJLBJLe JLo Slot 1 RTD Inputs LA 8 TIME J PULSES aj B c o ANALOG OUTPUT ier N 2 press EXIT key Slot 1 Frequency Outputs ama zoma rest er Jet INPUT gt CajCejCej Ce CALIBRATING Full Scale ser Slope SET POINT TEMP SLOPE TEMP anes ur pown numer store asort CALIBRATING mA Reading STORE reont NOTE Plain text represents prompt area meassages eee and boxed text represents option bar choices Fx represent function keys to select option bar choices Figure 3 Calibration Menu Map DigitalFlow XGM868i Service Manual 11 Chapter 1 Calibration Pin 1 DIO nn gt on 11 12 Pin 1 Doo an on 11 12 Pin 1 Ion gt on 11 12 01 AA HH ALARMA NO ALARM A COM ALARM A NC ALARM B NO ALARM B COM ALARM B NC ALARM C NO ALARM C COM ALAR
2. DN Signal Q Displays the signal quality for the downstream transducer gt 1200 400 to 400 UP Amp Discrim Displays value for signal amplitude of upstream transducer 24 5 lt 19 or gt 29 DN Amp Discrim Displays the value for the signal amplitude of the downstream transducer 245 lt 19 or gt 29 UP DAC Count Displays the AGC DAC count for the upstream gain setting N A DN DAC Count Displays the AGC DAC count for the downstream gain setting N A 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 Temperature Displays the gas temperature from 0 4 20 mA input N A Pressure Displays the gas pressure from 0 4 20 mA input zZ Act Vol Displays actual volumetric flow Std Vol Displays standard volumetric flow UP Transit St Displays Skan transit time upstream DN Transit S1 Displays Skan transit time downstream Delta T S Displays Skan Delta T UP Transit M1 Displays Measure transit time upstream DN Transit M1 Displays Measure transit time downstream Delta T M Displays Measure Delta T Vinst Displays the instantaneous velocity 2 2 2 2l zizi zzz gt gt gt gt gt gt gt gt gt gt 2 2 2
3. meterConfigs mdb NewLog1 txt gt PanaCom ocx IR Panaview exe i Panaview Idb Y Panaview mdb 8 raw Ext a RawUP Sitet sit E sitet txt an Site2 sit a Sites sit Site4 prt a sited sit la Work1 sit a Wwork2 sit am working sit las workingl sit aa xXMTMEM El Ef Figure 13 Saving Signal Array Data to File DigitalFlow XGM868i Service Manual 53 Appendix B Calibration and Testing with PanaView B 5 2 Uploading XGM868i Memory Note This option is for factory use only The Upload XGM Memory option is another diagnostic tool IMPORTANT Consult GE before using this data to change any parameters 1 In the Calibration Test menu double click on the Upload XGM Memory option 2 The first prompt shows the Hex Start Address Click Next Item 3 The next prompt displays the value for the Hex Bytes Click Next Item 4 PanaView now offers two options for Uploading the XGM memory e If you double click on To Display the right pane of the window appears similar to Figure 14 and the data is available for immediate evaluation Click Exit Page to close the window and return to the Calibration Test menu is CALIBRATION TEST UPLOAD NOW TO DISPLAY HEX BYTES 0064 HEX START ADDRESS 00000000 Exit Page Figure 14 XGM868i Memory Data Displayed on PanaView e If you double click on To File the Save As window similar to Figure 13 on page 53 opens E
4. Appendix A Service Record Appendix A Service Record A 1 Introduction Whenever any service procedure is performed on the Model XGM868i 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 A 2 Data Entry Record complete and detailed service data for the Model XGM868i in Table 6 Make additional copies of the table as needed Table 6 Service Record Description of Service Performed By DigitalFlow XGM868i Service Manual 37 Appendix A Service Record oo ness EEE EEEE amp 2c _ ___ 0 EEE_ ww Table 6 Service Record cont Description of Service Performed By 38 DigitalFlow XGM868i Service Manual Appendix A Service Record A 3 Diagnostic Parameters After a successful initial installation of the Model XGM868i and whenever any system malfunction is noticed the values for the diagnostic parameters should be entered in Table 7 Table 7 Diagnostic Parameters Parameter Initial Current Parameter Initial Current SS up SS do SNDSP Tup Tdown DELTA REYN Tot K PEAK Qup Qdown AMPup AMPdn CNTup lavailable only if Burst Mode S M DigitalFlow XGM868i Service Manual 39 40 no c
5. 1 Disconnect the power to the XGM868i and move the electronics enclosure to a safe area Note If the electronics enclosure cannot be moved to a safe area be sure the surrounding area is free of ignitable gases before proceeding to step 2 WARNING The main power to the Model XGM868i must be disconnected before proceeding 2 Refer to Illustration 1 in Figure 6 on page 33 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 24 DigitalFlow XGM868i Service Manual Chapter 4 Parts Replacement 4 2 Removing the Circuit Board Assembly cont 4 From the rear of the enclosure disconnect the power line leads from terminal block TB5 Unplug terminal blocks TB1 to TB6 from connectors J1 J4 5 Refer to Illustration 2 in Figure 6 on page 33 and remove the four terminal board mounting screws and the ground screw This will disconnect one end of the green grounding jumper wire 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 6 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 slowl
6. 4 NC 5 NC 6 NC 7 RTD C 8 COMM C 9 COM C 10 RTD D 11 COMM D 12 COM D 16 HART 17 HART OI HARTIOUTA Pin 1 HARTIOUT A HARTIOUT A 2 HARTIOUT A NC 3 NC NC 4 NC NC 5 NC NC 6 NC NC ki OUTC 24V NC 8 INPUT C NC 9 INPUT D RTN NC 10 OUT D 24V NC 11 INPUTD NC 12 INPUT C RTN Pin 1 ooo vn 1 12 05 CI TI Fl 06 CR FR TR OUT A Pin 1 OUT A RIN A 2 RIN A NC 3 NC OUT B 4 OUT B RIN B 5 RIN B NC 6 NC OUTC 24V 7 RTD C INPUTC 8 COMM C INPUT C RTN 9 COM C OUTD 24Y 10 RID D INPUTD 1 COMM D INPUT D RTN 12 COM D 11 AR HR 12 11 ALARMA NO Pin1 OUTA 24V ALARMA COM 2 NPUTA ALARMA NC 3 INPUT A RTN ALARM B NO 4 OUTB 24V ALARM B COM E INPUTB ALARMB NC 6 INPUTB RTN RTD C F OUTC 24V COMM C 8 NPUTC COM C 9 INPUTC RTN RTD D 10 OUTD 24V COMM D 1 INPUTD COM D 12 INPUT D RTN 18 F F HH 19 HART RI Pin 1 AFREQOUT Pin1 HARTIOUT A 2 AFREQRTN 2 HARTIOUT A 3 ANC 3 NC 4 B FREQOUT 4 NC 5 B FREQRTN 5 NC 6 BNC 6 NC 7 C ALARM NO 7 RID A 8 C ALARM COM 8 COMMA 9 C ALARM NC 9 COMA 10 D ALARM NO 10 OUT D 24 1 D ALARM COM 11 INPUT D 12 D ALARM NC 12 INPUT D RTN NOTE R RTD Input A Standard Alarm H Hermetic Alarm F Frequency Output otalizer Output urrent Input C Current Output O Blank No Connection Figure 4 Option Card I O Connections DigitalFlow XG
7. Menus in the Edit Functions Option 5 To enter data into the user program double click on the Calibration Test menu The window appears similar to Figure 10 im CALIBRATION TEST TEST Calibration Signal array upload Upload XGM memory Hardware test Next Item Previous Item Figure 10 The Calibration Test Menu Proceed to the appropriate sections of this appendix to calibrate and or test any of the installed inputs and or outputs 42 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 3 Calibrating Slot O Analog Outputs Every Model XGM868i flowmeter includes two built in analog outputs A and B at terminal block J1 which is designated as Slot 0 Both the zero point and full scale values for each output must be calibrated After 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 for either O mA or 4 mA However the calibration procedure always uses the 4 mA point as the meter will extrapolate this value to obtain the 0 mA point Prepare for calibration by inserting an ammeter in series with the load on analog output A at terminal block J1 as shown in Figure 11 Terminal Block J1 Slot 0 B A SIG RTN ES Load EME Ammeter Figure 11 Ammeter Connection Output A 1 From the Calibration Test
8. OUTPUTS AA AS ae ta baud Pte a A eed a E 51 Testing XGM868i Software and HOndwares lt 2 ir Oh ea Bes Pe ad ee ee 52 B 5 1 Uploading Signal Array Data so ox cue aces ds ec ee Stee etd cae ened Laat 52 BS 2Uplod ding XGM868 MSM tc pts estes ates 54 B 5 3 Testing XGM868 HardWare casitas Paris dae cine ows A oe we cadets ias 55 Appendix C Factory Tests MAA o e o os cake suet hdc cect 63 Resetting the Number of CHONG a a a ea 63 Resetting the XGM868i to Factory Defaults tc A ite ied 63 ES vi DigitalFlow XGM868i Service Manual Chapter 1 Calibration Chapter 1 Calibration 1 1 Introduction Calibrating the Model XGM8681 s analog outputs and inputs is explained in this chapter In addition testing the optional totalizer frequency and alarm relay outputs is discussed The chapter includes the following specific topics calibrating the Slot O and Slot 1 analog outputs page 2 e calibrating option card analog inputs page 4 e calibrating option card RTD inputs page 6 testing option card alarm relays page 7 testing option card totalizer outputs page 8 testing option card frequency outputs page 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 MODBUS or HART 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
9. 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 must be replaced Contact GE 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
10. Verify that the frequency counter reads the correct value 4 Repeat steps 2 and 3 to test all of the available frequency outputs If any of the frequency outputs fails the test contact GE for assistance Click Exit Page to return to the Slot 1 window and calibrate additional inputs outputs or click Exit Page again to close the Calibration Test menu DigitalFlow XGM868i Service Manual 51 Appendix B Calibration and Testing with PanaView B 5 Testing XGM868i Software and Hardware In addition to calibration procedures for input and output cards the Calibration Test menu offers tests for XGM868i hardware and procedures for uploading signal array data and XGM memory contents into PC files for examination To test XGM8681 hardware and software 1 Open the Meter Browser window and highlight the XGM868i 2 Expand the Edit Functions option The window now appears similar to that shown in Figure 9 on page 42 3 Double click on the Calibration Test menu The window appears similar to Figure 10 on page 42 Proceed to the appropriate section to upload data and test hardware B 5 1 Uploading Signal Array Data By uploading XGM868i signal array data for examination a user can check if the transducer signal is the proper shape and change setup parameters if necessary IMPORTANT Consult GE before using this data to change any parameters 1 In the Calibration Test menu double click on the Signal Array Upload option 2 Double cli
11. 2 z 2 22 2 2 gt gt gt gt gt gt gt gt gt Sl gt tavailable only if Burst Mode S M DigitalFlow XGM868i Service Manual 61 62 no content intended for this page DigitalFlow XGM868i Service Manual Appendix C Factory Tests Appendix C Factory Tests C 1 Introduction For user security the XGM8681 offers two special functions in a separate menu selection of single or dual channel operation and the factory default reset While the first function enables you to reset the channel configurations set during manufacturing the reset function by restoring the meter to its original state allows you to purge potential errors in program memory To enter the Factory Test menu press Escape followed in succession by the up arrow key A the right arrow key gt the down arrow key V the left arrow key lt the up arrow key again forming a loop around the keypad and finally the Enter key The screen displays FACTORY TEST as shown below FACTORY TEST CHAN 1 lt C 2 Resetting the Number of Channels To reset the number of channels displayed 1 Inthe Factory Test menu scroll to CHAN and press Enter 2 Scroll to the desired number of channels 1 or 2 and press Enter 3 The XGM868i returns to the Factory Test menu Press Escape to return to parameter display C 3 Resetting the XGM868i to Factory Defaults 1 In the Factory Test menu sc
12. Washer 2 places RK NED iz z5 LCD Display and J1 Connector Interconnect Board female P6 Connector male lllustration 5 J9 Connector on Main Board J6 J7 Connector on Terminal Board P7 Connector on Terminal Board Keypad Board Mounting Screw and P9 Connector on Terminal Board connects to J10 Connector on Main Board J2 Connector Green Grounding Jumper nector on Terminal Board connects to Terminal Board connects to on Power Supply Board J7 Connector on Main Board connects to Standoff D Mounting Screw with Washer Assembly 3 places lllustration 7 J7 for AC Power Supply shown J6 for DC Power Supply Bracket Screw Fuse Cover DC Power Supply Board P8 Connector on Terminal Board connects to J8 Connector on Main Board llustration 6 Heatsink P21 Connector on Terminal Board 24 tor AC Power Supply only connects to J3 Connector on Option Board Slot 2 P22 Connector on Terminal Board connects to P2 Connector on I O Option Board Slot 1 gt Screw Lock Washer and Flat Washer 2 places Gap Filler for AC Power Supply only Bracket Nut Washer and Lock Washer AC Power Supply Assembly Main Board U6 Eprom Illustration 8 shown with AC Power Supply Note There are no Heat Sink and Gap Fillers with a DC Power Supply Figure 7 Model XGM868i LCD Display Interconnect Board Subasse
13. contact the factory for assistance 3 3 1 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 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 XGM868i 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 XGM868i will tolerate relatively large changes in the gas sound speed
14. er ees 61 DN Signal Oo ese ia Bees alot Ai e atl Ae 61 A Cede tng CU Nee Are Sota 61 DN Transit M vse to ds es 1d 61 DN Transistor 61 A A 61 DEM avia ae tea 19 DES aro rta 19 65 Index E EPROM Replici s ihc a palace ae 28 User Programs iat te Los a e ol dd 28 EPROM Tetudas lo 55 Error Code A hee ee arg abet tees Ss cee ig 14 A ces E eae YOM EEE 14 OG tte ae fate ee ER se add OU SN 16 na eae noe ae eee RES 16 PID ate ch ber Ga EE dee and hee oiy bens 16 PIS cto the disaibeg ae hohe Qik tha wa ke iA 16 A 16 A Gale ah etapa ae Pasa ae 14 A woe Ate whales Res G te 14 Bs Ge eae sda Sis te E a idee eee tore Le 15 TES pias Baap ae NAG A AS 15 EG bo Sale ee AG ewe CASE GOS 15 ett fa oe eR oe ER ENR 15 BG oc GSS ote os es ey ES og Die eel are 15 BO ir ekg Uta Ed So A yl arr 16 Error Message Display Screen 13 Expansion Mts i454 bsshed aoe dea hes 1 41 F Factory TEST aida an 63 Factory Test Men A a iia 63 POT a a Gok 56 Flowcell Problems GAS et dank A Sane eRe 20 PIE sof Resa AS EEE 21 Frequency Option Card Testin8 10 Frequency Outputs Testing w PanaView 51 Fuse Replacing si ew bain aed haces A ata 27 FWD Mass cos aaa 61 FWD Total a See EES 61 G Gas Contamination 0000 ss ceed vases be be nat 20 Physical Requirements 0005 20 Problems O oo tea ote ee hee ae eet 20 Soundspeed aia 20 66 H Hardware Testa vee nhen t here hee at 55 Initializing Meter with
15. error message appears verify that the RTD is at the programmed temperature Also if you replace the set slope range with a different range be sure to recalibrate the set and slope points Procedure Options This completes calibration of the Slot 1 RTD input Do one of the following e To calibrate or test another input press Escape and return to Step 3 in Accessing the Calibration Test Menu above e To leave the Keypad Program press Escape twice 6 DigitalFlow XGM868i Service Manual Chapter 1 Calibration 1 6 Testing Alarm Relays Alarm relays may be added to the Model XGM868i 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 1 6 1 Preparing for Testing Prepare for the testing procedure by connecting an ohmmeter to the NO and COM pins of the desired alarm on the option card Refer to Figure 4 on page 12 to identify NO NC and COM pins for the desired alarm on terminal block J2 1 6 2 Testing the Relay 1 From the Keypad Program press the right arrow key to scroll to the CALIB menu Press Enter 2 Inthe Cal window scroll to Slot 1 Press Enter Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 3 Scroll to the desired Output Output A will be used as an example in this manual Press Enter IMPORTANT The procedure for testing all the alarms is the same However when
16. high end of the output range Note Skip the following prompt if linearity testing of the output will not be performed at this time 7 Double click on Test to test the linearity of the currently selected analog output 8 Check the ammeter reading at 50 output Then enter a different output 0 100 and double click on percent Check the ammeter reading at this setting and press Exit Page when done Table 8 on page 45 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 the accuracy of the ammeter readings taken above If the linearity test readings are not within 5 uA of the values listed in the table 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 Click Exit Page to return to the Slot 1 window and calibrate additional inputs outputs or click Exit Page again to close the Calibration Test menu 46 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 4 2 Analog Inputs Analog inputs may be added to the Model XGM868i 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
17. if an option card is installed in this slot 3 Scroll to the desired Output Output A will be used as an example in this manual Press Enter 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 4 on page 12 for the correct pins 4 Enter a frequency between and 10 000 Hz and press Enter 5 Verify that the frequency counter reads the correct value Procedure Options This completes testing of the Slot 1 frequency outputs Do one of the following e To test another of the available frequency outputs return to Step 3 in Testing the Output above If any of the frequency outputs fails the test contact the factory for assistance e To calibrate test additional inputs outputs proceed to the appropriate section e To leave the Keypad Program press Escape twice 10 DigitalFlow XGM868i Service Manual Chapter 1 Calibration Esc Enter Esc Keypad Pgm
18. requires the use of a calibrated current source If an independent calibrated current source is not available one of the Slot 0 analog outputs may be used for the calibration During the analog input calibration the Slot 0 analog output will supply the low reference high reference 4 mA and 20 mA signals at the appropriate times IMPORTANT Zf a Slot 0 analog output will be used to calibrate the analog inputs the Slot 0 analog output calibration procedure must be completed first Prepare for the calibration procedure by connecting a Slot 0 analog output or independent calibrated current source to Input A of the option card See Figure 4 on page 12 to identify the IN and RTN pins for Input A 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 procedure always uses the 4 mA point as the meter will extrapolate this value to obtain the O mA point 1 Inthe center pane of the Calibration Test window double click on Slot 1 2 Double click on the desired input to open the Analog Input menu Input A will be used as an example in this manual IMPORTANT Calibrating Inputs B Cor D is identical to calibrating Input A However be sure to reconnect the current source on terminal block J2 Refer to Figure 4 on page 12 for the correct pin numbers 3 Double click on the appropriate option to select the reference point to be calibrated Proceed to the corresponding sub
19. 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 Channelx Set up Signal submenu of the Keypad Program Action Using the procedures in Chapter 3 Diagnostics check the components listed above Also check the limit values entered into the Channelx Set up Signal submenu as described in Chapter 1 Programming Site Data of the Programming Manual E2 Sound Speed Error Problem The sound speed exceeds the limits programmed in the Channelx Set up Signal submenu of the Keypad Program Cause The error may be caused by incorrect programming poor flow conditions or poor transducer orientation Action 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 E3 Velocity Range Problem Cause Action 14 The velocity exceeds the limits programmed in the Channelx Set up Signal submenu of the Keypad 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 a
20. the channel options on a two channel XGM868i press the lt or keys until you have reached the desired option DigitalFlow XGM868i Service Manual 17 Chapter 3 Diagnostics 3 2 Displaying Diagnostic Parameters cont For a 1 Channel XGM868i the data for Channel 1 is displayed automatically and you can skip to step 8 However for a 2 Channel meter the channel data to be displayed must be specified at the following prompt 7 Scroll to the desired Channel option as listed in Table 2 Table 2 Channel Options Channel 1 Channel 2 CH1 CH2 CH1 CH2 CH1 CH2 2 8 For each channel select the desired Measurement Parameter as shown in Table 3 on page 19 Note The measurement units that appear in these prompts are those selected in the GLOBL SYSTM menu earlier in this section Also when differences in one channel s programming invalidate an output previously chosen for the other the measurement defaults to the nearest selectable item in the parameter list The previous two prompts repeat until all of the specified of LCD Parameters have been set up When all of the display parameters have been set up the meter returns to the Global I O window To leave the Keypad Program press the Escape key three times After leaving the Keypad Program the XGM868i 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
21. the test 4 Ifthe NVR passes the test the screen appears similar to Figure 15 on page 56 Click Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu DigitalFlow XGM868i Service Manual 55 Appendix B Calibration and Testing with PanaView B 5 3b NVR Test cont is CALIBRATION TEST Program memory test Previous Item Next Item Execute test Yes WARNING 8RThe selected test will require several minutes for comp TESTS NVA TEST EPROM sum 51C6 TESTS EPROM TEST Z Exit Page Figure 15 Completion of the NVR Test B 5 5c RAM Test To check the RAM Note Ifyou are in the Hardware Test option skip to step 2 1 From the left pane of the Calibration Test window double click on Hardware Test 2 Inthe center pane double click on RAM TEST 3 The right pane displays the RAM Value along with an indication as to whether the RAM is functioning Click Next Item or Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu B 5 3d FIFO Test To check the FIFO Note Ifyou are in the Hardware Test option skip to step 2 1 From the left pane of the Calibration Test window double click on Hardware Test 2 In the center pane double click on FIFO TEST 3 In the right pane a message lists the desired number of bits along with the approximate bias and the average sample Click Next It
22. 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 Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken e Ifthe damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e If GE Sensing 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 repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned DigitalFlow XGM868i Service Manual 69 Warranty no content intended for this page 70 DigitalFlow XGM868i Service Manual Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com Ireland Sensing House Shannon Free Zone East Shannon County Clare Ireland Tel 353 0 61 470291 E mail gesensingsnnservices ge com An ISO 9001 2000 Certified Company www gesensinginspection com en about_us quality html 910 1975 Rev E www gesensinginspection com 2010 General Electric Company All rights reserved Technical content subject to change without notice
23. version To replace the User Program refer to Figure 7 on page 34 and complete the following steps 1 Complete the steps in Removing the Circuit Board Assembly on page 24 2 Place the circuit board assembly on a flat surface with the terminal board facing upward See Illustration 7 in Figure 7 on page 34 and remove the three PCB mounting screws with flat washers and lock washers indicated This will also remove the green grounding jumper 3 Locate and unscrew a fourth smaller bracket screw close to J2 on the terminal board capturing the lock washer flat washer and bracket nut on the back side Then carefully pull the terminal board away from the main board power supply board assembly and option board 4 Remove the two screws flat washers lock washers and heat sink in the corners of the power supply board see Illustration 8 in Figure 7 on page 34 Note A XGM868i with a DC power supply will include two more mounting screws but no heat sink 5 Carefully pull up the power supply board and heat sink assembly then slide it out The U6 EPROM is located along the upper edge of the main board on the side that was facing the power supply board see Illustration 8 in Figure 7 on page 34 It is the only socketed chip on this board and it has a white identification label 6 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 an
24. will be displayed in sequence with a pause of several seconds between display changes 18 DigitalFlow XGM868i Service Manual Chapter 3 Diagnostics 3 2 Displaying Diagnostic Parameters cont Option Bar Table 3 Available Diagnostic Parameters Description Bad SS up Displays the signal strength for the upstream transducer lt 50 or gt 75 SS do Displays the signal strength for the downstream transducer lt 50 or gt 75 SNDSP Displays the measured speed of sound in the gas Tup Displays the upstream ultrasonic signal transit time Tdown Displays the downstream ultrasonic signal transit time DELTA Displays the transit time difference between the upstream and downstream signals Tot K Displays the total number of K factors PEAK Displays the percentage of peak set to 50 by default Qup Displays the signal quality for the upstream transducer 400 to 400 Qdown Displays the signal quality for the downstream transducer 400 to 400 AMPup Displays the value for the signal amplitude of the upstream transducer lt 19 or gt 29 AMPdn Displays the value for the signal amplitude of the downstream transducer lt 19 or gt 29 CNTup Displays the AGC DAC count for the upstream gain setting N A CNTdn Displays the AGC DAC count for the downstream gain setting N A N A P up Displays s
25. GE Measurement amp Control Solutions Gas Analysis DigitalFlow XGM868i Panametrics General Purpose Gas Flow Transmitter 1 amp 2 Channel Service Manual nati t k 910 1975 Rev E Imagination at wor October 2010 DigitalFlow XGM868i Panametrics General Purpose Gas Flow Transmitter 1 amp 2 Channel Service Manual 910 1975 Rev E October 2010 GESensinginspection com 2010 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page Preface Information Paragraphs Note paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance e Caution paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to property or equipment e Warning paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to personnel Cautionary information is also included when applicable Safety Issues WARNING Itis the responsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe op
26. M To enable you to Choose an Opcard the center pane displays a list of possible option cards Scroll to and double click on the type of card installed The program asks for the Board Revision Enter the revision letter in the right pane and click Next Item The next prompt asks for the Group Enter the appropriate value and click Next Item The next prompt asks for the Special Mod Enter the appropriate value and click Next Item The program now asks for the Month Scroll to and double click on the desired month The next prompt asks for the Day Enter the desired value from 1 to 31 and click Next Item The next prompt asks for the Year Enter the appropriate value from 2002 to 2089 and click Next Item The final prompt asks for the Serial Enter the appropriate value and click Next Item The right pane now displays the programmed Header Information When you have reviewed the data click Next Item or Exit Page to return to the Hardware Test option DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 5 3k Reading an Optional Card EEPROM To read the data of the EEPROM for an optional card DI E A O From the left pane of the Calibration Test window double click on Hardware Test In the center pane double click on READ OPCARD EEPROM Double click on the Slot 1 or 2 that holds the optional card The right pane lists the Header Information When you hav
27. M C NC ALARM D NO ALARM D COM ALARM D NC 07 CIR OUT A RIN A NC OUT B RIN B NC OUTC 24V INPUT C INPUT C RTN RID D COMM D COM D 13 RR RTD A COMM A COM A RID B COMM B COM B RTD C COMM C COM C RID D COMM D COM D Pin 1 ONDAN 11 12 02 FF TT FT CT CF 03 FO TO CO Pin 1 OUT A Pin 1 OUT A 2 RIN A 2 RTN A 3 NC 3 NC 4 OUT B 4 OUT B 5 RTN B 5 RTN B 6 NC 6 NC 7 OUT C 7 NC 8 RIN C 8 NC 9 NC 9 NC 10 OUT D 10 NC 11 RIN D 11 NC 12 NC 12 NC 08 AI HI 09 Ol Pin1 ALARM A NO Pin 1 NC 2 ALARM A COM 2 NC 3 ALARMA NC 3 NC 4 ALARMB NO 4 NC 5 ALARMB COM 5 NC 6 ALARMB NC 6 NC 7 OUTC 241 i OUTC 24V 8 INPUTC 8 INPUTC 9 INPUTC RTN 9 INPUTC RTN 10 OUTD 24V 10 OUTD 24V 1 INPUTD 11 INPUTD 12 INPUT D RTN 12 INPUT D RTN 14 IR 15 FHII OUTA 24V Pin 1 AFREQOUT Pin 1 INPUTA 2 AFREQRTN 2 INPUTA RTN 3 ANC 3 OUTB 24V 4 B ALARM NO 4 INPUT B 5 B ALARMCOM 5 INPUT B RTN 6 B ALARM NC 6 RTD C 7 C 24 OUT 7 COMM C 8 C ANALOG IN 8 COM C 9 C ANALOGIN RTN 9 RTD D 10 D 24v OUT 10 COMM D 11 D ANALOG IN 11 CoM D 12 D ANALOGINRTN 12 04 FA FH TA TH CA CH Pin1 OUT A 2 RIN A 3 NC 4 OUT B S RIN B 6 NC 7 ALARMC NO 8 ALARMC COM 9 ALARMC NC 10 ALARMD NO Ti ALARM D COM 12 ALARMD NC 10 OR Pin1 NC 2 NC E NC
28. M868i Service Manual 12 Chapter 2 Error Codes Chapter 2 Error Codes 2 1 Introduction The Model XGM8681 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 XGM868i 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 5 Error Message CH1 MASS Bxx 4500 LB HR Y XGM868i LCD Display Figure 5 Error Message Location If an error message appears during normal operation of the Model XGM868i refer to the appropriate section of this chapter for instructions on how to proceed DigitalFlow XGM868i Service Manual 13 Chapter 2 Error Codes E0 No Error Problem No error condition currently exists Cause This message appears briefly to confirm that the response to another error message has corrected the problem Action No action is required E1 Low Signal Problem Poor ultrasonic signal strength or the signal exceeds the limits entered via the Keypad Program Cause Poor signal
29. PanaView 59 Inputs 20 mA Option is Sek el Oats ats 5 47 4 mA Option aaa 5 47 K K Re MultiK KFactor o o oooooo o 61 Keypad Program for Calibration 1 L LCD Contrast Changing with PanaVieW o oooo o 57 LED Display AS AA 26 LED Testi ra Roe ee Sees eee 57 Leaks Transducers 1 0 0 0 0 cee eee eee 22 Low Pressure Error Plica odos 16 Low Signal Error Elba oosakee Ge tatnG os 14 LVD Statement rs beaded wos dad hy 23 M MID O Visco ds tle raa e a ea E a de 61 Memory Data Uploading with PanaView 54 N NG Eros ati eel ae 14 INV IR Testa ie uy O eS ue 55 O Option Card Alarm Relay eare See hee pees ess 7 Analog Inputs s reser asus ee ae t nee tee cee 4 Analog Outputs rie es holas 2 46 47 48 A hangs kee ee oe Ee Go 29 Calibrating with PanaVieW 45 Expansion Slots 3 434 640s tardas 1 41 Frequency Outputs crias 10 A Se ook te ania ab ae a wees 29 RED AN pulsed ocio add 6 Totalizer Outputs cuts 8 DigitalFlow XGM868i Service Manual O cont Optional Card EEPROM Programming with PanaVieW 58 Reading with PanaVieW ooooo o 59 Over Range Error ElB oo ooooooooo o 16 P Pd oye Laat bala eg ey ede 19 A edna bGSk Hew ee Ok hee eee 19 PanaView for Calibrating 42 PEAK DAA SRG 19 61 Pipe AAA dota niles 21 Problems st ass il od wena ad 21 PRESR A ee E E 19 Pressure jk ada A Fae Oe eee 61 Pre
30. STORE to accept the new slope point value or ABORT to cancel the entry Click Exit Page to return to the Slot 1 window and calibrate additional inputs outputs or click Exit Page again to close the Calibration Test menu 48 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 4 6 Testing Alarm Relays Alarm relays may be added to the Model XGM868i 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 Alarm A of the option card See Figure 4 on page 12 to identify the NO NC and COM pins for Alarm A on terminal block J2 1 In the center pane of the Calibration Test window double click on Slot 1 2 Double click on the desired output to open the Alarm Relay menu Output A will be used as an example in this manual IMPORTANT The procedure for testing Alarms B C or D is identical to that for testing Alarm A However be sure to reconnect the ohmmeter on terminal block J2 See Figure 4 on page 12 for the correct pin numbers 3 The center pane now offers three choices Double clicking on Close should yield an ohmmeter reading of about zero Double clicking on Open should yield an infinite ohmmeter reading e Double clicking on Exit closes the Alarm Relay menu and returns you to the Output window 4 Repeat steps 2 and 3 until both the norm
31. 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 22 DigitalFlow XGM868i Service Manual Chapter 4 Parts Replacement Chapter 4 Parts Replacement 4 1 Introduction The Model XGM868i has been designed to permit easy on site upgrades and parts replacement See Figure 6 on page 33 for details of the standard XGM868i electronics enclosure assembly The instructions in this chapter along with a few common tools are all that is required to perform the following tasks e removing the circuit board assembly e replacing the LCD display interconnect subassembly e replacing the fuse e replacing the User Program e installing an option card e assembling installing the circuit board assembly WARNING Prior to performing any maintenance procedures be sure to disconnect the main power from the unit If the XGM868i is installed in a hazardous environment a the electronics enclosure must be moved to a safe area prior to removing the covers or b if the electronics enclosure cannot be moved to a safe area ensure that the surrounding area is free of ignitable gases Note For compliance with the European Union s Low Voltage Directive 73 23 EEC this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible dire
32. acket on the main board as shown in Illustration 11 in Figure 8 on page 35 Note Do not lose the nylon washer located between the small angle bracket on the terminal board and the main board 4 If necessary remove any option card and optional I O heat sink currently in use 5 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 Note 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 To install an I O option card with optional heat sink 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 connector 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 However the optional heat sink will extend beyond the edge To attach an optional heat sink to an I O option card see page 30 Whe
33. alibration procedure by connecting the RTD temperature transmitter to the desired input A B C or D on the option card See Figure 4 on page 12 to identify the RTD and COM pins for the desired input on terminal block J2 1 5 2 Accessing the Calibration Test Menu 1 From the Keypad Program press the right arrow key to scroll to the CALIB menu Press Enter 2 Inthe Cal window scroll to Slot 1 Press Enter Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 3 Scroll to the desired Input Input A will be used as an example in this manual Press Enter IMPORTANT When calibrating the other inputs be sure to reconnect the current source at terminal block J2 See Figure 4 on page 12 for the correct pins 1 5 3 Entering the Set Point 1 Before proceeding place the RTD in a temperature bath and allow it to stabilize at the desired set point temperature 2 Scroll to Set to program the RTD set point Press Enter 3 Use the arrow keys to enter the desired set point temperature and press Enter 4 Scroll to STORE to accept the new set point value or ABORT to cancel the entry Press Enter 1 5 4 Entering the Slope 1 Scroll to Slope to program the RTD slope point Press Enter 2 Use the arrow keys to enter the desired slope point temperature and press Enter 3 Press STORE to accept the new slope point value or ABORT to cancel the entry Press Enter Note If an
34. ally open and normally closed contacts for all alarm relays have been tested Then click Exit Page to return to the Slot 1 window and calibrate additional inputs outputs or click Exit Page again to close the Calibration Test menu DigitalFlow XGM868i Service Manual 49 Appendix B Calibration and Testing with PanaView B 4 7 Testing Totalizer Outputs Totalizer outputs may be added to the Model XGM868i 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 pulse counter to Output A of the option card See Figure 2 on page 8 for totalizer output wiring and Figure 4 on page 12 to identify the OUT and RTN pins for Output A on terminal block J2 1 Inthe center pane of the Calibration Test window double click on Slot 1 2 Double click on the desired output to open the Totalizer Output menu Output A will be used as an example in this manual IMPORTANT The procedure for testing Outputs B Cor D is identical to that for testing Output A However be sure to reconnect the frequency counter on terminal block J2 See Figure 4 on page 12 for the correct pin numbers At the Pulse On Time prompt enter the width of the high time for the totalizer square wave and click Next Item 4 At the Pulses prompt enter the number of pulses desired between 1 and 10 000 and click Next Item That numbe
35. ammeter readings at various Full Scale settings for both 4 20 mA and 0 20 mA scales Refer to this table to verify the accuracy of the ammeter readings taken above Table 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 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 10 Scroll to EXIT and press Enter to return to the Cal menu Then choose another output to calibrate or press Escape to leave the CALIB menu This completes calibration of the Slot 0 analog outputs Proceed to the appropriate section to calibrate additional inputs outputs 1 4 Calibrating Analog Inputs Analog inputs may be added to the Model XGM868i 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 requires the use of a calibrated current source If an independent calibrated current source is not available one of the Slot O analog outputs may be used for the calibration During the analog input calibration the Slot 0 analog output will supply th
36. 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 XGM868i will result in erratic or inaccurate flow rate readings Refer to Chapter 2 Initial Setup of the Startup Guide and make sure that the appropriate sound speed is programmed into the meter 20 DigitalFlow XGM868i Service Manual Chapter 3 Diagnostics 3 3 2 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 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 the correct data will be included in the documentation For othe
37. ate 5 1 4 2 Accessing the Calibration Test MENU onc ocd4 ee cx ened acdc aed nti aa persa 5 Calibrating RTDINP Sk ynearsten EEE wee beat ciara uta east lets acia 6 1 5 1 Preparing for COME REO M AAA A tae cA ede eae eh a a eee et ES 6 1 5 2 Accessing the Calibration Test Menu e a ad ts 6 ME the SetPoint a A O ENRE E 6 as A E E E E E S E EN EES E ENE 6 Testing Alarm RELAYS a iaa 7 LATORRE ROU MESHING EE E E SAO E EE 7 162 1estina THe Redy co e e a eso til cea rah tat ere A aaa 7 Testing Totalize r Qut uts nres s a el e o E de tado Da tas aed aso Dd at e RA 8 AD ZUG LIME TO MS SUNN e a re e o a boa O S 8 UZ PPS UG Ce Omputra s ea E E a A a a Ea A SEA 8 Testing the Frequency OUTPUTS ereraa Sener a die tener i A E 10 18 1 Preparing for TOS vs ri AAA AAA AAA 10 18 2 Testing the DU aaa AER 10 Chapter 2 Error Codes 2 1 IEROGUETION A O O OR 13 Chapter 3 Diagnostics 3 1 3 2 3 3 3 4 DigitalFlow XGM868i Service Manual IATFOGUCHOM Sr tt ct desert 6208 A ek Bet eh le al AS ais cae ok ce A REG ie E RB Sek Co ane e a es 17 Displaying Diagnostic Parameters occiso 17 AE E A E A EE E E T AE EEE 20 SS KGS PROBISMIS ta a a e a a abe Mes aie a a a a a a E toa ake Wht ele piee aana 20 O AN AA E a Ss EE Roe e O 21 Transducer Prol SMS SA e remot 22 Contents Chapter 4 Parts Replacement 4 1 4 2 4 3 44 45 4 6 4 7 A 1 A 2 uote dels APR AA eRe E T tea gn er a re ee A ST 23 Removing the Circuit Board Assembly n
38. attached by a connector located beneath the top edge of the LCD display board see Illustration 5 in Figure 7 on page 34 The LCD display is attached to the interconnect board as one subassembly Do not disassemble the LCD display from the interconnect board Place the keypad board directly over the new LCD display interconnect board subassembly and align the J1 connector on the rear of the keypad board with the P6 pins on the interconnect board Firmly push the two boards together until the interconnect board contacts the two standoffs on the keypad board Secure the keypad board to the interconnect board with the two screws flat washers and lock washers previously removed Firmly insert and seat the complete assembly by aligning the P4 connector on the interconnect board to the J4 connector on the main board and the P1 and P2 connectors to any option card as applicable Replace the three screws removed in step 2 while referring back to Illustration 4 in Figure 7 on page 34 Complete the LCD display interconnect board subassembly replacement by proceeding to Installing the Circuit Board Assembly on page 32 26 DigitalFlow XGM868i Service Manual Chapter 4 Parts Replacement 4 4 Replacing the Fuse Note This procedure applies only to the fuse on the DC power supply The fuse on the AC power supply is not field replaceable please consult the factory for replacement If it has been determined that the fuse in the XGM8681 has
39. b o o nonan eaae 8 XMT868 Hardware oi dla apra 55 Testing with PanaView Frequency Outputs o an it 51 Hardware and Software oooooooooo 52 Totalizer Outputs ita annuae 50 TIME io Gps li a at 61 TOS A A A A E 19 Totalizer Option Card Testing 8 Totalizer Outputs Testing with PanaView 50 Totals Overflow Error El4 o o 16 Transducers COMOSION nye A A A 22 Internal Damage visa lada 22 Leaks ui a 22 Physical Damage ar ia 22 A tow ee ceewoe es 21 Problems pt i 22 A acta Mes CMe Bee a 22 A korida hu eadi E iA 19 Tirada esti obtain ra BAE da 19 TUD PE RD 19 67 Index U UP Amp Disc peda eho he ade ee hee ees 61 UP Sig rad Rees Pee Ae 61 AE alone Mes E Se 61 UP Tra sit oy ss a Se eae 61 UP Transit Mo si naga ed ove ete ta oes 61 UP Transit S AA ae ee Bee ee 61 UP Peaks 2c ane veka A a 61 Upload XMT Memory with PanaView 54 Uploading Signal Array Data 52 User Program EPROM setie eee hd dia 28 Upgrading ag ds oot 28 V Melci St a id o a A 61 Velocity Range Error E3 oo ooooooooo 14 Miss orita a la rie 19 61 A State a eet Oe ge Rag eds 61 W A ta aie Denne in Seo ene 4 ON ae 69 68 DigitalFlow XGM868i Service Manual Warranty Warranty Each instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring t
40. been blown complete the following steps to install a new fuse 1 Complete the steps in Removing the Circuit Board Assembly on page 24 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 refer to Illustration 6 in Figure 7 on page 34 4 Pull the plastic cover off the fuse holder and remove the old fuse 5 Obtain a new fuse of the same rating and type Use only a type 3AG 1 1 4 x 1 4 Slo Blo fuse having a rating as indicated in Table 4 Table 4 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 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 32 Note Be sure to record the fuse replacement in Appendix A Service Record DigitalFlow XGM868i Service Manual 27 Chapter 4 Parts Replacement 4 5 Replacing the User Program The Model XGM8681 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
41. bling Installing the Circuit Board Assembly 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 8 on page 35 and follow the instructions in this section to assemble the circuit board assembly and or to install it in the electronics enclosure 4 7 1 Assembling the Circuit Board Assembly If the circuit board assembly has been disassembled to any degree complete the steps below Otherwise proceed directly to Installing the Circuit Board Assembly on page 32 See Figure 8 on page 35 and complete the following steps 1 Ifnecessary replace the angle bracket on the main board insert the screw with flat washer and lock washer and screw it into the standoff on the main board See Illustration 11 in Figure 8 on page 35 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 them 2 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 30 DigitalFlow XGM868i Service Manual Chapter 4 Parts Replacement 4 7 1 Assembling the Circuit B
42. brating Output A However when calibrating Output B be sure to reconnect the ammeter on terminal block J1 See Figure 1 on page 2 for the correct pin numbers 4 Scroll to 4 mA to calibrate the low end of the output range Press Enter 5 Scroll to UP or DOWN to adjust the ammeter reading UP or DOWN until a 4 mA reading is achieved or Scroll to Numer and directly enter the mA reading In either case press Enter to confirm the entry 6 Once you have achieved a 4 mA reading scroll to either STORE to store the calibration or to ABORT to exit the menu without storing the calibration In either case press Enter Note Ifthe ammeter reading cannot be adjusted within 5 0 yA of the 4 or 20 mA setting contact the factory for assistance 1 3 3 Calibrating the High End of the Output Range 7 The XGM868i returns to the Analog Output window Scroll to 20 mA and repeat steps 4 and 5 to calibrate the high end of the output range Note Skip the following prompt if linearity testing of the output will not be performed at this time 1 3 4 Testing Output Linearity 8 Scroll to TEST to test the linearity of the currently selected analog output Press Enter 9 Check the ammeter reading at 50 Full Scale Then use the arrow keys to enter a different Full Scale 0 100 Press Enter when done DigitalFlow XGM868i Service Manual 3 Chapter 1 Calibration 1 3 4 Testing Output Linearity cont Table 1 lists the expected
43. brating 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 4 on page 12 for the correct pin numbers 5 Do one of the following e Proceed to lt Title Font gt 4 mA Option on page 5 e Proceed to lt Title Font gt 20 mA Option on page 5 142a 4mA Option Set the calibrated current source to 4 mA e Ifyou selected the 4 mA option in the ANALOG INPUT menu scroll to STORE to accept the current 4 mA value or on ABORT to cancel the entry Press Enter In either case the XGM868i returns to the Analog Input window 1 4 26 20 mA Option Set the calibrated current source to 20 mA e Ifyou selected the 20 mA option in the ANALOG INPUT option scroll STORE to accept the current 20 mA value or to ABORT to cancel the entry Press Enter In either case the XGM868i returns to the ANALOG INPUT window e Press Escape to return to the Slot 1 window and calibrate additional inputs outputs or press Escape again to close the CALIB menu DigitalFlow XGM868i Service Manual 5 Chapter 1 Calibration 1 5 Calibrating RTD Inputs RTD analog inputs may be added to the XGM868i by installing an appropriate option card in Slot 1 The option card contains two or four RTD inputs that 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 1 5 1 Preparing for Calibration Prepare for the c
44. ck on the desired Channel 3 The next prompt asks for the specific Array to Load Five choices are available Raw UP Upstream Signal Raw DOWN Downstream Signal e CFUNC UP Correlation Function Upstream e CFUNC DOWN Correlation Function Downstream e CCFUNC Cross Correlation Function Double click on the desired array 52 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 5 1 Uploading Signal Array Data cont 4 PanaView now offers two options for Uploading the array data e If you double click on To Display the right pane of the window appears similar to Figure 12 and the data is available for immediate evaluation Click Exit Page to close the window and return to the Calibration Test menu i CALIBRATION TEST Calibration Upload XGM memory Hardware test UPLOAD NOW TO DISPLAY Arranto load Raw UP signal Cha Channel 1 UPLOAD NOW TO DISPLAY HEX BYTES 0064 Exit Page Figure 12 Signal Array Data Displayed on PanaView e If you double click on To File another window opens similar to Figure 13 Enter a file name and click Save PanaView stores the array data in a Windows file and closes the Calibration Test window Save in Y Panaview e e Ed History Desktop My Documents My Computer TAO My Network pa Save as type Chart Logs PanaView_1 3 11_EXE_ONLY _ Panaview_1 3 7_Exe_Only i v an Files y Log3 txt
45. ctly accessible and located within 1 8 m 6 ft of the Model XGM868i Use Figure 6 on page 33 Figure 7 on page 34 and Figure 8 on page 35 to locate the relevant components while completing the service procedures discussed in this chapter IMPORTANT Keep a detailed record of all parts installations and replacements performed on the XGM868i in the Appendix A Service Record This service history may prove very helpful in diagnosing any future problems DigitalFlow XGM868i Service Manual 23 Chapter 4 Parts Replacement 4 2 Removing the Circuit Board Assembly All parts replacement procedures for the Model XGM868i 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 XGM868i 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 e LCD Display Interconnect Board Subassembly REAR BOARD e Terminal Board MIDDLE BOARDS e Main Board e Receiver Board e Power Supply Board e Slot 1 Input Output Card optional e Slot 2 Logging RS485 Card optional To disassemble the circuit board assembly refer to Figure 6 on page 33 and complete the following steps
46. d detailed account of any parts replacement performed on the Model XGM868i 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 XGM868i at the time of purchase 32 DigitalFlow XGM868i Service Manual Chapter 4 PartsReplacement Terminal Block on Slot 2 Option Card TB6 Enclosure Assembly Set Screw Set Screw Rear Cover solid L Front Cover with Window Illustration 1 Electronics Assembly Mounting Screw with Ground Screw wey Label Plate with Ground Symbol Grounding Jumper Wire TB4 Washer Assembly 4 places s A TBI S S s TBS TB3 Illustration 2 Illustration 3 Figure 6 Model XGM868i Electronics Console Assembly DigitalFlow XGM868i Service Manual 33 Chapter 4 PartsReplacement Washer Assembly 3 places LCD Display Keypad Board and Interconnect Board Sub Assembly P1 Connector P4 Connector P2 Connector P10 Con J1 Connector J4 Connector J2 Connector Power Tab Illustration 4 shown with heatsinks removed for clarity Screw Lock Washer and Flat
47. d lower left corners of the socket Gently 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 7 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 8 By applying equal 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 30 28 DigitalFlow XGM868i Service Manual Chapter 4 Parts Replacement 4 6 Installing an Option Card The Model XGM868i flowmeter can accommodate up to two option cards A data logging or RS485 card may be installed in Slot 2 and a variety of I O option cards are available for installation in Slot 1 To install an option card see Illustrations 9 10 and 11 in Figure 8 on page 35 and complete the following steps 1 Complete the steps in the Removing the Circuit Board Assembly section on page 24 2 Remove the terminal board from the main board power supply board subassembly by completing Steps 1 3 in Replacing the User Program on page 28 3 Remove the screw from the angle br
48. dix B Calibration and Testing with PanaView B 5 3m Initializing the XGM868i to Default Values cont Note When you first initialize the XGM868i the number of LCD parameters is set to OFF You must program the LCD to display any measured parameters In the Edit Functions menu double click on the Site Edit Menu In the Site Edit Menu double click on the Global entry and then on the Input Output option From the Input Output option highlight and double click on the Display option in the center pane a 2 UN oa The first prompt asks for the of LCD Parameters Double click on the desired number from OFF through 1 4 and KEY The OFF setting switches the measurement display off while the KEY setting enables users to change the measurement display via the arrow keys without accessing the Keypad Program If you select KEY e To view a parameter other than the one currently displayed press the A or V keys to scroll through the various parameters e To scroll through the channel options on a two channel XGM868i press the lt or gt keys until you have reached the desired option Note Fora 1 channel XGM866i skip to step 6 5 Scroll to the desired Channel option as listed in Table 9 Table 9 Channel Options Channel 1 Channel 2 CH1 CH2 CH1 CH2 CH1 CH2 2 6 For each channel select the desired Measurement Parameter as shown in Table 10 on page 61 7 Repeat steps 3 and 4 for each para
49. e additional inputs outputs B 4 Calibrating Slot 1 Option Cards To calibrate any option card installed in Slot 1 of the XGM868i enter the Calibration Test menu as shown in Figure 10 on page 42 1 Inthe center pane double click on Slot 1 Note The Slot 1 option only appears in the center pane if an option card has been installed in this slot Notice that all of the available outputs usually four appear at the above prompt The desired type of output may appear as the A and B output pair and or as the C and D output pair Simply select the appropriate output for calibration and or testing For clarity in this chapter the desired outputs are always placed in the A and B positions and the C and D positions are not specifically listed In addition Output A is always used as an example Proceed to the appropriate sub section for specific instructions and substitute the correct output letter for the A shown in the procedures DigitalFlow XGM868i Service Manual 45 Appendix B Calibration and Testing with PanaView B 4 1 Analog Outputs Additional analog outputs may be added to the Model XGM868i by installing an appropriate option card in Slot 1 This option card contains two or four analog outputs which are designated as A B C and D Both the zero point and full scale values for each output must be calibrated After calibrating the outputs which have a resolution of 5 0 uA 0 03 full scale their linearity should be tes
50. e low reference high reference 4 mA and 20 mA signals at the appropriate times IMPORTANT If a Slot O analog output will be used to calibrate the analog inputs the Slot O analog output calibration procedure must be completed first 4 DigitalFlow XGM868i Service Manual Chapter 1 Calibration 1 4 1 Preparing for Calibration Prepare for the calibration procedure by connecting a Slot 0 analog output or an independent calibrated current source to the desired input on the option card See Figure 4 on page 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 O mA point 1 4 2 Accessing the Calibration Test Menu 1 From the Keypad Program press the right arrow key to scroll to the CALIB menu Press Enter 2 Inthe Cal window scroll to Slot 1 Press Enter 3 Scroll to the desired Input to open the ANALOG INPUT menu Input A will be used as an example in this manual Press Enter IMPORTANT Calibrating Input B C or D is identical to calibrating Input A However be sure to reconnect the current source on terminal block J2 Refer to Figure 4 on page 12 for the correct pin numbers 4 Scroll to the appropriate option to select the reference point to be calibrated Press Enter IMPORTANT The procedure for cali
51. e reviewed this data click Next Item The right pane now shows Calibration Values When you have reviewed this data click Next Item The right pane now shows RTD Calibration Values When you have reviewed this data click Next Item or Exit Page to return to the Hardware Test option B 5 31 Setting the Number of Channels To set the number of XGM868i channels for display 1 2 3 From the left pane of the Calibration Test window double click on Hardware Test In the center pane double click on Set Chans In the Number of Channels window double click on or 2 Channels PanaView returns to the Hardware Test option Click Exit Page to return to the main Calibration Test menu and Close to exit the Calibration Test menu B 5 3m_ Initializing the XGM868i to Default Values To restore the XGM868i to its original default values 1 2 From the left pane of the Calibration Test window double click on Hardware Test In the center pane double click on Initialize Meter The right pane displays a Warning that all application parameters must be reentered after initialization Click Next Item to continue or Exit Page to return to the Hardware Test option In the center pane double click on Yes to Reset Meter or on No to leave the XGM868i in its current state If you select Yes the XGM868i returns to its default settings and PanaView exits the Calibration Test menu DigitalFlow XGM868i Service Manual 59 Appen
52. em to perform the test and return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu 56 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 5 3e LCD Test To test the LCD Note Ifyou are in the Hardware Test option skip to step 2 1 From the left pane of the Calibration Test window double click on Hardware Test 2 In the center pane double click on LCD TEST 3 The LCD display flashes three times while a message in the PanaView right pane displays the test values Click Next Item or Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu B 5 3f LCD Contrast To change the LCD contrast Note Ifyou are in the Hardware Test option skip to step 2 1 From the left pane of the Calibration Test window double click on Hardware Test 2 In the center pane double click on LCD CONTRAST 3 Double click on Darken or Lighten to shift the LCD contrast 4 When you have achieved the desired contrast double click on Store to save the contrast or on Abort to return to the Hardware Test menu without changing the contrast B 5 3g DAC Test To test the DAC digital to analog converter Note If you are in the Hardware Test option skip to step 2 1 From the left pane of the Calibration Test window double click on Hardware Test 2 In the center pane double click on DAC TEST 3 The c
53. en e erratic flow readings e readings of doubtful accuracy 1 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 3 2 Displaying Diagnostic Parameters The Model XGM8681 has built in Diagnostic Parameters to aid in the troubleshooting of flowcell transducer and or electrical problems To access these parameters use the Keypad Program Then complete the following instructions to display the desired diagnostic parameter Note To perform this function with PanaView software see Appendix C Programming with PanaView in the Programming Manual and or the PanaView User s Manual Press Escape Enter Escape In the Keypad Program window scroll to PROG and press Enter In the PROG menu scroll to GLOBL and press Enter Scroll to I O and press Enter Scroll to LCD and press Enter A A Ns a The window now asks for the of LCD Parameters Scroll to the desired number from OFF through 1 4 and KEY and press Enter The OFF setting switches the measurement display off while the KEY setting enables users to change the measurement display via the arrow keys without accessing the Keypad Program If you select KEY e To view a parameter other than the one currently displayed press the A or V keys to scroll through the various parameters e To scroll through
54. ent Parameter as shown in the Programming Manual Note The measurement units that appear in these prompts are those selected in the GLOBL SYSTM menu The previous two prompts repeat until all of the specified of LCD Parameters have been set up When all of the display parameters have been set up the meter returns to the Global I O window To leave the Keypad Program press the Escape key three times After leaving the Keypad Program the XGM868i 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 64 DigitalFlow XGM868i Service Manual A Acceleration Error E6 o oooooooooooo 15 Act Vol 6 ed cana eae ye eee a Ree Re ee 80 Ae 61 ACV OL se A AAA A SAI NS 19 Alarm Option Card Testing 7 Alarm Relays Testing oooooooo o 49 Ammeter in Calibration 0 0 0000 eee 2 AMP OR eo eere ty a A Weed 19 Amplitude Error ES Giana Gace s wae ee 15 AMP ad Le a o ad a e 19 Analog Inputs DOMAIN a o 5 47 AMAN Ag eo se SES eae Sees 5 47 Option Card Calibrating cesos ads 4 Analog Output Error E7 o ooooooooo o 15 Analog Outputs Option Card Calibrating in 2 Linearity oa VAG ees ee ee eS 2 R solution oes 4 tak E eas 2 Analog Outputs Slot 0 Ammeter Readings 4 44 46 As Calibra
55. ent units represented by each pulse between 1 and 10 000 and press Enter That number of pulses will then be output at the specified frequency 6 Verify that the pulse counter reads the correct value Procedure Options 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 3 in Testing the Output above If any of the totalizer outputs fails the test contact the factory for assistance e To calibrate test additional inputs outputs proceed to the appropriate section e To leave the Keypad Program press Escape twice DigitalFlow XGM868i Service Manual 9 Chapter 1 Calibration 1 8 Testing the Frequency Outputs Frequency outputs may be added to the Model XGM868i by installing an appropriate option card in Slot 1 This option card contains two or four frequency outputs which are designated A B C and D 1 8 1 Preparing for Testing Prepare for the testing procedure by connecting a frequency counter to the desired output on the option card See Figure 2 on page 8 for frequency output wiring and Figure 4 on page 12 to identify the OUT and RTN pins for the desired output on terminal block J2 1 8 2 Testing the Output 1 From the Keypad Program press the right arrow key to scroll to the CALIB menu Press Enter 2 Inthe Cal window scroll to Slot 1 Press Enter Note The Slot 1 option only appears at the above prompt
56. enter pane indicates whether or not the Zero Scale is functioning Click Next Item or Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu B 5 3h Site Checksums To display the site checksums Note Ifyou are in the Hardware Test option skip to step 2 1 From the left pane of the Calibration Test window double click on Hardware Test 2 In the center pane double click on SITE CHECKSUMS 3 The right pane displays a list of site checksum values Click Next Item or Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu DigitalFlow XGM868i Service Manual 57 Appendix B Calibration and Testing with PanaView B 5 3i Calibration Values To display the calibration values Note Ifyou are in the Hardware Test option skip to step 2 From the left pane of the Calibration Test window double click on Hardware Test In the center pane double click on CALIBRATION VALUES The right pane displays a list of DAC calibration values Click Next Item or Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu B 5 3j Programming an Optional Card EEPROM To program the EEPROM for an optional card 1 2 ad 58 From the left pane of the Calibration Test window double click on Hardware Test In the center pane double click on PROG OPCARD EEPRO
57. erating conditions are met for each installation Auxiliary Equipment Local Safety Standards The user must make sure that he operates all auxiliary equipment in accordance with local codes standards regulations or laws applicable to safety Working Area WARNING Auxiliary equipment may have both manual and automatic modes of operation As equipment can move suddenly and without warning do not enter the work cell of this equipment during automatic operation and do not enter the work envelope of this equipment during manual operation If you do serious injury can result WARNING Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maintenance procedures on the equipment Qualification of Personnel Make sure that all personnel have manufacturer approved training applicable to the auxiliary equipment Personal Safety Equipment Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment Examples include safety glasses protective headgear safety shoes etc Unauthorized Operation Make sure that unauthorized personnel cannot gain access to the operation of the equipment DigitalFlow XGM868i Service Manual iii Preface Environmental Compliance Waste Electrical and Electronic Equipment WEEE Directive GE Measurement amp Control Solutions is an active participant in Europe s Waste Electrical and Electronic Equipmen
58. g Out Error Problem The current in the analog output circuit exceeds the limits for the analog output port Cause The output load exceeds the specified limits for the analog output port Action Make sure the output load is lt 600 ohms for the Slot 0 analog outputs or is lt 1 000 ohms for an analog outputs option card in Slot 1 E8 Temperature In Problem This message indicates a temperature input error Cause The temperature exceeds the specified limits for the analog RTD inputs option card or no input device is connected Action Check the temperature transmitter and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog RTD inputs option card DigitalFlow XGM868i Service Manual 15 Chapter 2 Error Codes E9 Pressure In Problem This message indicates a pressure input error Cause The pressure exceeds the specified limits for the analog inputs option card or no input device is connected Action Check the pressure transmitter and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs option card E10 Special Input Problem This message indicates a special input error Cause The special input exceeds the specified limits for the analog inputs option card Action Check the special input device and the connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs option card E11 Not Used This error code message is not curre
59. h end of the output range Note Skip the following prompt if linearity testing of the output will not be performed at this time 8 Double click on Test to test the linearity of the currently selected analog output 9 Check the ammeter reading at 50 output Then enter a different output 0 100 and double click on percent Check the ammeter reading at this setting and click Exit Page when done Table 8 on page 45 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 the accuracy of the ammeter readings taken above 44 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 3 Calibrating Slot O Analog Outputs cont Table 8 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 8 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 10 Double click on Exit Function to return to the Calibration menu Then choose another output to calibrate or click on Exit Page to leave the Calibration Test menu This completes calibration of the Slot 0 analog outputs Proceed to the appropriate section to calibrat
60. he desired input of the option card See Figure 4 on page 12 to identify the RTD and COM pins for Input A on terminal block J2 1 Inthe center pane of the Calibration Test window double click on Slot 1 2 Double click on the desired input to open the RTD Calibration menu IMPORTANT The procedure for calibrating each input is identical However be sure to reconnect the temperature reference on terminal block J2 See Figure 4 on page 12 for the correct pin numbers Proceed to the corresponding sub section for specific instructions on each of the options shown above B 4 4 Entering the Set Point 1 Before proceeding place the RTD in a temperature bath and allow it to stabilize at the desired set point temperature If you have connected the RTD to an RTD simulator set the RTD simulator to the low temperature value 2 Double click on Set to program the RTD set point 3 In the right pane enter the desired set point temperature and click Next Item 4 Double click on STORE to accept the new set point value or ABORT to cancel the entry B 4 5 Entering the Slope 1 Place the RTD in a temperature bath and allow it to stabilize at the desired slope point temperature If you have connected the RTD to an RTD simulator set the RTD simulator to the high temperature value 2 Double click on Slope to program the RTD slope point 3 In the right pane enter the desired slope point temperature and click Next Item 4 Double click on
61. he instrument to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period is e one year from delivery for electronic or mechanical failures e one year from delivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties or merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Sensing 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 Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 IfGE Sensing instructs you
62. her 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 5 Secure the assembly together by installing the three mounting screws flat washers and lock washers previously removed from the terminal board Be sure to install one end of the green grounding jumper wire under the screw indicated in Illustration 7 in Figure 7 on page 34 The smaller screw should be used at the angle bracket location and secured with a nut lock washer and flat washer Proceed to the next section for instructions on installing the reassembled circuit board assembly in the electronics enclosure DigitalFlow XGM868i Service Manual 31 Chapter 4 Parts Replacement 4 7 2 Installing the Circuit Board Assembly Be sure that the circuit board assembly is completely assembled as described in the previous section Then refer to Illustrations 1 2 and 3 in Figure 6 on page 33 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 bosse
63. ignal peaks for the upstream transducer 100 2300 lt 100 or gt 2300 P dn Displays signal peaks for the downstream transducer 100 2300 lt 100 or gt 2300 TEMP Displays the gas temperature from 0 4 20 mA input N A Z PRESR Displays the gas pressure from 0 4 20 mA input Z AcVOL Displays actual volumetric flow StVOL Displays standard volumetric flow Tu S1 Displays Skan transit time upstream Td si Displays Skan transit time downstream oT st Displays Skan Delta T Tumi Displays Measure transit time upstream Td Mt Displays Measure transit time downstream DTM Displays Measure Delta T Vinst Displays the instantaneous velocity alai ee eee gt gt gt gt gt gt gt gt gt gt alzel 2 2 2 2 2 2E gt gt gt gt gt gt SP gt gt gt gt tavailable only if Burst Mode S M DigitalFlow XGM868i Service Manual 19 Chapter 3 Diagnostics 3 3 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 e gas problems e 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
64. mbly DigitalFlow XGM868i Service Manual 34 Chapter 4 PartsReplacement Screw with Washer Assembly and Mating Nut not shown 2 places 1 O Heatsink Bridge Gap Filler AS white surface xXx facing the Bridge a Gap Filler white surface facing the Bridge V O Heatsink S N Back Plate 1 O Board Illustration 9 Nylon Washer Bracket Screw with Washer Assembly 2 places Flat Washer Y HA V 3 Lock Washer Screw Standoff Slot 2 Option Board Illustration 10 Screw with Washer Assembly 3 places N Gap Filler white surface facing the I O Heatsink 1 O Board Slot 1 with Heatsink Power Supply Heatsink Screw Lock Washer and Flat Washer 2 places Power Supply Board Gap Filler white surface facing PCB J6 Connector on Main Board Standoff J2 Connector on J5 Connector on Main Board Power Supply J6 Connector on Bracket Screw Power Supply Nylon Washer Standoff Bracket Keypad Board Interconnect Board P1 Connector on Interconnect Board Main Board Figure 8 Model XGM868i I O Option Card Subassembly J1 Connector on I O Board Slot 1 with Heatsink J2 Connector on Option Board Slot 2 P2 Connector on Interconnect Board Illustration 11 DigitalFlow XGM868i Service Manual 35 Chapter 4 PartsReplacement AAA PP DigitalFlow XGM868i Service Manual 36
65. menu see Figure 10 on page 42 double click on the Calibration entry to open the option 2 Inthe center pane double click on Slot 0 Note The Slot 1 option only appears in the center pane if an option card has been installed in this slot DigitalFlow XGM868i Service Manual 43 Appendix B Calibration and Testing with PanaView B 3 Calibrating Slot O Analog Outputs cont 3 Double click on either Output A or Output B to open the Analog Output menu Output A will be used as an example in this manual IMPORTANT The procedure for calibrating Output B is identical to that for calibrating Output A However when calibrating Output B be sure to reconnect the ammeter on terminal block J1 See Figure 11 on page 43 for the correct pin numbers 4 Double click on 4 milliamps to calibrate the low end of the output range 5 Double click on 4 mA UP or 4 mA DOWN to adjust the ammeter reading UP or DOWN until a 4 mA reading is achieved or Double click on 4 mA Numer and directly enter the mA reading in the right pane 6 Once you have achieved a 4 mA reading double click on either 4 mA STORE to store the calibration or on 4 mA ABORT to exit the menu without storing the calibration Note Ifthe ammeter reading cannot be adjusted within 5 0 yA of the 4 or 20 mA setting contact the factory for assistance 7 PanaView returns to the Analog Output window Double click on 20 milliamps and repeat steps 5 and 6 to calibrate the hig
66. meter PanaView returns to the Global I O menu 60 DigitalFlow XGM868i Service Manual Option Bar Velocity Appendix B Calibration and Testing with PanaView Table 10 Available Measurement Parameters Description Displays the flow velocity Volumetric Displays the volumetric flow FWD Total Displays the forward totalized volume flow REV Total Displays the reverse totalized volume flow TIME Displays the total flow measurement time MDOT Displays the mass flow FWD Mass Displays the forward totalized mass flow REV Mass Displays the reverse totalized mass flow N A UP Sig Strength 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 DN Transit Displays the downstream ultrasonic signal transit time N Delta T Displays the transit time difference between the upstream and downstream signals N K Re Multik KFactor K factor based on the Reynolds number A A A A N PEAK Displays the percentage of peak set to 50 by default N A UP Signal Q Displays the signal quality for the upstream transducer gt 1200 400 to 400
67. n an ER AS 24 Replacing the LCD Display Interconnect Board Subassembly 0 0 00 c ccc e cece eee cence nee ees 26 Replacing the PUGS AMA tees Liners anh ON 27 Replacingthe User PROG a shy ane T a ening Are cermin Saad aes Ares Aud ag ce rae ao eee cera De 28 Stalin car loin cere ad 22 dl hed der he o lo Ce oak e ae tea 29 4 6 1 Attaching an Optional Heat Sink to an I O Option Card 6 ccc cee ener e eee eee ees 30 Assembling Installing the Circuit Board Assembly n asuna ccc ccc ccc e nee eee rr 30 4 7 1 Assembling the Circuit Board Assembly 0 0 ccc cece nee rr 30 4 7 2 Installing the Circuit Board Assembly n bin dee edd pa pederd eeeieeaecedee 32 Appendix A Service Record A 37 DOUG EME 32 wis ied ce te E N E S cr eo tuys 37 IGN OSEP ARAN e ma naka de A caer ol eA lone te abate 39 A 3 Appendix B Calibration and Testing with PanaView B 1 B 2 B 3 B 4 B 5 C 1 C2 jos AA o A doe Ree ee Ls 41 Accessing the Calibration Test Menu ccc 4 acme tered be dare cb 42 Calibrotirig Slot QAnalog OUtPUtS aa ri era 43 EMM e E o a e a do 45 E aTa 0188D 10a 010 LAA A A E E E E ES ERES REN A Ae Tr 46 a A O Ti tree 47 BAS RID US a e e lcd Leo res 48 BAA Entering Ane Seb dle LO 48 BASE 610 8 o 0 aie ee ae mee gee a e pe eae dd 48 BA esti AION AA A Ue Uh Anthea enti ke te da 2 ol oa abt do 49 Bay Testid Totalize OMS e eles ait cathe A Cah Anite Eds Stee atl AAR SEES ake E i 50 BAS Testing Frequency
68. n 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 After 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 0 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 3 1 Preparing for Calibration Prepare for calibration by inserting an ammeter in series with the load on the desired output Refer to Figure 1 and Figure 4 on page 12 to identify the OUT and RTN pins for the desired output Terminal Block J1 Slot 0 Ammeter Figure 1 Ammeter Connection Output A 2 DigitalFlow XGM868i Service Manual Chapter 1 Calibration 1 3 2 Calibrating the Low End of the Output Range 1 From the Keypad Program press the right arrow key to scroll to the CALIB menu Press Enter 2 Inthe Cal menu scroll to the Slot 0 or Slot 1 option and press Enter Note The Slot 1 option only appears in the menu if an option card has been installed in this slot 3 Scroll to either Output A or Output B to open the Analog Output menu Output A will be used as an example in this manual Press Enter IMPORTANT The procedure for calibrating Output B is identical to that for cali
69. n the XGM868i includes both an I O board Slot 1 and an option board Slot 2 the two boards must be attached to each other with the hardware shown in Illustration 10 in Figure on page 35 Pre attach the nylon washer to the screw before inserting the boards into the assembly DigitalFlow XGM868i Service Manual 29 Chapter 4 Parts Replacement 4 6 1 Attaching an Optional Heat Sink to an I O Option Card If you need to attach an optional heat sink to an I O option card the TI TR FI or FR options in Appendix B of the Startup Guide refer to Illustration 9 in Figure 8 on page 35 and complete the following steps 1 Orient the thermal heat pad s to the heat sink as shown in Figure 8 on page 35 and apply it to the heat sink 2 Loosely attach the aluminum backplate to the I O heat sink with three screws lock washers and flat washers Note The following step applies only to the TR and FR option cards Otherwise proceed to step 4 3 If you have an optional heat sink bridge attach it to the I O heat sink with two screws lock washers flat washers and nuts 4 Attach the assembled heat sink by straddling the power supply components on the option card with the aluminum plate to the left inside and the heat sink to the right outside 5 Tighten the three screws step 2 to secure the aluminum backplate to the heat sink Complete the option card installation by proceeding to Assembling the Circuit Board Assembly below 4 7 Assem
70. nter a file name and click Save PanaView stores the array data in a Windows file and closes the Calibration Test window 54 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 5 3 Testing XGM868i Hardware Using PanaView you can check crucial elements of the XGM868i hardware the EPROM the NVR the RAM FIFO and the DAC You can also e program and test optional cards read site checksums and calibration values e test and set the contrast for the LCD e set the number of channels either 1 or 2 and e reinitialize the XGM868i to its default values IMPORTANT Contact GE if the XGM868i fails any of the tests covered below B 5 3a EPROM Test To test the EPROM from the Calibration Test menu 1 From the left pane of the Calibration Test window double click on Hardware Test 2 In the center pane double click on EPROM TEST 3 The right pane displays the EPROM Sum Value Click Next Item or Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu B 5 36 NVR Test 1 From the left pane of the Calibration Test window double click on Hardware Test Note If you are in the Hardware Test option skip to step 2 2 Inthe center pane double click on NVR TEST 3 A message in the right pane cautions that the test will take several minutes and that interrupting the test may corrupt the memory Click Next Item to continue
71. ntly in use E12 Low Pressure Problem This error code is triggered when the pressure measurement is below the low pressure switch setting Cause The pressure measurement exceeds the specified limits as set in the Channelx Input Output submenu Cause Check the limit value 0 to 5 000 psia entered into the Channelx Input Output submenu as described in Chapter 1 Programming Site Data of the Programming Manual E13 Over Range Problem This error code message indicates that the present measurement exceeds the range of the meter Cause A internal mathematical overflow has occurred in either the volumetric or mass flow calculations Action 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 Channelx System menu See Chapter 2 Initial Setup of the Startup Guide for instructions E14 Totals Overflow Problem The totalizers are unable to keep up with the total accumulated flow signals Cause The programmed units pulse value is too small Action Select a larger number of units pulse value 16 DigitalFlow XGM868i Service Manual Chapter 3 Diagnostics Chapter 3 Diagnostics 3 1 Introduction This chapter explains how to troubleshoot the Model XGM868i if problems arise with the electronics enclosure the flowcell or the transducers Indications of a possible problem include e display of an error message on the LCD display scre
72. ny flowcell and or transducer problems DigitalFlow XGM868i Service Manual Chapter 2 Error Codes E4 Signal Quality Problem The signal quality is outside the limits programmed in the Channelx Set up Signal submenu of the Keypad Program Cause The peak of the upstream or downstream correlation signals has fallen below the correlation peak limit as set in the Channelx Set up Signal submenu This may be caused by a flowcell or electrical problem Action 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 See Chapter 3 Diagnostics for further instructions E5 Amplitude Error Problem The signal amplitude exceeds the limits programmed in the Channelx Set up Signal submenu of the Keypad Program Cause Excessive levels of an attenuating gas such as CO may be present in the flowcell Solid or liquid particulates may be present in the flowcell Action Refer to Chapter 3 Diagnostics to correct any flowcell problems E6 Cycle Skip Accel Problem The acceleration exceeds the limits programmed in the Channelx Set up Signal submenu of the Keypad Program Cause This condition is usually caused by poor flow conditions or improper transducer alignment Action Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems E7 Analo
73. oard Assembly cont Note Ifthe thermal gap filler pad of the power supply board has been damaged you must remove and replace it before reinserting the power supply board First remove and discard the damaged pad Then remove the blue protective liner from the new pad and apply it with the white face against the power supply board 3 Secure the power supply board and heat sink to the main board by reinstalling the screws flat washers and lock washer previously removed from the corners of the power supply board See Illustration 11 in Figure 8 on page 35 4 Refer back to Illustration 7 in Figure 7 on page 34 Carefully align the terminal board onto the main board power supply assembly and the two option boards Slot 1 and Slot 2 where applicable so that the connectors listed in Table 5 are facing each other Table 5 Matings for Terminal Board Terminal Board Mating Board J7 Connector Large Three Pin Connector Plug Power Tab on AC Power Supply Board J6 Connector Large Three Pin Connector Plug Power Tab on DC Power Supply Board P7 Connector J7 Connector on Main Board P10 Connector J9 Connector on Main Board P9 Connector J10 Connector on Main Board P8 Connector J8 Connector on Main Board P21 Connector J1 J3 Connector on I O Board Slot 2 Option P22 Connector P2 Connector on I O Board Slot 1 1 2 3 4 5 6 7 8 Firmly press the terminal board and the interconnect board toward each ot
74. ontent intended for this page DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView Appendix B Calibration and Testing with PanaView B 1 Introduction This appendix explains how to calibrate the Model XGM8681 s analog outputs and inputs using PanaView interface software In addition testing the optional totalizer frequency and alarm relay outputs and XGM hardware and software is discussed The appendix includes the following specific topics e calibrating the Slot O analog outputs e calibrating option card analog outputs e calibrating option card analog inputs and RTD inputs testing option card alarm relays e testing option card totalizer and frequency outputs e uploading XGM868i signal array data and memory data e testing the EPROM RAM and DAC setting the number of channels e resetting the XGM868i to default values The Model XGM868i 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 are available In addition every Model XGM8681 flowmeter includes two built in analog outputs A and B at terminal block J1 which is designated as Slot 0 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 RS485 option cards See Chapter 1 Installation and Appendix B Data Records in the Startup Guide f
75. or a complete description of the available option cards and the procedures for wiring them DigitalFlow XGM868i Service Manual 41 Appendix B Calibration and Testing with PanaView B 2 Accessing the Calibration Test Menu The Calibration Test menu is accessed through the New Meter Browser menu of PanaView software Use this menu to calibrate and test the Slot 0 analog outputs as well as to calibrate and or test any option cards that are installed in expansion Slot 1 Refer to the menu maps in Figure 3 on page 11 as a guide in following the calibration instructions IMPORTANT Before you attempt to communicate with the XGM8681 be sure you have linked your PC to the XGM868i via an RS232 interface For details on wiring the interface refer to Wiring the Serial Port in the Startup Guide and to the document EIA RS Serial Communications 916 054 You must also install PanaView as discussed in the PanaView User s Manual 910 211 Power up the XGM868i and wait until it has initialized Launch PanaView and wait until it initializes the XGM868i and displays the basic PanaView window As described in the PanaView User s Manual open the Meter Browser window and highlight the XGM8681 eS m Expand the Edit Functions option The window now appears similar to that shown in Figure 9 E 3 XGM868i Y4AM STD Channel 1 Channel 2 Sum Difference Average Meter Logs E 2 SITE EDIT MENU CALIBRATION TEST PAUSE MEASUREMENT Figure 9
76. r 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 instructions 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 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 Signal strength above 75 The XGM868i is supplied with a signal preamplifier However this amplifier may not be necessary for high pressure applications If the meter has a signal strength above 75 bypass the preamp and connect the coax cable directly to the transducers DigitalFlow XGM868i Service Manual 21 Chapter 3 Diagnostics 3 4 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
77. r of pulses will then be output at the specified frequency 5 Repeat steps 2 3 and 4 to test all of the available totalizer outputs If any of the totalizer outputs fails the test contact GE for assistance Click Exit Page to return to the Slot 1 window and calibrate additional inputs outputs or click Exit Page again to close the Calibration Test menu 50 DigitalFlow XGM868i Service Manual Appendix B Calibration and Testing with PanaView B 4 8 Testing Frequency Outputs Frequency outputs may be added to the Model XGM868i by installing an appropriate option card in Slot 1 This option card contains two or four frequency outputs which are designated A B C and D Prepare for the testing procedure by connecting a frequency counter to Output A of the option card See Figure 2 on page 8 for frequency output wiring and Figure 4 on page 12 to identify the OUT and RTN pins for Output A on terminal block J2 1 Inthe center pane of the Calibration Test window double click on Slot 1 2 Double click on the desired output to open the Frequency Output menu Output A will be used as an example in this manual IMPORTANT The procedure for testing Outputs B C or D is identical to that for testing Output A However be sure to reconnect the frequency counter on terminal block J2 See Figure 4 on page 12 for the correct pin numbers 3 At the Frequency prompt enter a frequency between 1 and 10 000 Hz and click Next Item
78. roll to INIT and press Enter 2 The screen displays the initial string ESKEO Use the left and right arrow keys to move among characters and the up and down arrow keys to alter each character until the string is FRIG plus the number of channels that is FRIG1 or FRIG2 Press Enter The XGM868i reinitializes with factory default settings and displays the message Review meter settings Since the default for the meter display is OFF you will need to enter the Keypad Program to reset the LCD as described below 3 Press Escape Enter Escape 4 Inthe Keypad Program window scroll to PROG and press Enter 5 Inthe PROG menu scroll to GLOBL and press Enter 6 Scroll to I O and press Enter DigitalFlow XGM868i Service Manual 63 Appendix C Factory Tests C 3 Resetting the XGM868i to Factory Defaults cont 7 Scroll to LCD and press Enter 8 The window now asks for the of LCD Parameters Scroll to the desired number from OFF through 1 4 and KEY and press Enter For a 1 Channel XGM868i the data for Channel 1 is displayed automatically and you can skip to step 9 However for a 2 Channel meter the channel data to be displayed must be specified at the following prompt 9 Scroll to the desired Channel option as listed in Table 11 Table 11 Channel Options Channel 1 Channel 2 CH1 CH2 CH1 CH2 CH1 CH2 2 10 For each channel select the desired Measurem
79. s at the rear of the enclosure Refer to Illustration 3 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 four mounting screws flat washers and lock washers previously removed Refer to Illustration 2 IMPORTANT Jf the circuit board assembly is inserted too far into the enclosure it cannot be rotated properly 3 Attach the loose end of the green grounding jumper wire 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 Refer to Illustration 2 4 From the rear of the enclosure connect the power line leads to terminal block TBS Plug the connectors back into terminal blocks J1 J4 If necessary see Chapter 1 Installation of the 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 Refer to Illustration 1 The Model XGM8681 is now ready to be placed back into service Before taking measurements with the Model XGM868i 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 an
80. section for specific instructions on each of the options available in step 3 B 4 2a 4mA Option Set the calibrated current source to 4 mA e Ifyou selected the 4 mA option in the Analog Input menu double click on Store to accept the current 4 mA value or on Abort to cancel the entry In either case the Analog Input prompt reappears B 4 2b 20 mA Option Set the calibrated current source to 20 mA e If you selected the 20 mA option in the Analog Input menu double click on Store to accept the current 20 mA value or on Abort to cancel the entry In either case the Analog Input prompt reappears Click Exit Page to return to the Slot 1 window and calibrate additional inputs outputs or click Exit Page again to close the Calibration Test menu DigitalFlow XGM868i Service Manual 47 Appendix B Calibration and Testing with PanaView B 4 3 RTD Inputs RTD inputs may be added to the Model XGM8681 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 and slope temperature values for each input must be calibrated Calibration of the RTD inputs requires the use of a calibrated RTD source IMPORTANT Zf a Slot O analog output will be used to calibrate the analog inputs the Slot 0 analog output calibration procedure must be completed first Prepare for the calibration procedure by connecting an independent calibrated RTD source to t
81. ssure Input Error E9 o o oooooooo 16 Printed Circuit Board EPROM 28 Problems Transducers 000 00000 eee 22 Q Odown bn aia els cda da Ol REL e e 19 UP II A A ere ey oes 19 R RAM Tetudas bata 56 Replacing See Part Name Return Pole A oS cat le eS tha 69 REV Massi ie See 61 REY Totals adas road be eee as 61 RTD Inputs Option Card Calibrating 6 RTD Inputs Calibrating with PanaView 48 RTD Set Point Entering in PanaView 48 RTD Slope Point Entering in PanaView 48 S Service Record osa ARA 37 Set Point in RTD Calibrati0d 6 Signal Array Data Uploading w PanaView 52 Signal Quality Error E4 oo ooooo 15 SOPAS EY 48 in RTD Calibrations lt sccs45 sdaude aeaee 6 SND SPa tes ss Nisei Sa tat os Bred is ld MS A IR 19 DigitalFlow XGM868i Service Manual Index S cont Sotindspeeds vi e a ata pee hoe Lite de 61 A Kew ie we NERS AO aA 14 Gas eye eye Soe Lees Pee nk Teo se 20 Special Input Error El0 o ooooooo 16 SOdO ii rs oa 19 ESTU A eee 19 O gine ee eh eR EERE EL he eS 61 VOL aria 19 T A A eee 19 A silico N Senn tat ele SSed ES 19 A ce orc E r En hase teh AA 19 TEMP tios Dene Bee Hae hehe e Ate ida e 19 Temperature e eee Se eh eh ead eek 61 Temperature Input Error E8 15 Testing Alimi A estas ade a ag aaa 7 Frequency Outputs podais 10 Totalizer Outputs c
82. t WEEE take back initiative directive 2002 96 EC The equipment that you bought has required the extraction and use of natural resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the appropriate take back systems Those systems will reuse or recycle most of the materials of your end life equipment in a sound way The crossed out wheeled bin symbol invites you to use those systems If you need more information on the collection reuse and recycling systems please contact your local or regional waste administration Visit http www gesensing com environment weee htm for take back instructions and more information about this initiative iv DigitalFlow XGM868i Service Manual Contents Chapter 1 Calibration 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 Introduce cae do ale 1 Accessind tie Can DOOM A ag a ea ey ere A 1 Calibrating and Testing Analog QUIPUES at a Jade eee ladda See ee than wa acd eee i 2 aio ose AON AAA A tied fdedc ca tent Moa 2 1 3 2 Calibrating the Low End of the Output Range tiie sce ce e oe 3 1 3 3 Calibrating the High End of the Output Range scientists ds ida 3 1 34 Testing ASA A A tee 3 Calibrating Andog Als a a te a A ne Na ES 4 sl se AAA eek doe ee Soe oe ete cadena td ee cane ab
83. ted Note The zero point of the analog output may be set for either O mA or 4 mA However the calibration procedure always uses the 4 mA point as the meter will extrapolate this value to obtain the O mA point Prepare for calibration by inserting an ammeter in series with the load on Output A of the option card See Figure 4 on page 12 to identify the OUTI and RTN pins for Output A on terminal block J2 2 Double click on either Output A or Output B to open the Analog Output menu Output A will be used as an example in this manual IMPORTANT The procedure for calibrating Output B is identical to that for calibrating Output A However be sure to reconnect the ammeter on terminal block J2 See Figure 4 on page 12 for the correct pin numbers 3 Double click on 4 milliamps to calibrate the low end of the output range 4 Double click on 4 mA UP or 4 mA DOWN to adjust the ammeter reading UP or DOWN until a 4 mA reading is achieved or Double click on 4 mA Numeric Cal and directly enter the mA reading in the right pane 5 Once you have achieved a 4 mA reading double click on either 4 mA STORE to store the calibration or on 4 mA ABORT to exit the menu without storing the calibration Note Ifthe ammeter reading cannot be adjusted within 5 0 yA of the 4 or 20 mA setting contact the factory for assistance 6 PanaView returns to the Analog Output window Double click on 20 milliamps and repeat steps 3 through 5 to calibrate the
84. ted Current Source 4 47 48 Calibrating a Aia 43 A e enere penr ees eRe AS ae ai 43 R solutions neeese ene eevee eek ee cee Rt 43 Analog Outputs Option Card A pS Gk ine ar ae ues ake Bae 46 Calibrating with PanaView 47 48 Bi AAA es a Aea EE at 46 47 48 Resolution inate eit ee Bek 46 47 48 Arow Keys mre o a de 63 B Bracket Option Card 2s44nc500 datos a 29 DigitalFlow XGM868i Service Manual Index C Calibrating See Parameter Name Calibration Values Displaying on PanaView 58 with Keypad Program asia da 1 Calibration Test Menu 00 1 42 Entering Meni dais 42 Channels Resetting Number of cd bts es 63 Setting Number with PanaView 59 ENT sarta Aa eee 19 INTE td a ha lc ce Rap a 19 Contamination Gas 0 0 cee eee eee 20 Corrosion Transducers ooooo ooo 22 D DAC Vest 580 ces en a 57 Defaults Resetting Meter t0 o ooooooo 63 DELTA 05 8 aa ek koi OM sat SS a aes 19 Deli Efes dd la ahd vt de bl er Ot SE 61 Delta TM irritan 61 Delta T S sii DARE A 61 Diagnostic Parameters Displaying 0 ias da 17 Table Ol Vale orase tpe Ra ii 39 Display OD aa ea Sy E tage a E ay a 26 a ty fo Reet Rute Oe ey ee 26 Display Screen Error Messar par atea 13 Illustration DA A RS 13 Displaying Diagnostics oooooooooooo o 17 DN Amp Discrim seri iaa Aaa 61 DN DAG Counte lr 61 DN Sip Strength tE Sens
85. testing a different output be sure to reconnect the ohmmeter at terminal block J2 See Figure 4 on page 12 for the correct pin numbers 4 Do one of the following Press Enter on Close The ohmmeter should yield a reading of about zero Press Enter on Open 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 is selected and zero when Open Alarm is selected Procedure Options This completes testing of the Slot 1 alarm relays Do one of the following To test the normally open and normally closed contacts for another alarm relay return to Step 3 in Testing the Relay above e To calibrate test additional inputs outputs proceed to the appropriate section e To leave the Keypad Program press Escape twice DigitalFlow XGM868i Service Manual 7 Chapter 1 Calibration 1 7 Testing Totalizer Outputs Totalizer outputs may be added to the Model XGM868i 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 1 7 1 Preparing for Testing Prepare for the testing procedure by connecting a pulse counter to the desired output of the option card See Figure 2 for totalizer output wiring and Figure 4 on page 12 to identify the OUT and RTN pins for Outp
86. the procedures for wiring them 1 2 Accessing the Calibration Menu The Calibration menu is accessible through the Keypad Program as well as through PanaView software If you are using PanaView to calibrate the XGM868i refer to Appendix B Use this menu to calibrate and test the Slot 0 analog outputs as well as to calibrate and or test any option cards that are installed in expansion Slot 1 Refer to the menu maps in Figure 3 on page 11 as a guide in following the calibration instructions 1 Power up the XGM868i and wait until it has initialized 2 Press the Escape Enter Escape keys The Keypad Program appears on the screen 3 Press the right arrow key to scroll to the CALIB menu Press Enter The Cal window opens Proceed to the appropriate sections of this chapter to calibrate and or test any of the installed inputs and or outputs Note The Calibration menu never returns to the Keypad Program Pressing Escape to exit the menu causes the XGMS68i to restart DigitalFlow XGM868i Service Manual 1 Chapter 1 Calibration 1 3 Calibrating and Testing Analog Outputs Every Model XGM868i 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 XGM868i 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 a
87. ut A on terminal block J2 Totalizer Output Transmitter Pulse Counter Volts Int Pwr Sup lt Load Volts Common Frequency Output Transmitter Frequency Counter 5V gt 2000 OUT IN RTN Common Figure 2 Totalizer and Frequency Output Wiring 1 7 2 Testing the Output 1 From the Keypad Program press the right arrow key to scroll to the CALIB menu Press Enter 2 Inthe Cal window scroll to Slot 1 Press Enter Note The Slot 1 option only appears at the above prompt if an option card is installed in this slot 3 Scroll to the desired Output Output A will be used as an example in this manual Press Enter IMPORTANT The procedure for testing all the outputs is the same However when testing another output be sure to reconnect the pulse counter at terminal block J2 See Figure 4 on page 12 for the correct pins 8 DigitalFlow XGM868i Service Manual Chapter 1 Calibration 1 7 2 Testing the Output cont 4 Use the arrow keys to enter a value for the minimum pulse on time between 1 usec and 10 000 usec for the frequency of the totalizer pulses and press Enter Note A complete pulse consists of equal amounts of ON and OFF times Choose a value that is compatible with the pulse counter to be used 5 Use the arrow keys to enter a value for the number of measurem
88. y push the circuit board assembly through the enclosure and remove it from the front of the enclosure Refer to Illustration 3 in Figure 6 on page 33 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 DigitalFlow XGM868i Service Manual 25 Chapter 4 Parts Replacement 4 3 Replacing the LCD Display Interconnect Board Subassembly The LCD display normally provides years of dependable service but it is easily field replaceable when necessary To replace the LCD display see Figure 7 on page 34 for the component locations and complete the following steps 1 2 Complete the steps in Removing the Circuit Board Assembly on page 24 Place the circuit board assembly on a flat surface with the LCD display board facing upward Refer to Illustration 4 in Figure 7 on page 34 and remove the three mounting screws with flat washers and lock washers indicated Grasp the LCD display keypad board interconnect board subassembly at the top and bottom edges and carefully pull it straight upward until it comes free from the main board and option boards Refer to Illustration 5 in Figure 7 on page 34 Remove two screws from the back of the interconnect board Then hold the edge of the keypad board by one hand and the edge of the LCD display interconnect board by the other hand and pull the two boards apart Note The two circuit boards are

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