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DigitalFlow™ XGF868i Service Manual

1. DigitalFlow XGF868i Service Manual no content intended for this page 60 Appendix C Factory Tests Appendix 6 Factory Tests C 1 Introduction For user security the XGF8681 offers two special functions in a separate menu selection of one channel or two 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 Escapel 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 In the 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 XGF868i returns to the Factory Test menu Press Escape to return to parameter display 6 3 Resetting the XGF868i to Factory Defaults 1 In the Factory Test menu scroll 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 a
2. Nylon Washer Bracket Bracket Keypad Board Screw with Washer Assembly gt ON 2 places E E Interconnect Board I O Board Slot 1 Flat Washer cS with Heatsink P1 Connector on Interconnect Board Figure 8 Model XGF868i 0 Option Card Subassembly Lock Washer messes J2 Connector on J1 Connector on I O Board Option Board Slot 2 Slot 1 with Heatsink id Screw Illustration 1 Illustration 10 DigitalFlow XGF868i Service Manual 35 Chapter 4 Parts Replacement no content intended for this page DigitalFlow XGF868i Service Manual 36 Appendix A Service Record Appendix A Service Record A 1 Introduction Whenever any service procedure is performed on the XGF8681 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 XGF868i in Table 6 below Make additional copies of the table as needed Table 6 Service Record Description of Service Performed By DigitalFlow XGF868i Service Manual 37 Appendix A Service Record Table 6 Service Record cont
3. Description of Service Performed By 38 DigitalFlow XGF868i Service Manual Appendix A Service Record A 3 Diagnostic Parameters After a successful initial installation of the XGF868i and whenever any system malfunction is noticed the values for the diagnostic parameters should be entered in Table 7 below Table 7 Diagnostic Parameters Parameter Initial Current Parameter Initial Current DELTA Mw REYN Tot K PEAK Qup Qdown AMPup AMPdn lavailable only if Burst Mode S M DigitalFlow XGF868i Service Manual 39 DigitalFlow XGF868i Service Manual no content intended for this page 40 Appendix 8 Calibration and Testing with PanaView Appendix B Calibration and Testing with PanaView B 1 Introduction This appendix explains how to calibrate the XGF868i analog outputs and inputs using PanaView interface software In addition testing the optional totalizer frequency and alarm relay outputs and XGM868i hardware and software is discussed The appendix includes the following specific topics e Calibrating the Slot 0 analog outputs e Calibrating option card analog outputs e Calibrating option card analog inputs and RTD inputs e Testing option card alarm relays e Testing option card totalizer and frequency outputs e Uploading XGF868i signal array data and memory data e Testing the EP
4. 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 85 30 NVR Test 1 From the left pane of the Calibration Test window double click on Hardware Test Note Jf you are in the Hardware Test option skip to step 2 2 In the 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 the test 4 Ifthe NVR passes the test the screen appears similar to Figure 15 below Click Exit Page to return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu Program memory test Previous Item Inverted bit pattern 54 No errors detected Next Item Execute test Yes WARNING RThe selected test will require several minutes for comp TESTS NVR TEST EPROM sum 56 TESTS EPROM TEST p Exit Page w CALIBRATION TEST Figure 15 Completion of the NVR Test 53 DigitalFlow XGF868i Service Manual Appendix B Calibration and Testing with PanaView 8 5 36 RAM Test To check the RAM Note f 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 RAM TEST 3 The right pane displays
5. CE Ntrod ctoMcs senate tae Scat a ele tea ae eat CAN C 2 Resetting the Number of Channels uuaa C 3 Resetting the XGF868i to Factory Defaults vi Chapter 1 Calibration Chapter 1 Calibration 1 1 Introduction Calibrating the XGF868i 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 e 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 e Testing option card frequency outputs page 7 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 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 XGF868i 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 9 as a guide in following th
6. 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 on page 29 4 7 Assembling 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 31 See Figure 8 on page 35 and complete the following steps 1 If necessary 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
7. 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 ouble 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 the 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 high 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 XGF868i Service Manual Appendix 8 Calibration and Testing with PanaView 8 3 Calibrating Slot 0 Analog Outputs cont Table 8 Expect
8. 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 see Illustration 1 The XGF868i is now ready to be placed back into service Before taking measurements refer to Chapter 2 Initial Setup of the Startup Guide and Chapter 1 Calibration of this manual for instructions on properly setting up the meter for accurate flow rate measurements Note Be sure to enter a complete and detailed account of any parts replacement performed on the XGF868i in Appendix A Service Record To purchase the parts mentioned in this chapter or any items not specifically discussed contact GE for assistance To make sure the proper components are obtained be sure to include the serial number of your XGF868i when you place your parts order DigitalFlow XGF868i Service Manual 31 Chapter 4 Parts Replacement no content intended for this page 32 DigitalFlow XGF868i Service Manual Chapter 4 Parts Replacement Figure 6 Model XGF868i Electronics Console Assembly 33 Electronics Assembly Set Screw Rear Cover solid Illustration 3 Illustration 1 Enclosure Assembly Mounting Screw with Washer Assembly 4 places TB1 Set Screw 0 6 e elo 8 6 6 aooo 006 6 ooo 0 0 6 8 6 8 60 0 oO 6 Illustration 2 Terminal Block on Slot 2 Option Card Groun
9. Appendix 8 Calibration and Testing with PanaView B 5 1 Uploading the Signal Array Data cont e If you double click on To File another window opens similar to Figure 13 below Enter a file name and click Save PanaView stores the array data in a Windows file and closes the Calibration Test window Save in ja PanaView Log3 txt sa Site2 sit Logs meterConfigs mdb lus Site3 sit History Panaview_1 3 11_EXE_ONLY NewLog1 txt a Site4 prt 4 PanaYiew_1 3 7_Exe_Only s PanaCom ocx lus Site4 sit f d Panaview exe la Work1 sit Desktop B Panaview db am Work2 sit A Y Panaview mdb la working sit aa i E raw txt a working sit My Documents f a RawUP a xmTMEM a Site1 sit E sitet txt File name l My Network E Save as type an Files y Figure 13 Saving Signal Array Data to File B 5 2 Uploading the XGF868i Memory IMPORTANT This option is for factory use only The Upload XGM Memory option is another diagnostic tool IMPORTANT Consult with 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 DigitalFlow XGF868i Service Manual 51 Appendix 8 Calibration and Testing with PanaView 8 5 2 Uploading the XGF868i Memory cont 4 PanaVie
10. 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 Analog 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
11. 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 DigitalFlow XGF868i Service Manual 29 Chapter 4 Parts Replacement 4 7 1 Assembling the Circuit Board Assembly cont Note f the 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 below are facing each other Then firmly press the terminal board and the interconnect board toward each other until all of the conne
12. INPUT D RIN OUTD 24V INPUTD INPUT C RTN 17 HART OI 05 CI TIF 06 CR FR TR OUT A JOUT A c 14 IR 15 FHII 16 HART NOTES 1 MATERIAL 003 THK REF MYLAR WITH REVERSE SCREENING AND 3M 467MP OR EQUIVALENT ADHESIVE BACKING 2 MARKINGS BACKGROUND WHITE ALL MARKINGS PROCESS BLACK C 3 ALL COLORS PER PANTONE MATCHING SYSTEM 4 ALL DIMENSIONS PER 01 5 ARTWORK CREATED IN ADOBE ILLUSTRATOR FILE 442 615_N AI 6 ALL DIMENSIONS REFERENCE 04 FA FH TA TH CA CH 22 ORI 03 FO TO CO 01 AA HH 02 FF TT FT CT CF 11 AR HR 20 A GATE HART 10 OR OUT A OUT A 6 RTD A COMM A COM A OUTD 24V INPUT D INPUT D RTN 19 HART RI DigitalFlow XGF868i Service Manual Chapter 2 Error Codes Chapter 2 Error Codes 2 1 Introduction The XGF8681 ultrasonic flow transmitter is a reliable easy to maintain instrument When properly installed and operated as described in the
13. Sey ae cee den 3 13 4 Testing OULD UE Linearity el od cl 6 lg 3 1 4 Calibrating the Analog IN pits bat coe uh deh et Da et duties A a veneers Read 4 1 4 1 Preparing for Calibration A de ahah ee rnnr AEAEE EEEE 5 1 4 2 Accessing the Calibration Test MENU 0 cc cect cece teen rete een rr 5 1 5 Calibrating the RTD Inputs 00 dese laud edwertateiWaaataaeoy vada teewwey taeda ed ed 6 1 5 1 Preparing for CAMION a doo dE oa 6 1 5 2 Accessing the Calibrations Test Menu iis 045 2 ews ti eens AA ya eed 6 1 53 Entering the Set sexes ieee ola AA AA AAA CAER 6 1 5 4 Entering the 2 Gis cal tee ba tt Seas ta ache clas ated dd 6 1 6 Testing the Frequency Outputs 25 icons codons eos woe ee beens sid dad 7 1 6 1 Preparing for Testing A EA twee a bases 7 1 0 2 Testing th UU abla 8 Chapter 2 Error Codes 2 1 e he EE A 0 es 11 Chapter 3 Diagnostics BAL o A 3 17 3 2 Displaying Diagnostic Parameters 17 3 3 Flowcell Problems 5 a ii 20 3 21 G s Problems ati ida 20 3 3 2 Pipe Proble a gs da 21 34 Transducer rro MS 0 5 0 stole eth yt o ad e E 5 et ka 22 Chapter 4 Parts Replacement AT o O 23 4 2 Removing the Circuit Board Assembly 24 4 3 Replacing the LCD Display Interconnect Board Subassembly 0022022202 rererere 25 26 45 Replacing the
14. 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 XGF868i 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 18 DigitalFlow XGF868i Service Manual Chapter 3 Diagnostics 3 2 Displaying Diagnostic Parameters cont Table 3 Available Diagnostic Parameters Description Displays the flow velocity A N A Displays the volumetric flow A N A Displays the forward totalized volume flow A N A Displays the reverse totalized volume flow A N A Displays the total flow measurement time A N A Displays the mass flow A N A Displays the forward totalized mass flow A N A Displays the reverse totalized mass flow A N A Displays the signal strength for the upstream transducer gt 50 or gt 75 Displays the signal strength for the downstream transducer lt 50 or gt 75 Displays the measured speed of sound in the gas A N A Displays the upstream ultrasonic signal transit time A N A Displays the downstream ultrasonic signal transit time A N A Displays the transit time difference between the upstream and A N A downstream signals Displays the total number of K factors A N A PEAK Displays the percentage of peak s
15. 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 XGF868i press the lt or gt keys until you have reached the desired option 5 Scroll to the desired Channel option as listed in Table 9 below Table 9 Channel Options Option Description 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 59 7 Repeat steps 3 and 4 for each parameter PanaView returns to the Global I O menu 58 DigitalFlow XGF868i Service Manual Appendix 8 Calibration and Testing with PanaView gt 50 or gt 75 gt 50 or gt 75 N A N A N A N A N A N A 400 to 400 400 to 400 lt 19 or gt 29 lt 19 or gt 29 N A N A lt 100 or gt 2300 lt 100 or gt 2300 59 N A N A 100 2300 100 2300 B 5 3m Initializing the XGF868i to Default Values cont Table 10 Available Measurement Parameters Description Displays the flow velocity Displays the volumetric flow Displays the forward totalized volume flow Displays the reverse totalized volume flow Displays the total flow measurement time Displays the mass flow Displays the forward totalized mass flow Displays the reverse totalized mass flow Displays the signal strength for the upstream transducer Displays the s
16. 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 the Analog Inputs Analog inputs may be added to the XGF868i 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 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 f a Slot 0 analog output will be used to calibrate the analog inputs the Slot 0 analog output calibration procedure must be completed first 4 DigitalFlow XGF868i 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 c
17. outputs or is lt 1 000 ohms for an analog outputs option card in Slot 1 DigitalFlow XGF868i Service Manual 13 Chapter 2 Error Codes 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 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 currently 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
18. programmed path and axial length dimensions are correct DigitalFlow XGF868i Service Manual 15 Chapter 2 Error Codes no content intended for this page 16 DigitalFlow XGF868i Service Manual Chapter 3 Diagnostics Chapter 3 Diagnostics 3 1 Introduction This chapter explains how to troubleshoot the XGF868i 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 screen e Erratic flow readings e Readings of doubtful accuracy i e readings that are not consistent with readings from another flow measuring device connected to the same process If any of the above conditions occurs proceed with the instructions presented in this chapter 3 2 Displaying Diagnostic Parameters The XGF868i 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 Pana View 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 A 2 Scroll
19. 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 14 DigitalFlow XGF868i Service Manual Chapter 2 Error Codes 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 E15 Equation Limit Problem The meter cannot resolve the molecular weight of the gas based on the measured sound speed temperature pressure and N concentration Note The mw reading will appear as 2 0e3 or 3 0e3 in order to flag this condition Cause One or more of the above measurements must be incorrect Action Verify the pressure and temperature readings are correct Verify the programmed or input nitrogen concentration is correct Verify that the acoustic transit time measurements are operating properly and that the
20. A RS Serial Communications 916 054 You must also install PanaView as discussed in the PanaView User s Manual 910 211 Power up the XGF868i and wait until it has initialized Launch PanaView and wait until it initializes the XGF868i and displays the basic PanaView window As described in the PanaView User s Manual open the Meter Browser window and highlight the XGF868i e p p m Expand the Edit Functions option A window now appears similar to that shown in Figure 9 below E m XGM868i Y4AM STD Channel 1 Channel 2 Sum Difference Average Meter Logs Els r SITE EDIT MENU gt CALIBRATION TEST r PAUSE MEASUREMENT 1 Figure 9 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 below is 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 or test any of the installed inputs or outputs 42 DigitalFlow XGF868i Service Manual Appendix 8 Calibration and Testing with PanaView B 3 Calibrating Slot 0 Analog Outputs Every XGF868i flowmeter includes two built in analog outputs A and B at terminal block 1 which is designated as Slot 0 Both the zero point and full scale values for each output must be calibrated Aft
21. Displays Measure Delta T Displays the instantaneous velocity lavailable only if Burst Mode S M 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 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 XGF868i 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
22. GE Measurement 6 Control Flow DigitalFlow XGF868i Panametrics Flare Gas Flow Transmitter Service Manual 910 1985 Rev C imagination at work i www ge mcs com 2014 General Electric Company All rights reserved Technical content subject to change without notice DigitalFlow XGF8681 Panametrics Flare Gas Flow Transmitter Service Manual 910 1985 Rev C January 2014 no content intended for this page Preface Information Paragraphs Note These paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions IMPORTANT These paragraphs provide information emphasizing instructions which are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance WARNING Indicates a potentially hazardous situation which can result in serious personal injury or death if it is not avoided CAUTION Indicates a potentially hazardous situation which can result in minor or moderate injury to personnel or damage to the equipment if it is not avoided HIGH VOLTAGE This symbol indicates the presence of high voltage It calls your attention to situations or operations that could be dangerous to you and other persons operating the equipment Read these messages and follow the instructions carefully gt gt lt Safety Issues WARNING It is the respo
23. NG STORE ABORT Slot 1 y RTD Inputs 8 eJ b press EXIT key RTD INPUT Slope SLOPE TEMP 808 SET POINT TEMP CALIBRATING store aBORT EN Full Scale RESET Reset Totals cs Slot 1 y Analog Outputs a TEST ABORT En Full Scale Ca ANALOG OUTPUT mA STORE mA Reading Esc Enter Esc Keypad Pgm See Programming Manual SLOTO Slot 0 yAnalog Outputs e TEST ABORT 20 4 CALIBRATING Down Numer mA Reading a ANALOG OUTPUT 20 mA Numer Numer STORE gt Fama CALIBRATING DOWN P J DigitalFlow XGF868i Service Manual Chapter 1 Calibration Figure 4 Option Card I O Connections 10 C C RIN D D RIN OUTC INPU INPU OUTD INPU INPUT 09 Ol 08 Al HI HART OUT A HART OUT A c c c c OUTC 24V INPUT
24. ROM RAM and DAC Setting the number of channels Resetting the XGF868i to default values The XGF868i 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 XGF868i flowmeter includes two built in analog outputs A and B at terminal block J 1 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 communication cards See Chapter 1 Installation and Appendix B Data Records in the Startup Guide for a complete description of the available option cards and the procedures for wiring them DigitalFlow XGF868i Service Manual 41 Appendix 8 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 9 as a guide in following the calibration instructions IMPORTANT Before you attempt to communicate with the XGF868i be sure you have linked your PC to the XGF868i via an RS232 interface For details on wiring the interface refer to Wiring the Serial Port in the Startup Guide and to the document EI
25. 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 XGF868i 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 below Error Message CH1 MASS 4500 LB HR XGF868i LCD Display Figure 5 Error Message Location If an error message appears during normal operation of the Model XGF868i refer to the appropriate section of this chapter for instructions on how to proceed DigitalFlow XGF868i Service Manual 11 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 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
26. User Program siii A A dd 27 4 6 Installing an Option Card ci A a bs das 28 4 6 1 Attaching an Optional Heat Sink to an I O Option Card ccc ccc c eee ener e renee teen ene enees 29 4 7 Assembling Installing the Circuit Board ASSEMbIY ccc cece eect cece eter ence teen ene ne ee enenes 29 4 7 1 Assembling the Circuit Board Assembly 1 0 cc ccc cece cece eee eee eee nee eee eee teen eens 29 4 7 2 Installing the Circuit Board ASSEMDIY 1 cece cece eee nee en ene rr 31 DigitalFlow XGF868i Service Manual V DigitalFlow XGF868i Service Manual Contents Appendix A Service Record A L AU eS AZ Date ENY o OE A A 3 Diagnostic Parameters 002202022 Appendix B Calibration and Testing with PanaView A A hoot ante B 2 Accessing the Calibration Test Menu ro B 3 Calibrating Slot 0 Analog Outputs cece eee eee B 4 Calibrating Slot 1 Option Cards ccc cece eee e eens B 4 1 Analog Outputs coucooccicra tha ed ee ve thea va bad 0 4 2 Analog Input nee alee enue ens B43 ta att eii a taal oeaie de 8 4 4 Entering the Set Point ro 8 4 5 Entering the Slope ooocoococccccccnnccrnrnrr 8 4 6 Testing Frequency Outputs 00006222 B 5 Testing the XGF868i Software and Hardware B 5 1 Uploading the Signal Array 8 8 5 2 Uploading the XGF868i 160 8 5 3 Testing the XGF868i 306 Appendix C Factory Tests
27. 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 XGF868i Service Manual Appendix 8 Calibration and Testing with PanaView B 4 2 Analog Inputs Analog inputs may be added to the XGF868i 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 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 f 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 10 to identify the IN and RTNE pins for Input A on terminal block J2 Note The zero point of the analog input may be set for ei
28. ce 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 f the 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 XGF868i 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 XGF868i Service Manual 3 Chapter 1 Calibration 1 3 4 Testing Output Linearity cont Table 1 below lists the expected ammeter readings at various Full Scale settings for both 4 20 mA and 0 20 mA scales Refer to this table to verify the accuracy of the ammeter readings taken above Table 1 Expected Ammeter Readings Full Scale 4 20 mA Scale 0 20 mA Scale 0 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
29. ctors are completely seated Table 5 Mating Connectors for Terminal Board Terminal Board Mating Board J 7 Connector Large Three Pin Connector Plug Power Tab on AC Power Supply Board J 6 Connector Large Three Pin Connector Plug Power Tab on DC Power Supply Board P7 Connector 1 7 Connector on Main Board P10 Connector J 9 Connector on Main Board P9 Connector J 10 Connector on Main Board P8 Connector J 8 Connector on Main Board P21 Connector J 1 3 Connector on O Board Slot 2 Option P22 Connector P2 Connector on I O Board Slot 1 B wI N FP NM 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 llustration 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 30 DigitalFlow XGF868i Service Manual Chapter 4 Parts Replacement 4 7 2 Installing the Circuit B
30. d Screw Label Plate with Ground Symbol Grounding Jumper Wire DigitalFlow XGF868i Service Manual Chapter 4 Parts Replacement Figure 7 Model XGF868i LCD Display Interconnect Board Subassembly 34 Fuse Cover DC Power Supply Board Heatsink for AC Power Supply only Screw Lock Washer and Flat Washer 2 places Gap Filler for AC Power Supply only AC Power Supply Assembly 2 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 J2 Connector Bracket Screw P8 Connector on Terminal Board connects to J8 Connector on Main Board P21 Connector on Terminal Board connects to 43 Connector on Option Board Slot 2 P22 Connector on Terminal Board connects to P2 Connector on I O Option Board Slot 1 Bracket Nut Washer and Lock Washer Illustration 7 J7 for AC Power Supply Shown Mounting Screw and Washer Assembly 7 3 places P9 Connector on Terminal Board connects to J10 Connector on Main Board Green Grounding Jumper P10 Connector on Terminal Board connects to J9 Connector on Main Board Terminal Board igs connects to Power Tab on Power Supply Board P7 Connector on Terminal Board connects to J7 Connector on Main Board Standoff Pii Keypad B
31. d 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 1 IMPORTANT Transducers must be replaced in pairs Refer to Chapter 2 Initial Setup of the Startup Guide to program the new transducer data into the meter If the instructions in this section fail to resolve the problem contact GE for assistance DigitalFlow XGF868i Service Manual 22 Chapter 4 Parts Replacement Chapter 4 Parts Replacement 4 1 Introduction The XGF868i has been designed to permit easy on site upgrades and parts replacement See Figure 6 on page 33 for details of the standard XGF868i 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 Replacing the fuse Replacing the User Program e Installing an option card e Assembling installing the circuit board assembly WARNING Prior to performing any maintenance procedures be s
32. e calibration instructions 1 Power up the XGF868i 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 XGF868i to restart DigitalFlow XGF868i Service Manual 1 Chapter 1 Calibration 1 3 Calibrating and Testing the Analog Outputs Every XGF868i flowmeter includes two built in analog outputs A and B at terminal block J 1 which is designated as Slot 0 Additional analog outputs may be added to the Model XGF868i by installing an appropriate option card in Slot 1 This option card contains two analog outputs which are also designated as A and B Before beginning calibration an ammeter must be connected to the desired analog output Both the zero point and full scale values for all of these outputs must be calibrated After calibrating the outputs which have a resolution of 5 0 LA 0 03 full scale their linearity should be tested Note The zero point of the analog output may be set at either O mA or 4 mA However the calibration always uses the 4 mA point as the meter extrapolates this value to obtain the 0 mA point 1 3 1 Preparing fo
33. e es 53 Testing with PanaView Frequency Outputs oonan ns eset aes 49 Hardware and Software 49 TIME RS 19 59 TOUR eroris 2 EARS ELS 19 59 Totals Overflow Error El4 o o oo 15 MOTE a Sd 19 59 Transducers ComrosiONn 3 246 nce eee ee eed eae ewe ee a 22 Internal Damage aia 22 Leaks eresia e a a r r r E T aA 22 DigitalFlow XGF868i Service Manual Index 66 DigitalFlow XGF868i 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 the 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 one year from delivery for electronic or mechanical failures 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 incl
34. ed 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 above check the accuracy and wiring of the ammeter Then repeat the low and high end calibrations If the analog output still does not pass the linearity test contact the factory for assistance 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 calibrate additional inputs outputs B 4 Calibrating Slot 1 Option Cards To calibrate any option card installed in Slot 1 of the XGF868i 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 exam
35. ep 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 1 2 3 B 5 3 Programming an Optional Card EEPROM To program the EEPROM for an optional card From the left pane of the Calibration Test window double click on Hardware Test In the center pane double click on PROG OPCARD EEPROM 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 Inf
36. er 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 Terminal Block J1 Slot 0 Ammeter Figure 11 Ammeter Connection Output A A B SIG B shown in Figure 11 below 1 From the Calibration Test 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 3 DigitalFlow XGF868i Service Manual Appendix B Calibration and Testing with PanaView B 3 Calibrating Slot 0 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 1 See Figure 11 on page 43 for the correct pin numbers 4
37. et to 50 by default N A N A Qup Displays the signal quality for the upstream transducer gt 1200 400 to 400 Qdown Displays the signal quality for the downstream transducer gt 1200 400 to 400 AMPup Displays the value for the signal amplitude of the upstream trans 5 lt 19 or gt 29 ducer AMPdn Displays the value for the signal amplitude of the downstream 24 5 lt 19 or gt 29 transducer CNTup Displays the AGC DAC count for the upstream gain setting N A N A CNTdn Displays the AGC DAC count for the downstream gain setting N A N A P up Displays signal 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 N A PRESR Displays the gas pressure from 0 4 20 mA input N A N A Mw Displays the molecular weight N A N A 2 Displays the compressibility N A N A Displays actual volumetric flow N A N A Displays standard volumetric flow N A N A Displays Skan transit time upstream DigitalFlow XGF868i Service Manual 19 Chapter 3 Diagnostics Table 3 Available Diagnostic Parameters cont Option Bar Description Displays Skan transit time downstream Displays Skan Delta T Displays Measure transit time upstream Displays Measure transit time downstream
38. h law ag ee pate 11 Ammeter Readings 4 44 46 Displaying Diagnostics 7 17 As Calibrated Current Source 4 47 48 1 20 59 A id acacia OF Be eet a eet a he 43 DTS eee eee eee eee eee ees 20 59 Linearity eea 0 et eg ieee kG 43 E R solution wae Ss 43 EPROM Analog Outputs pion Card Replacing iee ware Rare oe we 27 Calibrating 45 s ser Aaa 46 Sins eat eee ts 27 0 53 Linearity A eres SHR Ses 46 47 48 Error Code Resolution ooocooooocomcorc om 46 47 48 OS E wap ete oy eee a ey es 12 KEYS 01 12 8 PER Sd ce Was he Mes ad IN 14 Bracket Option Calas cies tan in 28 14 AE E EE Berar anger ear er ar Baer Te prey are 14 c EA T 15 Calibrating EET 15 See Parameter Name PA nea a A e a eee 12 Calibration 8 12 Values Displaying on PanaView 56 Pt edo 13 with Keypad Program sees eee 1 BS 25 0 0 OR oe 13 Calibration Test Menu naonnana aaan 1 42 e MAA EA AN 13 EnterineMenlss 6 42 A e 13 DigitalFlow XGF868i Service Manual 63 M IAS A AA 19 59 MDOT 8 19 59 Memory Data Uploading with PanaView 51 N N Errors El cita et doit 12 A II beanie wf 53 0 Option Card Analog pus Seg eee at Bees 4 Analog Outputs 3 steers 2 46 47 48 Bickle satura a TS ee 28 Calibrati
39. his page 68 DigitalFlow XGF868i 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 ge mcs com en about_us quality html www ge mcs com 2014 General Electric Company All rights reserved Technical content subject to change without notice 910 1985 Rev C
40. iched 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 1 Disconnect the power to the XGF8681 and move the electronics enclosure to a safe area Note fthe 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 XGF868i must be disconnected before proceeding 2 Refer to Illustration 1 in Figure 6 on page 33 and loosen the set screw on the rear cover Place a rod or long screwdriver across the cover in the slots provided and rotate the cover counterclockwise until it comes free from the enclosure 3 Repeat Step 2 to remove the front cover 4 From the rear of the enclosure disconnect the power line leads from terminal block TB5 Unplug terminal blocks TB1 to TB6 from connectors 11 14 24 DigitalFlow XGF868i Service Manual Chapter 4 Parts Replacement 4 2 Removing the Circuit Board Assembly cont 5 Refer to Illustration 2 in Figure 6 on page 33 and remo
41. ifier 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 1 DigitalFlow XGF868i 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 LEAKS Leaks may occur around the transducer and or the flowcell fittings Repair such leaks immediately If the leaking gas is corrosive carefully check the transducer and cables for damage after the leak has been repaired CORROSION DAMAGE If the transducer material was not properly chosen for the intended application the transducers may suffer corrosion damage The damage usually occurs either at the electrical connector or on the transducer face If corrosion is suspected remove the transducer from the flowcell and carefully inspect the electrical connector and the transducer face for roughness and or pitting Any transducer damaged in this manner 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 an
42. ignal strength for the downstream transducer Displays the measured speed of sound in the gas Displays the upstream ultrasonic signal transit time Displays the downstream ultrasonic signal transit time Displays the transit time difference between the upstream and downstream signals Displays the total K factor Displays the percentage of peak set to 50 by default Displays the signal quality for the upstream transducer Displays the signal quality for the downstream transducer Displays the signal amplitude value of the upstream transducer Displays the signal amplitude value of the downstream transducer Displays the AGC DAC count for the upstream gain setting Displays the AGC DAC count for downstream gain setting Displays signal peaks for the upstream transducer Displays signal peaks for the downstream transducer Displays the gas temperature from 0 4 20 mA input Displays the gas pressure from 0 4 20 mA input Displays the molecular weight Displays the compressibility Displays actual volumetric flow Displays standard volumetric flow Displays Skan transit time upstream Displays Skan transit time downstream Displays Skan Delta T Displays Measure transit time upstream Displays Measure transit time downstream Displays Measure Delta T Displays the instantaneous velocity TIME MDOT MASS MASS Tot K PEAK Qup AMPup DigitalFlow XGF868i Service Manual
43. in the gas flow may result in erratic or inaccurate flow rate readings 20 DigitalFlow XGF868i Service Manual Chapter 3 Diagnostics 3 3 1 Gas Problems cont 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 El error code message will appear on the display screen to indicate that the ultrasonic signal strength is insufficient for reliable measurements The gas sound speed must not vary excessively The XGF868i will tolerate relatively large changes in the gas sound speed as may be caused by variations in gas composition and or temperature However such changes must occur slowly Rapid fluctuations in the gas sound speed to a value that is considerably different from that programmed into the XGF868i 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 2 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 The collection of material at the transducer location s Accumulated debris at the transducer location s will interfere with transmission of the
44. ipment WEEE Directive GE Measurement amp Control is an active participant in Europe s Waste Electrical and Electronic Equipment 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 ge mcs com en about us environmental health and safety weee html for take back instructions and more information about this initiative iv DigitalFlow XGF868i Service Manual nts Conte Chapter 1 Calibration 7 1 1 2 Accessing the Calibration Menu 0 sive AAA AAA AAA AAA AAA ee 1 13 Calibrating and Testing the Analog Outputs 00 0 0 cece ccc e eee eer e eee rr 2 1 3 1 Preparing pais adios 2 1 3 2 Calibrating the Low End of the Output RANGe cece eee c cece een ee erence rr 3 1 3 3 Calibrating the High End of the Output Range gt aes ce ae Pie
45. l to STORE to accept the current 4 mA value or on ABORT to cancel the entry Press Enter In either case the XGF868i returns to the Analog Input window 1426 20 mA Option Set the calibrated current source to 20 mA e If you 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 XGF868i 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 XGF868i Service Manual 5 Chapter 1 Calibration 1 5 Calibrating the RTD Inputs RTD analog inputs may be added to the XGF868i 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 calibration 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 10 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 appea
46. led 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 Removing the Circuit Board Assembly 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 27 3 Remove the screw from the angle bracket on the main board as shown in llustration 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 Thereis a 36 pin connector P2 and a 30 pin connector P1 on the rear of the interconnect board The option cards must be plugged into these connectors a To install a communication 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 1ts connector When properly installed the side of the option card with the 36 pin connector must face the center of the interconnect board and the edge of the option card must not overhang the edge of the interconnect board b To install an I O option card with optional heat sink into Slot 1 orient the option card so that its 30 pin connector is positioned
47. ly 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 llustration 8 in Figure 7 on page 34 It is the only socketed chip on this board and it has a white identification label Using a chip puller remove the EPROM from its socket If a chip puller is unavailable a straightened paper clip may be used in the notches at the upper right and lower left corners of the socket Gently 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 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 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 5 7 Complete the User Program replacement by proceeding to Assembling the Circuit Board Assembly on page 29 DigitalFlow XGF868i Service Manual 27 Chapter 4 Parts Replacement 4 6 Installing an Option Card The XGF868i flowmeter can accommodate up to two option cards A communication card may be instal
48. n E A 5 47 AMAPOLA S 47 K Keypad Program for Calibrati0N 1 L LCD Contrast Changing with PanaVieW o oo 55 LCD Displays A a Ca 2 25 LCD Test 4 0 nicr bradanan dde pea ene 54 Leaks 118500068 22 Low Pressure Error E12 none Gaede ob aek 14 Low Signal Error El aid ada dra 12 LVD Statement asada 23 64 Index 65 Physical Damage o Placement Tu M Upload XMT Memory with PanaView Uploading Signal Array Data User Program EPROM Upgrading ooo See Part Name e A 70 0 07 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 5 Service 6001 ew aw eae x 37 Set Point in RTD Calibration 6 Signal Array Data Uploading w PanaView 50 Signal Quality Error 4 4 13 A 5 0 8 48 in RTD Calibre 0 oe ee 6 dr 19 59 Soundspeed PRO a e ls 12 Gas 0 60700 ii dir 21 Special Input Error BIO oo 14 A O ati 19 59 0 ui iaa 19 59 O A Eee Ge ek ees eS 19 59 T IEE CR 20 59 gt A O ah eee 20 59 ole A PG Lee ee 19 59 5 10 e ad eel 19 59 Temperature Input Error E8 o oooooo 14 Testing Frequency Outputs 4 gt 7 XMT868 Hardware 4007 vpwtace terse ee
49. nd 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 XGF868i re initializes 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 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 ee Scroll to I O and press Enter DigitalFlow XGF868i Service Manual 61 Appendix 6 Factory Tests 6 3 Resetting the XGF868i 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 9 Scroll to the desired Channel option as listed in Table 11 below Table 11 Channel Options option Description Channel 1 Channel 2 CH1 CH2 CH1 CH2 CH14CH2 2 10 For each channel select the desired Measurement 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 Gl
50. ng with PanaVieW 45 Expansion a ta ea dd do de 1 41 Frequency Outputs aonana snanar nunna 7 Spe a Da A ee SNS od EA 28 IR AA O A 6 Optional Card EEPROM Programming with PanaVieW 56 Reading with PanaVieW 57 Over Range Error E13 cee aches casas 15 P 19 59 A A E 19 59 PanaView for Calibrating 42 PEAK ui AAA 19 59 Pipe 6 cit dada eee 21 Problems dt ap rio we au 21 PRES E eat aaa 19 59 Pressure Input Error 9 14 Printed Circuit Board EPROM 27 Problems 17450100678 22 0 6 O a O A th 8 19 59 OUP miy rRe poe AR 19 59 R RAM Testi 45 abe wes ee ee tes 54 Replacing DigitalFlow XGF868i Service Manual Index BS paces y cele ee katie eects 14 BO edad teats eek eben l 14 Error Message Display Screen 11 Expansion Slots cias iaa 1 41 F Factory Test anos dnd 61 Factory Test Menu ara 61 FIFO Tests Sard dete paid ado da 54 Flowcell Problems Casa e alos o adas so Bo a 20 a 21 Frequency Option Card Testin8 7 Frequency Outputs Testing w PanaView 49 Fuse Replacing 3 0044 io oe ie wee ee 26 G Gas Contamination eeose seese eere 20 Physical Requirements sa 829 044 20 Pr blemS enpo er EEEE UTS 20 Ji A A Sens aps ER 21 H Hardware Testo 53 l Initializing Meter with PanaView 57 Inputs 20 mA Optio
51. nnect 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 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 4 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 5 Secure the keypad board to the interconnect board with the two screws flat washers and lock washers previously removed 6 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 i
52. nsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe operating conditions are met for each installation gt 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 DigitalFlow XGF868i Service Manual iii Preface 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 Environmental Compliance Waste Electrical and Electronic Equ
53. nterconnect board subassembly replacement by proceeding to Installing the Circuit Board Assembly on page 31 DigitalFlow XGF868i Service Manual 25 Chapter 4 Parts Replacement 4 4 Replacing the Fuse IMPORTANT This procedure applies only to the fuse on the DC power supply The fuse on the AC power supply is not field replaceable please contact GE for replacement If the fuse in the XGF868i has 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 below Table 4 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 12 28 VDC 2 0 A Slo Blo 85 250 VAC Not field replaceable contact GE 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 31 Note Be s
54. oard J1 Connector male female a Mounting Screw with Washer Assembly 3 places J6 for DC Power Supply LCD Display y Keypad Board and Interconnect Board Sub Assembly i aa P4 Connector J4 Connector J6 J7 Connector on Terminal Board P1 Connector P2 Connector J1 Connector J2 Connector Illustration 4 shown with heatsinks removed for clarity Screw Lock Washer and Flat Washer 2 places LCD Display and P6 Connector Interconnect Board Illustration 5 DigitalFlow XGF868i Service Manual Chapter 4 Parts Replacement Screw with Washer Assembly I O Heatsink Bridge and Mating Nut not shown 2 places Gap Filler white surface a facing the Bridge RR 4 Screw Lock Washer and RA T Flat Washer 2 places Power Supply Heatsink Screw with Washer Assembly 3 places Gap Filler Power Supply Board white surface l facing the Bridge I O Heatsink J6 Connector on Main Board 7 7 S Gap Filler white A surface facing PCB Gap Filler white surface facing the I O Heatsink Standoff Back Plate ae J2 Connector on J5 Connector on Main Board Power Supply I O Board Brank 2 OA J6 Connector on racket Screw Power Supply Illustration 9 Nylon Washer Standoff
55. oard Assembly Be sure that the circuit board assembly is completely assembled as described in the previous section Then refer to Illustrations I 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 bosses at the rear of the enclosure see 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 see Illustration 2 IMPORTANT f 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 see 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
56. obal I O window To leave the Keypad Program press the Escape key three times After leaving the Keypad Program the XGF868i 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 62 DigitalFlow XGF868i Service Manual Index Symbols Channels a 9 hh 19 59 Resetting Number of 02 4 0 44 4545 cs 61 A A E SESTA 19 50 Seteme Number with Pana MEN se quoi gat no z ENT sips eee 19 59 A EEE ANN 19 59 Acceleration Error E6 casa es 13 Contamination 080000 20 O tart ae ee oes Aiea e Er O 19 59 Corrosion Transducers 5551 22 Ammeter in Calibration n se 3 2 19 59 D Amplitud Erro oa e dida 13 DAG 1656 si id tias 55 A a ha aa ai oia piai 19 59 Defaults Resetting Meter 0 61 Analog Inputs Cad 19 59 OO aana 5 47 Diagnostic Parameters 4 mA Option AA ncaa eS 5 47 Displaying A AA A 17 Option Card Calibrating 224222 4 Table Of Valles eked 39 Analog Output 2 dd 13 Display Analog Outputs Option Card LCD Cy 25 Calibrating 04 2 Replacing 5 25 Pineal A tee eevee eee ene eas 2 Display Screen R sOnitiOny vow ceed ee 2 Error Messag tinada aiiin reer gt 1 Analog Outputs Slot 0 AAA a i an
57. 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 f the 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 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
58. on Test Menu above e To leave the Keypad Program press Escape twice 1 6 Testing the Frequency Outputs Frequency outputs may be added to the XGF868i 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 6 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 below for frequency output wiring and Figure 4 on page 10 to identify the OUT and RTN pins for the desired output on terminal block J2 Totalizer Output Transmitter Pulse Counter Volts Int Pwr Sup Load Volts Common Frequency Output Transmitter Frequency Counter 5V IN Common Figure 2 Totalizer Frequency Output Wiring DigitalFlow XGF868i Service Manual 7 Chapter 1 Calibration 1 6 2 Testing the Output 1 From the Keypad Program press the right arrow key to scroll to the CALIB menu Press Enter 2 In the 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 ou
59. on page 42 Proceed to the appropriate section to upload data and test hardware DigitalFlow XGF868i Service Manual 49 Appendix 8 Calibration and Testing with PanaView B 5 1 Uploading the Signal Array Data By uploading XGF868i signal array data for examination a user can check if the transducer signal is the proper shape and change setup parameters 11 necessary IMPORTANT Consult with GE before using this data to change any parameters In the Calibration Test menu double click on the Signal Array Upload option 2 Double click on the desired Channel 1 3 The next prompt asks for the specific Array to Load Five choices are available Raw UP Upstream Signal Raw DOWN Downstream Signal CFUNC UP Correlation Function Upstream CFUNC DOWN Correlation Function Downstream CCFUNC Cross Correlation Function Double click on the desired array 4 PanaView now offers two options for Uploading the array data If you double click on To Display the right pane of the window appears similar to Figure 12 below 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 Previous Item Next Item UPLOAD NOW TO DISPLAY Arafo load Raw UP signal Charel Channel 1 UPLOAD NOW TO DISPLAY HEX BYTES 0064 Exit Page Figure 12 Signal Array Data Displayed on PanaView DigitalFlow XGF868i Service Manual 50
60. ormation When you have reviewed the data click Next Item or Exit Page to return to the Hardware Test option DigitalFlow XGF868i Service Manual 1 2 RA E 10 56 Appendix 8 Calibration and Testing with PanaView B 5 3k Reading an Optional Card EEPROM To read the data of the EEPROM for an optional card 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 S ot 1 or 2 that holds the optional card The right pane lists the Header Information When you have 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 1 2 3 4 5 6 8 5 3 Setting the Number of Channels To set the number of XGF8681 channels for display 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 J 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 1 2 3 B 5 3m Initializing the XGF868i to Default Values To restore the XGF868i to its original default
61. 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 Note To attach an optional heat sink to an I O option card see Attaching an Optional Heat Sink to an I O Option Card on page 29 When the XGF8681i 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 8 on page 35 Pre attach the nylon washer to the screw before inserting the boards into the assembly 28 DigitalFlow XGF868i Service Manual 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
62. ple Proceed to the appropriate sub section for specific instructions and substitute the correct output letter for the A shown in the procedures DigitalFlow XGF868i Service Manual 45 Appendix B Calibration and Testing with PanaView B 4 1 Analog Outputs Additional analog outputs may be added to the XGF868i 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 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 Output A of the option card See Figure 4 on page 10 to identify the OUT 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 2 See Figure 4 on page 10 for the correct pin numbers 3 Double click
63. r Calibration Prepare for calibration by inserting an ammeter in series with the load on the desired output Refer to Figure 1 below and Figure 4 on page 10 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 XGF868i 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 In the 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 calibrating 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 On
64. rs 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 2 See Figure 4 on page 10 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 Ifan 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 6 DigitalFlow XGF868i Service Manual Chapter 1 Calibration 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 Calibrati
65. 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 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 any flowcell and or transducer problems DigitalFlow XGF868i Service Manual Problem Cause Action 12 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
66. 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 8 5 36 FIFO Test To check the FIFO Note fyou 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 Item to perform the test and return to the Hardware Test option and Exit Page again to return to the main Calibration Test menu B 5 3e LCD Test To test the LCD Note f 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 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 54 DigitalFlow XGF868i Service Manual Appendix 8 Calibration and Testing with PanaView B 5 3f LCD Contrast To change the LCD contrast Note f you are in the Hardware Test option skip to step 2 1 From the left pane of the Calibration Test window do
67. the 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 Cor is identical to that for testing Output A However be sure to reconnect the frequency counter on terminal block 2 See Figure 4 on page 10 for the correct pin numbers 3 At the Frequency prompt enter a frequency between 1 and 10 000 Hz and click Next Item 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 B 5 Testing the XGF868i Software and Hardware In addition to calibration procedures for input and output cards the Calibration Test menu offers tests for XGF8681 hardware and procedures for uploading the signal array data and the XGM868i memory contents into PC files for examination To test the XGF8681 hardware and software 1 Open the Meter Browser window and highlight the XGF8681 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
68. ther 0 mA or 4 mA However the calibration procedure always uses the 4 mA point as the meter will extrapolate this value to obtain the 0 mA point 1 In the 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 is 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 J 2 Refer to Figure 4 on page 10 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 section for specific instructions on each of the options available in step 3 B 4 2a 4 mA 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 Ifyou 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 XGF868i Service Man
69. to LCD and press Enter DigitalFlow XGF868i Service Manual 17 Chapter 3 Diagnostics 3 2 Displaying Diagnostic Parameters cont 6 The window now asks for the 4 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 To scroll through the channel options on an XGF868i press the lt or gt keys until you have reached the desired option 7 Scroll to the desired Channel option as listed in Table 2 below Table 2 Channel Options option Description 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
70. tor 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 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 XGF868i Service Manual Appendix 8 Calibration and Testing with PanaView 8 4 6 Testing Frequency Outputs Frequency outputs may be added to the XGF868i 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 7 for frequency output wiring and Figure 4 on page 10 to identify the OUT and RTNE pins for Output A on terminal block J2 1 In
71. tputs is the same However when testing another output be sure to reconnect the frequency counter at terminal block 2 See Figure 4 on page 10 for the correct pins 4 Enter a frequency between 1 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 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 To calibrate test additional inputs outputs proceed to the appropriate section e To leave the Keypad Program press Escape twice 8 DigitalFlow XGF868i Service Manual Chapter 1 Calibration Figure 3 Calibration Menu Map CNTRS LITEN Slot 1 Alarm Relays 8 6 JLo _ ALARMS CLOSE OP Slot 1 Totalizer Outputs PULSES Slot 17 Frequency Outputs 6 8 FREQUENCY NOTE Plain text represents prompt area meassages and boxed text represents option bar choices Fx represent function keys to select option bar choices DARKN STORE SLOT1 Slot 1 y Option Card Slot 1 Analog Inputs j 6 8 press EXIT key ANALOG INPUT 4mA 20 ma CALIBRATI
72. ual 47 Appendix B Calibration and Testing with PanaView 8 4 3 RTD Inputs RTD inputs may be added to the XGF868i by installing an appropriate option card in Slot 1 This option card contains two or four RT D 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 f 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 an independent calibrated RTD source to the desired input of the option card See Figure 4 on page 10 to identify the RTD and COM pins for Input A on terminal block 2 1 In the 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 2 See Figure 4 on page 10 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 simula
73. uble 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 f 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 center 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 f 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 Inthe 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 XGF868i Service Manual 55 Appendix B Calibration and Testing with PanaView 8 5 3 Calibration Values To display the calibration values Note f you are in the Hardware Test option skip to st
74. uding 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 If GE Sensing instructs you to send your instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 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 XGF868i Service Manual 67 Warranty no content intended for t
75. 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 other flowcells measure the pipe wall thickness and diameter with the same accuracy desired in the flow rate readings Also check the pipe for dents eccentricity weld deformity straightness and other factors that may cause inaccurate readings Refer to Chapter 2 Initial Setup of the Startup Guide for 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 XGF868i is supplied with a signal preampl
76. ure to disconnect the main power from the unit If the XGF868i is installed in a hazardous environment The electronics enclosure must be moved to a safe area prior to removing the covers or If the electronics enclosure cannot be moved to a safe area ensure that the surrounding area is free of ignitable gases IMPORTANT For compliance with the EU Low Voltage Directive 2006 95 EC 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 directly accessible and located within 1 8 m 6 ft of the unit 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 XGF8681 in Appendix A Service Record This service history will be helpful in diagnosing any future problems DigitalFlow XGF868i Service Manual 23 Chapter 4 Parts Replacement 4 2 Removing the Circuit Board Assembly All parts replacement procedures for the XGF868i 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 XGF868i circuit board assembly consists of circular front and rear circuit boards with several rectangular circuit boards sandw
77. ure to record the fuse replacement in Appendix A Service Record 26 DigitalFlow XGF868i Service Manual Chapter 4 Parts Replacement 4 5 Replacing the User Program The XGF868i s User Program is stored on an erasable programmable read only memory EPROM chip The EPROM which is designated as component U6 is mounted in a socket on the front of the main circuit board EPROM replacement may be required to replace a defective chip or to upgrade to a newer software version To replace the User Program refer to Figure 7 on page 34 and complete the following steps Complete the steps in Removing the Circuit Board Assembly on page 24 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 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 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 1 2 Note An XGF868i with a DC power supply will include two more mounting screws but no heat sink Careful
78. urrent source to the desired input on the option card See Figure 4 on page 10 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 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 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 10 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 calibrating all the inputs is the same However when calibrating a different input be sure to reconnect the current source at terminal block 2 See Figure 4 on page 10 for the correct pin numbers 5 Do one of the following e Proceed to the 4 mA Option on page 5 e Proceed to the 20 mA Option on page 5 1428 4mA Option Set the calibrated current source to 4 mA e Ifyou selected the 4 mA option in the ANALOG INPUT menu scrol
79. values 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 XGF868i in its current state If you select Yes the XGF868i returns to its default settings and PanaView exits the Calibration Test menu 1 2 3 DigitalFlow XGF868i Service Manual 57 Appendix B Calibration and Testing with PanaView B 5 3m Initializing the XGF868i to Default Values cont Note When you first initialize the XGF868i 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 amp aN A 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
80. ve 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 installed Be careful not to lose these washers 6 Refer to Illustration 3 in Figure 6 on page 33and carefully rotate the circuit board assembly counterclockwise about 20 until the five bosses in the enclosure are visible through the slots along the circumference of the terminal board Then slowly push the circuit board assembly through the enclosure and remove it from the front of the enclosure Bring the circuit board assembly to a clean safe work area and proceed to the appropriate section of this chapter to perform the desired service procedure 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 Complete the steps in Removing the Circuit Board Assembly on page 24 2 Place the circuit board assembly on a flat surface with the LCD display board facing upward See Illustration 4 in Figure 7 on page 34 and remove the three mounting screws with flat washers and lock washers indicated 3 Grasp the LCD display keypad board interco
81. w 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 below 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 H BYTES 0064 HEX START ADDRESS 00000000 Exit Page Figure 14 XGF868i Memory Data Displayed on PanaView e If you double click on To File the Save As window similar to Figure 13 on page 51 opens Enter a file name and click Save PanaView stores the array data in a Windows file and closes the Calibration Test window B 5 3 Testing the XGF868i Hardware Using PanaView you can check crucial elements of the XGF868i hardware the EPROM the NVR the RAM FIFO and the DAC You can also Program and test optional cards Read site checksums and calibration values e Test and set the contrast for the LCD Set the number of channels either 1 or 2 and e Re initialize the XGF8681 to its default values IMPORTANT Contact GE if the XGF868i fails any of the tests in the following sections 52 DigitalFlow XGF868i Service Manual Appendix B Calibration and Testing with PanaView 8 5 38 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 Inthe center pane double click on EPROM TEST

DigitalFlow™ XGF868i Service Manual

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DigitalFlow™ XGF868i Service Manual