GE DigitalFlow GS868 Service Manual
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GE DigitalFlow GS868 Service Manual

Panametrics steam ultrasonic mass flowmeter
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GE
Measurement & Control
Flow
DigitalFlow™ GS868
Panametrics Steam Ultrasonic Mass Flowmeter
Service Manual
910-190S Rev. E
February 2015
Table of Contents
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Summary of Contents for GE DigitalFlow GS868

  • Page 1 Measurement & Control Flow DigitalFlow™ GS868 Panametrics Steam Ultrasonic Mass Flowmeter Service Manual 910-190S Rev. E February 2015...
  • Page 3 DigitalFlow™ GS868 Panametrics Steam Ultrasonic Mass Flowmeter Service Manual 910-190S Rev. E February 2015 www.ge-mcs.com ©2015 General Electric Company. All rights reserved. Technical content subject to change without notice.
  • Page 4 [no content intended for this page]...
  • Page 5 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.
  • Page 6 Environmental Compliance Waste Electrical and Electronic Equipment (WEEE) Directive GE Measurement & Control is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-back initiative, directive 2012/19/EU. 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.

  • Page 7: Table Of Contents

    Contents Chapter 1. Calibration 1.1 Introduction ................... . 1 1.2 Menu Map .
  • Page 8 Contents Chapter 2. Error Codes and Screen Messages 2.1 Introduction...................17 2.2 E0: No Error .
  • Page 9 Contents Appendix B. Optional Enclosures B.1 Introduction ...................45 B.2 Rack Mount Enclosure .
  • Page 10 Contents viii DigitalFlow™ GS868 Service Manual...

  • Page 11: Chapter 1. Calibration

    Chapter 1. Calibration Chapter 1. Calibration 1.1 Introduction Calibrating the Model GS868’s analog outputs and inputs is explained in this chapter. In addition, testing the optional totalizer/frequency and alarm relay outputs is discussed. The following specific topics are included: • calibrating Slot 0-6 analog outputs •...

  • Page 12: Calibrating The Analog Outputs

    Chapter 1. Calibration 1.3 Calibrating the Analog Outputs Every Model GS868 flowmeter includes two built-in analog outputs (A and B) at terminal block , which is Slot 0 designated as . Additional analog outputs may be added to the Model GS868 by installing an Analog Outputs Option Card in one (or more) of the six expansion slots.
  • Page 13 Chapter 1. Calibration Calibrating the Analog Outputs (cont.) Terminal Block (Option Card) Ammeter Figure 2: Ammeter Connection for Slots 1-6 (Output A) DigitalFlow™ GS868 Service Manual...

  • Page 14: Accessing The Calibration Menu

    Chapter 1. Calibration 1.4 Accessing the Calibration Menu [CAL] 1. Press the key to enter the Calibration Program. [Fx] 2. Press to calibrate the desired slot. (The option bar will include a slot listing for each installed option card.) [Fx] 3.
  • Page 15 Chapter 1. Calibration 1.4.3 Testing the Analog Output Linearity (cont.) Table 1: 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 16.800 16.000 18.400...

  • Page 16: Calibrating The Analog Inputs

    Chapter 1. Calibration 1.5 Calibrating the Analog Inputs Analog inputs may be added to the Model GS868 flowmeter by installing an Analog Inputs Option Card in one (or more) of the six expansion slots. The option card contains two analog inputs, which are designated as A and B. Each of the inputs, which may be either a 0/4-20 mA input or an RTD input, must be calibrated at both the zero-point and full-scale values.

  • Page 17: Accessing The Calibration Menu

    Chapter 1. Calibration 1.5.1 Accessing the Calibration Menu [CAL] 1. Press the key to enter the Calibration Program. [Fx] 2. Press to calibrate the desired slot. (The option bar will include a slot listing for each installed option card.) [Fx] 3.

  • Page 18: Ma Option = [F4]

    Chapter 1. Calibration 1.5.5 20 mA Option = [F4] 1. Connect the 20 mA current source to the currently selected analog input, as shown in Figure 3 on page 6. [F1] [F2] ANALOG INPUT 2. Press to store the current 20 mA value or press to cancel the entry.

  • Page 19: Calibrating The Rtd Inputs

    Chapter 1. Calibration 1.6 Calibrating the RTD Inputs Calibrating an RTD option card involves a different procedure than for other analog input cards. However, you access the card in the same manner as other cards. 1.6.1 Accessing the Calibration Menu [CAL] 1.

  • Page 20: Numer Option = [F2]

    Chapter 1. Calibration 1.6.3 Numer Option = [F2] The Numer option forces the user to calculate the temperature vs. resistance information. To do this, the user must first PRINT collect data using the RTDs option in the menu (discussed in Chapter 5 of the Programming Guide). The RTDs option allows you to know what point value the GS868 is reading at a given temperature.

  • Page 21: Testing The Alarm Relays

    Chapter 1. Calibration 1.7 Testing the Alarm Relays Alarm relays may be added to the Model GS868 by installing an Alarms Option Card in one (or more) of the six expansion slots. Each option card includes three alarm relays, which are designated as A, B, and C. To test the alarm relays, connect an ohmmeter to the option card terminal block as shown in Figure 4 below.
  • Page 22 Chapter 1. Calibration Testing the Alarm Relays (cont.) Note: The procedure for testing Alarm Relay A Alarm Relays B and C is identical to that for testing . However, make sure that the ohmmeter is connected to the desired normally-open or normally-closed contact of the currently selected relay.

  • Page 23: Testing The Totalizer/Frequency Outputs

    Chapter 1. Calibration 1.8 Testing the Totalizer/Frequency Outputs Totalizer/Frequency outputs may be added to the Model GS868 by installing a Totalizer/Frequency Option Card in one (or more) of the six expansion slots. Each option card includes four outputs, which are designated as A, B, C and D. To test the outputs, connect a frequency counter to the card’s terminal block as shown in Figure 5 below.

  • Page 24: Entering Pulse Number

    Chapter 1. Calibration 1.8.3 Entering Pulse Number [ENT] 5. Enter the number of pulses desired (between 1 and 10,000) and press the key. That number of pulses will then be output at the specified frequency. 6. Repeat Steps 3, 4 and 5 to test all four of the frequency/totalizer outputs. If any of the outputs fails to pass the test, contact the factory for assistance.
  • Page 25 Chapter 1. Calibration SLOT0 SLOT1 SLOT2 SLOT3 SLOT4 SLOT5 SLOT6 Slot x (Option Card) Slot 0 Outputs (TB I/O) Slot x Inputs (Analog Inputs) Slot x Outputs (Alarms) ANALOG OUTPUT ANALOG INPUT ALARMS 4 mA 20 mA TEST EXIT aLOW aHIGH 4 mA 20 mA...
  • Page 26 Chapter 1. Calibration DigitalFlow™ GS868 Service Manual...

  • Page 27: Chapter 2. Error Codes And Screen Messages

    Chapter 2. Error Codes and Screen Messages Chapter 2. Error Codes and Screen Messages 2.1 Introduction The Model GS868 ultrasonic flowmeter 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 28: E0: No Error

    Chapter 2. Error Codes and Screen Messages 2.2 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. 2.3 E1: Low Signal Problem: Poor ultrasonic signal strength or the signal exceeds the limits entered via the User Program.

  • Page 29: E4: Signal Quality

    Chapter 2. Error Codes and Screen Messages 2.6 E4: Signal Quality Problem: SETUP The signal quality is outside the limits programmed in the submenu of the User Program. Cause: The peak of the upstream or downstream correlation signals has fallen below the correlation peak limit, as SIGNL set in the submenu.

  • Page 30: E9: Press In

    Chapter 2. Error Codes and Screen Messages 2.11 E9: Press 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 on the option card.

  • Page 31: E14: Totals Overflow

    Chapter 2. Error Codes and Screen Messages 2.16 E14: Totals Overflow Problem: The totalizers are unable to keep up with the total flow signals. Cause: The programmed units/pulse value is too small. Action: Select a larger number of units/pulse value. 2.17 E15: Equation Limit Problem: The meter cannot determine if the steam measurement is within 1% accuracy.

  • Page 32: Screen Messages

    Chapter 2. Error Codes and Screen Messages 2.18 Screen Messages A variety of messages may appear on the display screen during the performance of a task. Since the error codes have already been discussed in this chapter and the locator bar messages are discussed in detail in Chapter 3, Operation, of the Startup Guide, they will not be repeated here.
  • Page 33 Chapter 2. Error Codes and Screen Messages Table 2: Screen Messages (cont.) Message Meaning End Time must exceed This message appears when in the menu. Enter an end time that is at Start Time least five minutes later than the start time. by 5 min.
  • Page 34 Chapter 2. Error Codes and Screen Messages [no content intended for this page] DigitalFlow™ GS868 Service Manual...

  • Page 35: Chapter 3. Diagnostics

    Chapter 3. Diagnostics Chapter 3. Diagnostics 3.1 Introduction This chapter explains how to troubleshoot the Model GS868 if problems arise with the electronics console, the flowcell, or the transducers. Indications of a possible problem include: • display of an error message on the active display screen •...
  • Page 36 Chapter 3. Diagnostics Displaying Diagnostic Parameters (cont.) [F1] Tdown For example, pressing displays the parameter, as shown in the following prompt. Press the  and  keys and the appropriate [Fx] label gSITE key to display a different EXIT diagnostic parameter or to the Diagnostics Menu.
  • Page 37 Chapter 3. Diagnostics Table 3: Available Diagnostic Parameters (cont.) Option Bar Screen Display Description Good P#up UP +- Peak Displays signal peaks for the upstream transducer. 100-2300 <100 or >2300 P#dn DN +- Peak Displays signal peaks for the downstream transducer. 100-2300 <100 or >2300 TEMP...

  • Page 38: Diagnostic Record

    Chapter 3. Diagnostics 3.3 Diagnostic Record [EXIT] EXIT Upon leaving the Diagnostic Menu via the key or the option on the option bar, the display screen will continue to show the last diagnostic parameter that was selected. To return to normal measurement mode, select a channel to display (for a 2-Channel meter only) and then select the desired display parameter.

  • Page 39: 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 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.
  • Page 40 Chapter 3. Diagnostics [no content intended for this page] DigitalFlow™ GS868 Service Manual...

  • Page 41: Chapter 4. Parts Replacement

    Chapter 4. Parts Replacement Chapter 4. Parts Replacement 4.1 Introduction The Model GS868 has been designed to permit easy on-site upgrades and parts replacement. See Figure 8 on page 39 and Figure 9 on page 40 for details of the standard GS868 electronics console assembly. The instructions in this chapter, along with a few common tools and replacement parts, are all that is required to perform the following tasks: •...

  • Page 42: Fuse Replacement

    Chapter 4. Parts Replacement 4.1.1 Fuse Replacement Complete the following steps to replace the fuse in the Model GS868 flowmeter: WARNING! The main power to the Model GS868 must be disconnected before proceeding. 1. Open the cover on the electronics console. For LVD compliant units, remove the two mounting screws and lift the clear plastic shroud out of the electronics console.

  • Page 43: Removing The Printed Circuit Board

    Chapter 4. Parts Replacement 4.2 Removing the Printed Circuit Board All of the remaining procedures require removal of the printed circuit board. To accomplish this task, refer to Figure 8 on page 39 and Figure 9 on page 40 while completing the following steps: 1.

  • Page 44: Replacing The Eprom

    Chapter 4. Parts Replacement 4.3 Replacing the EPROM The Model GS868’s User Program is stored on an erasable programmable read only memory (EPROM) chip. The EPROM, which is designated as component , is located in the top left corner of the rear of the printed circuit board. See Figure 9 on page 40 for a rear view of the printed circuit board.

  • Page 45: Installing An Option Card

    Chapter 4. Parts Replacement 4.4 Installing an Option Card The Model GS868 flowmeter can accommodate up to six option cards. The option cards are installed into sockets on the rear of the printed circuit board, and they are held in place with a metal bracket. A single metal bracket is used to secure all the installed option cards.

  • Page 46: Replacing The Lcd Display

    Chapter 4. Parts Replacement 4.5 Replacing the LCD Display The Model GS868’s measurements are displayed on a a two-pane LCD graphic display panel. The LCD display normally provides years of dependable service, but it is easily field-replaceable when necessary. To replace the LCD display, see Figure 8 on page 39 for the component locations, and complete the following steps: 1.

  • Page 47: Installing The Printed Circuit Board

    Chapter 4. Parts Replacement 4.6 Installing the Printed Circuit Board Whether the printed circuit board was removed for replacement or for one of the other procedures discussed in this chapter, reinstallation of the printed circuit board is the final step in the process. Refer to Figure 8 on page 39 and complete the following steps: 1.

  • Page 48: Spare Parts

    Chapter 4. Parts Replacement Installing the Printed Circuit Board (cont.) 9. For LVD compliant units, position the clear plastic LVD shroud over the electrical connections so that the two holes in the shroud align with the standoffs on the printed circuit board. Secure the shroud to the standoffs with the two sets of screws and washers.
  • Page 49 Chapter 4. Parts Replacement Front View Keypad Cable Mounting Screw Main Shroud Main Shroud 8 places Display Cable Nuts & Washers Nuts & Washers WARNING 4 places Display Shroud Option Card Socket GATE DRTN TWIND RWIND ALARMS ANALOG OUT ANALOG IN TOTL/FREQ RTD IN LCD Display...
  • Page 50 Chapter 4. Parts Replacement Keypad Cable Short Standoff Vertical Components 3 places Backlight Cable Long Standoff EPROM (U4) 3 places LCD Display Beveled BLACK Corner Keypad Connector (J50) Display Connector (J52) Display Cable – N/L2 J2 Connector Fasteners (typ.) Option Card Connectors Metal Bracket Rear View PC Board Ground Wire...

  • Page 51: Appendix A. Service Record

    Appendix A. Service Record Appendix A. Service Record A.1 Introduction Whenever any service procedure is performed on the Model GS868 flowmeter, 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 52 Appendix A. Service Record Table 6: Service Record (cont.) Date Description of Service Performed By DigitalFlow™ GS868 Service Manual...

  • Page 53: Diagnostic Parameters

    Appendix A. Service Record A.3 Diagnostic Parameters After a successful initial installation of the Model GS868 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...
  • Page 54 Appendix A. Service Record [no content intended for this page] DigitalFlow™ GS868 Service Manual...

  • Page 55: Appendix B. Optional Enclosures

    Appendix B. Optional Enclosures Appendix B. Optional Enclosures B.1 Introduction The Model GS868 is available in optional enclosure types, each of which has been designed to permit easy on-site upgrades and parts replacement. See the foldout drawings at the end of this appendix for details of the applicable GS868 electronics console assembly.

  • Page 56: Rack Mount Fuse Replacement

    Appendix B. Optional Enclosures B.3 Rack Mount Fuse Replacement If it has been determined that the fuse in the Model GS868 requires replacement, refer to Figure 10 on page 53 and Figure 11 on page 54, and complete the following steps: 1.

  • Page 57: Rack Mount Option Card Installation

    Appendix B. Optional Enclosures B.4 Rack Mount Option Card Installation The Model GS868 flowmeter can accommodate up to six option cards in a manner similar to that used in a PC. The option cards are installed into sockets on the printed circuit board, and they are held in place with a metal bracket. A single metal bracket is used to secure all the installed option cards.

  • Page 58: Rack Mount Eprom Replacement

    Appendix B. Optional Enclosures B.5 Rack Mount EPROM Replacement The Model GS868’s User Program is stored on an erasable programmable read only memory (EPROM) chip. The EPROM, which is designated as component , is located on the corner of the printed circuit board just behind the keypad on the front panel.

  • Page 59: Rack Mount Lcd Display Replacement

    Appendix B. Optional Enclosures B.6 Rack Mount LCD Display Replacement The Model GS868 measurements are displayed on a a two-pane LCD graphic display panel. The LCD display normally provides years of dependable service, but it is field-replaceable when necessary. To replace the LCD display, refer to Figure 11 on page 54 and complete the following steps: 1.

  • Page 60: Rack Mount Printed Circuit Board Replacement

    Appendix B. Optional Enclosures B.7 Rack Mount Printed Circuit Board Replacement If troubleshooting procedures have indicated a defective printed circuit board, follow the instructions in this section to replace the defective board with a new one. B.7.1 Circuit Board Removal Refer to Figure 11 on page 54 and complete the following steps: 1.

  • Page 61: Circuit Board Installation

    Appendix B. Optional Enclosures B.7.2 Circuit Board Installation Refer to Figure 11 on page 54 and complete the following steps: 1. Position the new printed circuit board within the electronics console so that it rests on the six standoffs in the base of the enclosure and the option card sockets are located near the rear of the enclosure.
  • Page 62 Appendix B. Optional Enclosures [no content intended for this page] DigitalFlow™ GS868 Service Manual...
  • Page 63 Appendix B. Optional Enclosures Fuse 14.83 (377) 16.99 (432) 4.19 (106) 11.82 11.37 13.13 (300) (289) (333) 15.70 (399) 3.31 (84) 5.22 HELP EXIT 2.25 (57) (133) DISP PROG PRNT SCREEN GS868 18.25 (464) 19.00 (483) DigitalFlow™ GS868 Service Manual...
  • Page 64 Appendix B. Optional Enclosures Option Card Slot Cover Line Lead (Black) Option Card Socket Analog Output Connector Neutral Lead (White) (typ.) CH1 Transducer Connector Fuse RS232 Connector CH2 Transducer Connector Ground Lead (Green) Top Panel Mounting Hole Power Terminal Block 4 places Printed Circuit Board Display Cable...
  • Page 65 Index ......17 Display Screen ..... . 19 Acceleration Error - E6 .
  • Page 66 Index Option Card ....19 Temperature Input Error - E8 ......2 Analog Outputs .
  • Page 67 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.
  • Page 68 Warranty [no content intended for this page] DigitalFlow™ GS868 Service Manual...
  • Page 69 Cable glands of an approved flameproof design are required for Ex d rated equipment. These must be installed according to the manufacturer’s instructions. Where the cable glands are provided by GE, the manufacturer’s instructions, as supplied to GE, will be included in the documentation.
  • Page 70 Certification & Safety Statements for GE Infrastructure Products Used in Hazardous Locations August 2014 Special Conditions for Safe Use Consult the manufacturer if dimensional information on any flameproof joint is necessary. Follow the manufacturer’s instructions to reduce the potential of an electrostatic charging hazard.
  • Page 71 EC DECLARATION Sensing CONFORMITY DOC-0013, Rev. B GE Sensing 1100 Technology Park Drive Billerica, MA 01821 declare under our sole responsibility that the DigitalFlow™ DF8688 Liquid Ultrasonic Flowmeter DigitalFlow™ GC868 Clamp-On Gas Ultrasonic Flowmeter DigitalFlow™ GF868 Flare Gas Mass Ultrasonic Flowmeter DigitalFlow™...
  • 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: [email protected] Ireland Sensing House Shannon Free Zone East Shannon, County Clare Ireland Tel: +353 (0)61 470200 E-mail: [email protected] An ISO 9001:2008 Certified Company www.ge-mcs.com/en/about_us/quality.html...

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