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Summary of Contents for Panametrics DigitalFlow XGS868i
- Page 1 Flow DigitalFlow™ XGS868i Panametrics Steam Ultrasonic Mass Flow Transmitter (1 & 2 Channel) Service Manual 910-196S G panametrics.com Jul 2021...
- Page 3 Flow DigitalFlow™ XGS868i Panametrics Steam Ultrasonic Mass Flow Transmitter (1 & 2 Channel) Service Manual 910-196S Rev. G Jul 2021 panametrics.com Copyright 2021 Baker Hughes company. This material contains one or more registered trademarks of Baker Hughes Company and its subsidiaries in one or more countries.
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- Page 5 Information Paragraphs • Note paragraphs provide information that provides a deeper understanding of the situation, but is not essential to the proper completion of the instructions. • Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment.
- Page 6 Environmental Compliance Waste Electrical and Electronic Equipment (WEEE) Directive Panametrics Solutions 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.
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Page 7: Table Of Contents
Contents Chapter 1. Calibration Introduction ..................... .1 Accessing the Calibration Menu . - Page 8 Contents Calibrating Slot 1 Option Cards .................43 B.4.1 Analog Outputs .
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Page 9: Chapter 1. Calibration
Chapter 1. Calibration Chapter 1. Calibration Introduction Calibrating the Model XGS868i’s analog outputs and inputs is explained in this chapter. In addition, testing the optional totalizer, frequency and alarm relay outputs is discussed. The chapter includes the following specific topics: •... -
Page 10: Calibrating And Testing Analog Outputs
Chapter 1. Calibration Calibrating and Testing Analog Outputs Every Model XGS868i flowmeter includes two built-in analog outputs (A and B) at terminal block J1, which is designated as Slot 0. Additional analog outputs may be added to the Model XGS868i by installing an appropriate option card in Slot 1. -
Page 11: Calibrating The Low End Of The Output Range
Chapter 1. Calibration 1.3.2 Calibrating the Low End of the Output Range From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter]. 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. -
Page 12: Calibrating Analog Inputs
Chapter 1. Calibration 1.3.4 Testing Output Linearity (cont.) Table 1 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*... -
Page 13: Preparing For Calibration
Chapter 1. Calibration 1.4.1 Preparing for Calibration Prepare for the calibration procedure by connecting a Slot 0 analog output (or an independent calibrated current source) to the desired input on the option card. See Figure 4 on page 12 to identify the IN(+) and RTN(-) pins for the desired input on terminal block J2. -
Page 14: Calibrating Rtd Inputs
Chapter 1. Calibration Calibrating RTD Inputs RTD analog inputs may be added to the XGS868i 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. -
Page 15: Testing Alarm Relays
Chapter 1. Calibration Testing Alarm Relays Alarm relays may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option card contains two or four alarm relays, which are designated A, B, C and D. 1.6.1 Preparing for Testing Prepare for the testing procedure by connecting an ohmmeter to the NO and COM pins of the desired alarm on the... -
Page 16: Testing Totalizer Outputs
Chapter 1. Calibration Testing Totalizer Outputs Totalizer outputs may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option card contains two or four totalizer outputs, which are designated A, B, C and D. 1.7.1 Preparing for Testing Prepare for the testing procedure by connecting a pulse counter to the desired output of the option card. -
Page 17: Testing The Output
Chapter 1. Calibration 1.7.2 Testing the Output From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter]. 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. Scroll to the desired Output . -
Page 18: Testing The Frequency Outputs
Chapter 1. Calibration Testing the Frequency Outputs Frequency outputs may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option card contains two or four frequency outputs, which are designated A, B, C and D. 1.8.1 Preparing for Testing Prepare for the testing procedure by connecting a frequency counter to the desired output on the option card. - Page 19 [Esc] [Enter] [Esc] Keypad Pgm. PROG RESET CALIB CNTRS See Programming Manual Reset Totals DARKN LITEN STORE ABORT SLOT0 SLOT1 Slot 1 Option Card Slot 0 Analog Outputs Slot 1 Analog Inputs Slot 1 Alarm Relays ANALOG OUTPUT press [EXIT] key ALARMS 4 mA 20 mA...
- Page 20 -01 (AA,HH) -02 (FF,TT,FT,CT,CF) -03 (FO,TO,CO) -04 (FA,FH,TA,TH,CA,CH) -05 (CI,TI,FI) -06 (CR,FR,TR) Pin 1 Pin 1 Pin 1 Pin 1 Pin 1 Pin 1 -07 (CIR) -08 (AI,HI) -09 (OI) -10 (OR) -11 (AR,HR) -12 (II) Pin 1 Pin 1 Pin 1 Pin 1 Pin 1...
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Page 21: Chapter 2. Error Codes
Chapter 2. Error Codes Chapter 2. Error Codes Introduction The Model XGS868i ultrasonic flow transmitter is a reliable, easy to maintain instrument. When properly installed and operated, as described in the Startup Guide , the meter provides accurate flow rate measurements with minimal user intervention. - Page 22 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 User Program .
- Page 23 Chapter 2. Error Codes E5: Amplitude Error Problem: The signal amplitude exceeds the limits programmed in the SETUP-SIGNL submenu of the User 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.
- Page 24 Chapter 2. Error Codes E11: Saturated Problem: This message indicates that, based on the temperature and pressure readings, the steam is saturated and may become two-phase. Cause: Low temperature in the system. Action: Raise the system temperature or lower the system pressure until all of the water vaporizes. E12: Low Pressure Problem: If the low pressure switch is active, this message indicates that the pressure reading has dropped below...
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Page 25: Chapter 3. Diagnostics
Chapter 3. Diagnostics Chapter 3. Diagnostics Introduction This chapter explains how to troubleshoot the Model XGS868i if problems arise with the electronics enclosure, the flowcell, or the transducers. Indications of a possible problem include: • display of an error message on the LCD display screen •... - Page 26 Chapter 3. Diagnostics Displaying Diagnostic Parameters (cont.) For a 1-Channel XGS868i, the data for Channel 1 is displayed automatically, and you can skip to step 8. However, for a 2-Channel meter, the channel data to be displayed must be specified at the following prompt. Scroll to the desired Channel option , as listed in Table 2.
- Page 27 Chapter 3. Diagnostics Table 3: Available Diagnostic Parameters Option Bar Description Good P#up Displays signal peaks for the upstream transducer. 100-2300 <100 or >2300 P#dn Displays signal peaks for the downstream transducer. 100-2300 <100 or >2300 TEMP Displays the gas temperature (from 0/4-20 mA input). N.A.
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Page 28: Flowcell Problems
Chapter 3. Diagnostics Flowcell Problems If preliminary troubleshooting with the Error Code Messages and/or the Diagnostic Parameters indicates a possible flowcell problem, proceed with this section. Flowcell problems fall into two categories: • gas problems • pipe problems. Read the following sections carefully to determine if the problem is indeed related to the flowcell. If the instructions in this section fail to resolve the problem, contact the factory for assistance. -
Page 29: Pipe Problems
The accuracy of the flow rate measurements is no better than the accuracy of the programmed pipe dimensions. For a flowcell supplied by Panametrics, 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. -
Page 30: Transducer Problems
Chapter 3. Diagnostics 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. -
Page 31: Chapter 4. Parts Replacement
Chapter 4. Parts Replacement Chapter 4. Parts Replacement Introduction The Model XGS868i has been designed to permit easy on-site upgrades and parts replacement. See Figure 6 on page 31 for details of the standard XGS868i electronics enclosure assembly. The instructions in this chapter, along with a few common tools, are all that is required to perform the following tasks: •... -
Page 32: Removing The Circuit Board Assembly
Chapter 4. Parts Replacement Removing the Circuit Board Assembly All parts replacement procedures for the Model XGS868i require the removal of the circuit board assembly from the electronics enclosure. Therefore, complete the instructions in this section before attempting any other service tasks. The Model XGS868i circuit board assembly consists of circular front and rear circuit boards with several rectangular circuit boards sandwiched between the circular end boards and oriented perpendicular to them. -
Page 33: Replacing The Lcd Display/Interconnect Board Subassembly
Chapter 4. Parts Replacement Removing the Circuit Board Assembly (cont.) Refer to Illustration 2 in Figure 6 on page 31, and remove the four terminal board mounting screws and the ground screw. This will disconnect one end of the green grounding jumper wire and the label plate with the ground symbol will come loose from beneath it. -
Page 34: Replacing The Fuse
Chapter 4. Parts Replacement Replacing the Fuse Note: This procedure applies only to the fuse on the DC power supply. The fuse on the AC power supply is not field-replaceable; please consult the factory for replacement. If it has been determined that the fuse in the XGS868i has been blown, complete the following steps to install a new fuse: Complete the steps in Removing the Circuit Board Assembly on pages 4-2 to 4-3. -
Page 35: Replacing The User Program
Chapter 4. Parts Replacement Replacing the User Program The Model XGS868i’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. -
Page 36: Installing An Option Card
Chapter 4. Parts Replacement Installing an Option Card The Model XGS868i flowmeter can accommodate up to two option cards. A data logging or RS485 card may be installed in Slot 2 and a variety of I/O option cards are available for installation in Slot 1. To install an option card, see Illustrations 9, 10 and 11 in Figure 8 on page 33 and complete the following steps: Complete the steps in the Removing the Circuit Board Assembly section on page 24. -
Page 37: Assembling/Installing The Circuit Board Assembly
Chapter 4. Parts Replacement 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. -
Page 38: Installing The Circuit Board Assembly
Chapter 4. Parts Replacement 4.7.2 Installing the Circuit Board Assembly Be sure that the circuit board assembly is completely assembled, as described in the previous section. Then, refer to Illustrations 1, 2 and 3 in Figure 6 on page 31 and install the circuit board assembly into the electronics enclosure as follows: Slide the terminal board end of the circuit board assembly into the front of the electronics enclosure. - Page 39 Set Screw Set Screw Rear Cover (solid) Front Cover with Window Illustration 1 Electronics Assembly Enclosure Assembly Mounting Screw with Washer Assembly (4 places) Terminal Block on Slot 2 Option Card Ground Screw Label Plate with Ground Symbol Grounding Jumper Wire Illustration 2 Illustration 3 DigitalFlow™...
- Page 40 Mounting Screw and Fuse Cover DC Power Supply Board Washer Assembly (3 places) P9 Connector on Terminal Board LCD Display, connects to Keypad Board and J10 Connector on Main Board Interconnect Board J2 Connector Sub-Assembly P1 Connector Bracket Screw Green Grounding Jumper P4 Connector P2 Connector P10 Connector on Terminal Board...
- Page 41 Screw with Washer Assembly I/O Heatsink Bridge and Mating Nut (not shown) (2 places) Gap Filler (white surface Power Supply Heatsink facing the Bridge) Screw, Lock Washer and Flat Washer (2 places) Screw with Washer Assembly (3 places) Gap Filler Power Supply Board (white surface I/O Heatsink...
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Page 43: Appendix A. Service Record
Appendix A. Service Record Appendix A. Service Record Introduction Whenever any service procedure is performed on the Model XGS868i 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. - Page 44 Appendix A. Service Record Table 6: Service Record Date Description of Service Performed By DigitalFlow™ XGS868i Service Manual...
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Page 45: Diagnostic Parameters
Appendix A. Service Record Diagnostic Parameters After a successful initial installation of the Model XGS868i and whenever any system malfunction is noticed, the values for the diagnostic parameters should be entered in Table 7. Table 7: Diagnostic Parameters Parameter Initial Current Parameter Initial... - Page 46 Appendix A. Service Record [no content intended for this page] DigitalFlow™ XGS868i Service Manual...
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Page 47: Appendix B. Calibration And Testing With Panaview
Appendix B. Calibration and Testing with PanaView Appendix B. Calibration and Testing with PanaView Introduction This appendix explains how to calibrate the Model XGS868i’s analog outputs and inputs using PanaView™ interface software. In addition, testing the optional totalizer, frequency and alarm relay outputs, and XGS hardware and software is discussed. -
Page 48: Accessing The Calibration/Test Menu
Appendix B. Calibration and Testing with PanaView 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. -
Page 49: Calibrating Slot 0 Analog Outputs
Appendix B. Calibration and Testing with PanaView Calibrating Slot 0 Analog Outputs Every Model XGS868i flowmeter includes two built-in analog outputs (A and B) at terminal block J1, which is designated as Slot 0. Both the zero-point and full-scale values for each output must be calibrated. After calibrating the outputs, which have a resolution of 5.0 A (0.03% full scale), their linearity should be tested. - Page 50 Appendix B. Calibration and Testing with PanaView Calibrating Slot 0 Analog Outputs (cont.) Double-click on either Output A or Output B to open the Analog Output menu. (Output A will be used as an exam- ple in this manual.) IMPORTANT: The procedure for calibrating Output B is identical to that for calibrating Output A .
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Page 51: Calibrating Slot 1 Option Cards
Appendix B. Calibration and Testing with PanaView Calibrating Slot 0 Analog Outputs (cont.) Table 8: Expected Ammeter Readings % Full Scale 4-20 mA Scale* 0-20 mA Scale* 4.000 0.000 5.600 2.000 7.200 4.000 8.800 6.000 10.400 8.000 12.000 10.000 13.600 12.000 15.200 14.000... -
Page 52: Analog Outputs
Appendix B. Calibration and Testing with PanaView B.4.1 Analog Outputs Additional analog outputs may be added to the Model XGS868i 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. -
Page 53: Analog Inputs
Appendix B. Calibration and Testing with PanaView B.4.2 Analog Inputs Analog inputs may be added to the Model XGS868i 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. -
Page 54: Rtd Inputs
Appendix B. Calibration and Testing with PanaView B.4.3 RTD Inputs RTD inputs may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option card contains two or four RTD inputs, which are designated as A, B, C and D. Both the set and slope temperature values for each input must be calibrated. -
Page 55: Testing Alarm Relays
Appendix B. Calibration and Testing with PanaView B.4.6 Testing Alarm Relays Alarm relays may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option card contains two or four alarm relays, which are designated A, B, C and D. Prepare for the testing procedure by connecting an ohmmeter to Alarm A of the option card. -
Page 56: Testing Totalizer Outputs
Repeat steps 2, 3 and 4 to test all of the available totalizer outputs. If any of the totalizer outputs fails the test, contact Panametrics 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. -
Page 57: Testing Xgs868I Software And Hardware
By uploading XGS868i signal array data for examination, a user can check if the transducer signal is the proper shape, and change setup parameters if necessary. IMPORTANT: Consult Panametrics before using this data to change any parameters. In the Calibration/Test menu, double-click on the Signal Array Upload option. Double-click on the desired Channel . - Page 58 Appendix B. Calibration and Testing with PanaView B.5.1 Uploading Signal Array Data (cont.) 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, and the data is available for immediate evaluation.
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Page 59: Uploading Xgs868I Memory
The Upload XGS Memory option is another diagnostic tool. IMPORTANT: Consult Panametrics before using this data to change any parameters. In the Calibration/Test menu, double-click on the Upload XGS Memory option. The first prompt shows the Hex Start Address . Click [Next Item]. -
Page 60: Testing Xgs868I Hardware
• set the number of channels (either 1 or 2), and reinitialize the XGS868i to its default values. • Contact Panametrics if the XGS868i fails any of the tests covered below. IMPORTANT: B.5.3a EPROM Test To test the EPROM from the Calibration/Test menu: From the left pane of the Calibration/Test window, double-click on Hardware Test . - Page 61 Appendix B. Calibration and Testing with PanaView B.5.3b NVR Test (cont.) Figure 15: Completion of the NVR Test B.5.3c RAM Test To check the RAM: Note: If you are in the Hardware Test option, skip to step 2. From the left pane of the Calibration/Test window, double-click on Hardware Test . In the center pane, double-click on RAM TEST .
- Page 62 Appendix B. Calibration and Testing with PanaView B.5.3e LCD Test To test the LCD: Note: If you are in the Hardware Test option, skip to step 2. From the left pane of the Calibration/Test window, double-click on Hardware Test . In the center pane, double-click on LCD TEST .
- Page 63 Appendix B. Calibration and Testing with PanaView B.5.3j 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.
- Page 64 Appendix B. Calibration and Testing with PanaView B.5.3m Initializing the XGS868i to Default Values To restore the XGS868i to its original default 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.
- Page 65 Appendix B. Calibration and Testing with PanaView B.5.3 Testing XGS868i Hardware (cont.) Table 10: Available Measurement Parameters Option Bar Description Good Velocity Displays the flow velocity. N.A. N.A. Volumetric Displays the volumetric flow. N.A. N.A. FWD Total Displays the forward totalized volume flow. N.A.
- Page 66 Appendix B. Calibration and Testing with PanaView Table 10: Available Measurement Parameters Option Bar Description Good Displays Measure Delta T. N.A. N.A. DeltaT M Vinst Displays the instantaneous velocity. N.A. N.A. Displays the saturation temperature for steam at the current pressure.
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Page 67: Appendix C. Factory Tests
Appendix C. Factory Tests Appendix C. Factory Tests Introduction For user security, the XGS868i offers two special functions in a separate menu: selection of single- or dual-channel operation, and the factory-default reset. While the first function enables you to reset the channel configurations set during manufacturing, the reset function, by restoring the meter to its original state, allows you to purge potential errors in program memory. - Page 68 Appendix C. Factory Tests Resetting the XGS868i to Factory Defaults (cont.) Scroll to LCD and press [Enter]. The window now asks for the # of LCD Parameters. Scroll to the desired number (from OFF through 1-4 and KEY) and press [Enter]. For a 1-Channel XGS868i, the data for Channel 1 is displayed automatically, and you can skip to step 9.
- Page 69 Index Acceleration Error - E6 ........15 EPROM AcVOL.
- Page 70 Index SS up ............18 Option Card StVOL .
- Page 71 RETURN AUTHORIZATION NUMBER (RAN), and shipping instructions for the return of the instrument to a service center will be provided. If Panametrics 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.
- Page 72 Warranty [no content intended for this page] DigitalFlow™ XGS868i Service Manual...
- Page 74 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: mstechsupport@bakerhughes.com Ireland Sensing House Shannon Free Zone East Shannon, County Clare Ireland Tel: +353 (0)61 470291 E-mail: mstechsupport@bakerhughes.com Copyright 2021 Baker Hughes company.
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