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Chapter 3. Diagnostics

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DigitalFlow™ GS868 Service Manual

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Summary of Contents for DigitalFlow GF868

Page 1: ...GE Measurement Control Flow 910 190S Rev E February 2015 DigitalFlow GS868 Panametrics Steam Ultrasonic Mass Flowmeter Service Manual ...

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Page 3: ... com 2015 General Electric Company All rights reserved Technical content subject to change without notice DigitalFlow GS868 Panametrics Steam Ultrasonic Mass Flowmeter Service Manual 910 190S Rev E February 2015 ...

Page 4: ...ii no content intended for this page ...

Page 5: ...ation 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 WARNING It is the responsibility of the u...

Page 6: ...pment 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 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 app...

Page 7: ...essing the Calibration Menu 7 1 5 2 aLOW Option F1 7 1 5 3 aHIGH Option F2 7 1 5 4 4 mA Option F3 7 1 5 5 20 mA Option F4 8 1 6 Calibrating the RTD Inputs 9 1 6 1 Accessing the Calibration Menu 9 1 6 2 Probe Option F1 9 1 6 2a Set Point Temperature 9 1 6 2b Slope Point Temperature 9 1 6 3 Numer Option F2 10 1 6 3a Set Number 10 1 6 3b Slope Number 10 1 7 Testing the Alarm Relays 11 1 7 1 Accessing...

Page 8: ... 16 E14 Totals Overflow 21 2 17 E15 Equation Limit 21 2 18 Screen Messages 22 Chapter 3 Diagnostics 3 1 Introduction 25 3 2 Displaying Diagnostic Parameters 25 3 3 Diagnostic Record 28 3 4 Flowcell Problems 28 3 4 1 Gas Problems 28 3 4 2 Pipe Problems 29 3 4 3 Transducer Problems 29 Chapter 4 Parts Replacement 4 1 Introduction 31 4 1 1 Fuse Replacement 32 4 2 Removing the Printed Circuit Board 33 ...

Page 9: ...2 Rack Mount Enclosure 45 B 3 Rack Mount Fuse Replacement 46 B 4 Rack Mount Option Card Installation 47 B 5 Rack Mount EPROM Replacement 48 B 6 Rack Mount LCD Display Replacement 49 B 7 Rack Mount Printed Circuit Board Replacement 50 B 7 1 Circuit Board Removal 50 B 7 2 Circuit Board Installation 51 ...

Page 10: ...Contents viii DigitalFlow GS868 Service Manual ...

Page 11: ...a number from 0 6 See Chapter 1 Installation of the Startup Guide for a complete description of the available option cards and the procedures for wiring them 1 2 Menu Map The Calibration Menu is accessed by pressing the CAL key on the keypad Use this menu to calibrate and test the Slot 0 analog outputs as well as to calibrate and test any option cards that are installed in the expansion slots Refe...

Page 12: ...cale 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 Note The zero point of the analog output may be set for either 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 Prepare for the calibration procedure ...

Page 13: ...8 Service Manual 3 Chapter 1 Calibration 1 3 Calibrating the Analog Outputs cont Figure 2 Ammeter Connection for Slots 1 6 Output A Terminal Block Option Card A SIG A RTN B SIG B RTN D SIG D RTN C SIG C RTN Ammeter 1 8 ...

Page 14: ...ry for assistance 1 4 2 Calibrating the High End of the Output Range 1 Press F2 to calibrate the high end of the output range 2 Press F1 or F2 to adjust the ammeter reading UP or DOWN until a 20 mA reading is achieved If you press F3 Numer enter a numeric value for the calibration point and press ENT Note If the ammeter reading cannot be adjusted within 5 0 A of the 20 mA setting contact the facto...

Page 15: ...d calibration of the analog output Do one of the following To calibrate or test another output press F4 EXIT and return to Step 3 in Accessing the Calibration Menu on page 4 To calibrate test additional slots press F4 EXIT twice and proceed to the appropriate section To leave the Calibration Menu press F4 EXIT three times Table 1 Expected Ammeter Readings Full Scale 4 20 mA Scale 0 20 mA Scale 0 4...

Page 16: ...on the Slot 0 analog output will supply the low reference high reference 4 mA and 20 mA signals at the appropriate times Note If a Slot 0 analog output will be used to calibrate the analog inputs make sure that the Slot 0 analog output calibration procedure has already been completed Connect the Slot 0 analog output s or an independent calibrated current source to the analog input s on the option ...

Page 17: ...LOW proceed to aLOW Option below If you selected F2 aHIGH proceed to aHIGH Option below If you selected F3 4 mA proceed to 4 mA Option below If you selected F4 20 mA proceed to 20 mA Option on page 8 1 5 2 aLOW Option F1 1 Enter the low reference value and press the ENT key 2 Press F1 to store the current low reference value or press F2 to cancel the entry In either case the ANALOG INPUT prompt wi...

Page 18: ...s F2 to cancel the entry In either case the ANALOG INPUT prompt reappears 3 Go to Procedure Options below Procedure Options You have completed calibration of the analog output Do one of the following To calibrate another input return to Step 3 in Accessing the Calibration Menu on the previous page To calibrate test additional slots press F4 EXIT and proceed to the appropriate section To leave the ...

Page 19: ...h both options 1 6 2 Probe Option F1 3 Press F1 to select Input A or F2 to select Input B 1 6 2a Set Point Temperature 4 Press F1 to enter the set point temperature 5 Enter the desired set point temperature and press ENT This temperature should be at the low end of your expected operating range 6 Press F1 to STORE the entered temperature or F2 to ABORT the calibration In either case the screen ret...

Page 20: ...ing Manual Printing RTD Data to obtain point values at your set point and slope point 1 Press F1 to select Input A or F2 to select Input B 1 6 3a Set Number 2 Press F1 to enter the set number formerly known as the zero point 3 Enter the set point temperature and press ENT 4 The program then asks for the set point number Enter the points measured at the set temperature and press ENT 1 6 3b Slope Nu...

Page 21: ...inal block as shown in Figure 4 below Refer to the menu map in Figure 6 on page 15 as a guide Figure 4 Typical Ohmmeter Connections For this discussion assume that the option card has been installed in Slot x 1 7 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installe...

Page 22: ...pin numbers on the option card terminal block 4 Pressing F1 CLOSE should yield an ohmmeter reading of about zero Pressing F2 OPEN should yield an infinite ohmmeter reading 5 Press F3 to EXIT 6 Repeat the above procedure until both the normally open and normally closed contacts for all three alarm relays have been tested Then go to Procedure Options below Procedure Options You have completed testin...

Page 23: ...ure 6 on page 15 as a guide Figure 5 Frequency Counter Connections For this discussion assume that the option card has been installed in Slot x 1 8 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press F1 F4 to select output A B C or D respectiv...

Page 24: ... 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 Procedure Options You have completed testing the totalizer frequency outputs Do one of the following To calibrate test additional slots press F4 EXIT and proceed to the appropriate section To leave the Calibration Menu pre...

Page 25: ...TORE F2 ABORT HIGH REF CALIBRATING F1 F2 A B F1 F2 Set Slop F1 F2 Probe Numer F1 F2 SetPt Slope RTD Inputs Set Numer F1 F2 STORE ABORT Set Point Slope Point Set Point Slope Number Temp F1 F3 A C Alarms F2 B F1 F3 CLOSE EXIT F2 OPEN F1 F3 A C Freq Total F2 B F4 D NOTE Plain text represents prompt area messages and boxed text represents option bar choices Fx represent function keys to select option ...

Page 26: ...Chapter 1 Calibration DigitalFlow GS868 Service Manual 16 ...

Page 27: ...oting process All of the possible Model GS868 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 active pane of the display screen in the location shown in Figure 7 below Figure 7 A Typical Display Screen Note For a 2 Channel Model GS868 the channel number is displayed in front of the er...

Page 28: ...e entered into the SETUP SIGNL submenu in Chapter 1 Programming Site Data of the Programming Manual 2 4 E2 Sound Speed Error Problem The sound speed exceeds the limits programmed in the SETUP SIGNL submenu of the User 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...

Page 29: ...id particulates may be present in the flowcell Action Refer to Chapter 3 Diagnostics to correct any flowcell problems 2 8 E6 Cycle Skip Accel Problem The acceleration exceeds the limits programmed in the SETUP submenu of the User 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 ...

Page 30: ...cates that based on the temperature and pressure readings the steam is super saturated and may become two phase Cause Low temperature in the system Action Raise the system temperature or lower the system pressure until all the water vaporizes 2 14 E12 Low Pressure Problem This message indicates the pressure reading has dropped below the programmed PRESSURE LIMIT Cause System shutdown or a faulty p...

Page 31: ... E15 Equation Limit Problem The meter cannot determine if the steam measurement is within 1 accuracy Cause The temperature or pressure reading is outside the accuracy specification of the GS868 steam equations This error usually appears when the meter is running at a low temperature or the process has not come up to speed Action Adjust the pressure reading to within the range of 139 9685 kPa to 22...

Page 32: ... FAIL The non volatile RAM has failed Contact the factory NVR OK The non volatile RAM has passed Measurement Mode Messages All Logs Cleared hit key This message may appear during one of the following tasks 1 clearing a log there are no more logs to clear 2 logging data user has hit ENT instead of selecting an old log or entering a new name 3 printing a log there are no logs to print 4 displaying a...

Page 33: ...to clear the message and the GS868 will default to the last valid calibration The message will also appear if there is no ammeter connected to the analog output during calibration Overflow The display value overflowed Reduce the number of decimal places or change the units P L Enter L again The entered path length P is less than the axial dimension L Enter a new value for L range is X XX to X XX W...

Page 34: ...Chapter 2 Error Codes and Screen Messages 24 DigitalFlow GS868 Service Manual no content intended for this page ...

Page 35: ... of flowcell transducer and or electrical problems The Diagnostics Menu may only be entered from the Big or Dual measurement mode display See Chapter 2 Displaying Data in the Programming Manual for instructions on setting the display screen to the desired format and enter the Diagnostics Menu as shown below Note For a 1 Channel meter the above prompt does not appear and the following prompt is the...

Page 36: ...gth for the downstream transducer 50 75 50 or 75 SNDSP Soundspeed Ft s Displays the measured sound speed of the fluid N A N A Tup UP Transit S usec Displays the upstream transit time of the ultrasonic signal in microseconds N A N A Tdown DN Transit usec Displays the downstream transit time of the ultrasonic signal in microseconds N A N A DELTA DeltaT usec Displays the difference in µsec between up...

Page 37: ...Displays Measure Tdn N A N A DT M DeltaT M usec Displays Measure Delta N A N A Vinst Vinst Ft s Displays the instantaneous velocity for comparison with Vel without averaging N A N A Tsat T Saturat deg K Displays the saturation temperature of steam for the operating pressure of the flow system N A N A Tsupr T Superht deg K Displays the operating temperature of the system minus the saturation temper...

Page 38: ...de 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 t...

Page 39: ...for a thorough discussion of this topic 3 4 3 Transducer Problems Ultrasonic transducers are rugged reliable devices However they are subject to physical damage from mishandling and chemical attack The most common transducer problems are listed below 1 LEAKS Leaks may occur around the transducer and or the flowcell fittings Repair such leaks immediately If the leaking gas is corrosive carefully ch...

Page 40: ...Chapter 3 Diagnostics 30 DigitalFlow GS868 Service Manual no content intended for this page ...

Page 41: ...ce such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model GS868 An aluminum shroud with a wiring diagram label is located over the main printed circuit board All of the procedures discussed in this chapter except for fuse replacement require removal of this shroud Note For compliance with the E...

Page 42: ...the fuse holder 4 Replace the defective fuse with a new one of the same rating and type Use only 1 1 4 x 1 4 Slo Blo fuses having a rating as indicated in Table 4 below and on the wiring diagram label 5 Press the new fuse into the fuse holder cap and insert the fuse into the fuse holder While applying a slight pressure with the screwdriver twist the fuse holder cap 1 4 turn clockwise 6 For LVD com...

Page 43: ... remove the two screws or standoffs along the bottom edge of the printed circuit board Note For an LVD compliant meter with the clear plastic shroud over the electrical connectors there will be standoffs in these two locations For meters not equipped with this shroud there will be Phillips head screws in these two locations 6 Carefully list the printed circuit board out of the enclosure Continue t...

Page 44: ... corner of the board 3 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 4 Make sure that the beveled corner on the new EPROM is aligned with the beveled corner of the socket and ...

Page 45: ...astic snap rivets or metal hardware in some older meters In either case they may be discarded as new plastic snap rivets will be provided 3 There are six 32 pin option card sockets J41 J46 on the rear of the printed circuit board To install an option card insert its 32 pin connector into any available option card socket and gently press the card into place Make sure that the pins in the connector ...

Page 46: ...unting studs 4 Place the new LCD display assembly over the mounting studs on the console cover and fasten it in place with the four standoffs Make sure that the LCD display assembly is oriented as shown in Figure 9 on page 40 5 Position the LCD display cables between the two right side mounting studs and install the display shroud over the mounting studs The top and bottom edges of the shroud are ...

Page 47: ...between the printed circuit board and the standoff beneath it install the remaining short standoff on the left side of the printed circuit board Securely tighten all eight standoffs and or screws IMPORTANT Correctly installing the grounding strap may require some patience but resist the temptation to place the grounding strap on top of the printed circuit board 5 Connect the twisted pair backlight...

Page 48: ...low rate measurements Note Be sure to enter a complete and detailed account of any parts replacement performed on the Model GS868 in Appendix A Service Record 4 7 Spare Parts All of the necessary components to upgrade or repair the Model GS868 flowmeter are readily available from the factory As a convenient reference some of the more common spare parts are listed in Table 5 below To purchase the p...

Page 49: ...Display Cable Keypad Cable Backlight Cable Mounting Screw 8 places Main Shroud Option Cards Fuse Holder Cap Card Guide Metal Bracket Main Shroud Option Card Socket Metal Bracket Fasteners Option Card Standoffs typ LVD Shroud Screw 8 places PC Board Standoffs LCD Display Display Shroud Nuts Washers Bottom View Side View Front View LVD Shroud Fuse Holder Power Connector PC Board Ground Wire Internal...

Page 50: ...2 Connector PC Board Ground Wire Screws or Standoffs Short Standoff 3 places Vertical Components Long Standoff 3 places Metal Bracket Option Card Connectors Fasteners typ Display Connector J52 Keypad Connector J50 EPROM U4 Beveled Corner Front View Rear View G N L2 L1 AC G DC Figure 9 Standard Model GS868 Printed Circuit Board Assembly ...

Page 51: ...eter the details of the service should be recorded in this appendix An accurate service history of the meter can prove very helpful in troubleshooting any future problems A 2 Data Entry Record complete and detailed service data for the Model GS868 in Table 6 below Make additional copies of the table as needed Table 6 Service Record Date Description of Service Performed By ...

Page 52: ...Appendix A Service Record 42 DigitalFlow GS868 Service Manual Table 6 Service Record cont Date Description of Service Performed By ...

Page 53: ... the values for the diagnostic parameters should be entered in Table 7 below Table 7 Diagnostic Parameters Parameter Initial Current Parameter Initial Current SS up Mw SS do z SNDSP AcVOL Tup StVOL Tdown Tu S DELTA Td S PEAK DT S Qup Tu M Qdown Td M AMPup DT M AMPdn Vinst CNTup Tsat CNTdn Tsupr P up Rho P dn Kelvn TEMP kPa PRES QUAL These parameters are available only in the Skan Measure mode ...

Page 54: ...Appendix A Service Record 44 DigitalFlow GS868 Service Manual no content intended for this page ...

Page 55: ...at unit Note For compliance with the European Union s Low Voltage Directive 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 Model GS868 B 2 Rack Mount Enclosure Refer to Figure 10 on page 53 and Figure 11 on page 54 for the location of the...

Page 56: ...e the defective fuse with a new one of the same rating and type Use only 5 x 20 mm Slo Blo fuses having a rating as indicated in Table 8 below and on the rear panel label 4 Reinstall the black plastic fuse cover and insert the power cord back into the receptacle Then position the power switch in the ON position The Model GS868 flowmeter may now be placed back into service Reconnect the main power ...

Page 57: ... new option card 4 To install the option card insert its 32 pin connector into the chosen option card socket and gently press the card into place Make sure that the pins in the connector are straight and properly aligned with the socket and that the option card is oriented with its external connector positioned in the opening on the rear panel 5 Repeat steps 3 and 4 to install any additional optio...

Page 58: ...up a little at a time at each notch until it comes free 3 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 4 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 After checking for a...

Page 59: ... LCD display assembly over the mounting studs on the front panel and fasten it in place with the four standoffs Make sure that the LCD display assembly is oriented with the cables pointing toward the left side away from the keypad of the meter 6 Position the LCD display cables between the two mounting studs and install the display shroud over the mounting studs The top and bottom edges of the shro...

Page 60: ...s from the printed circuit board Use a marker to identify pin 1 on the right side keypad side of these connectors Note These connectors should be pulled straight up and off the printed circuit board DO NOT remove the leads from the screw terminals 5 Remove the flat KEYPAD CABLE connector from terminal J50 near the front of the printed circuit board Mark pin 1 of the cable connector which is locate...

Page 61: ...and TRANSDUCER connectors onto the printed circuit board at the locations indicated in Figure 11 on page 54 Make sure the marked pin 1 sides of the connectors face the right side keypad side of the enclosure Note If any leads have come loose from the screw terminals on these connectors refer to Appendix C Optional Enclosures of the Startup Guide for wiring instructions 6 Reconnect the main POWER L...

Page 62: ...Appendix B Optional Enclosures 52 DigitalFlow GS868 Service Manual no content intended for this page ...

Page 63: ... E D 8 F TOTL FREQ RS232 USE ONLY WITH A 250V FUSE BEFORE SERVICING DISCONNECT POWER 100 120 VAC FUSE 1 AMP OFF ON 19 00 483 18 25 464 2 25 57 5 22 133 11 37 289 11 82 300 13 13 333 4 19 106 15 70 399 3 31 84 14 83 377 16 99 432 NC 3 3 4 5 6 7 8 NO C NC 4 6 5 NO 7 NC 9 C 8 B C NO NO NO B C D RTN SIG RTN SIG RTN SIG C C C 4 5 3 8 7 6 RTN INLO INHI 24V 4 5 3 INLO RTN 8 7 6 B D C A OUT 1 2 C 2 NO 1 A...

Page 64: ...g Output Connector CH1 Transducer Connector CH2 Transducer Connector EPROM U4 PCB Mounting Screw typ Printed Circuit Board Option Card Bracket Option Card Socket typ RS232 Connector Ground Lead Green Option Card Slot Cover Snap Rivets typ Beveled Corner Top Panel Mounting Hole Power Terminal Block Line Lead Black Neutral Lead White Fuse 4 places Figure 11 Model GS868 Rack Mount Console Assembly re...

Page 65: ...cuit Board Contamination Gas 28 Corrosion Transducers 29 D Diagnostic Parameters Initial Values 28 Table 26 Table of Values 43 Diagnostics Menu Entering 25 Exiting 28 Display Cable 33 LCD 36 Replacing 36 Display Screen 17 E EPROM Replacing 34 User Program 34 Error Codes 18 19 20 Error Message Display Screen 17 Expansion Slots 1 F Flowcell Problems Gas 28 Pipe 29 Fuse Holder 32 Rating 32 Replacing ...

Page 66: ...e Return Policy 57 S Screen Messages Table 22 Service Record 41 Shroud Aluminum 31 37 LCD Display 36 LVD 38 Plastic 38 Signal Quality Error E4 19 Sockets Option Card 35 Soundspeed Error E2 18 Gas 28 Spare Parts List 38 Special Input Error E10 20 Super Saturated Error E11 20 T Temperature Input Error E8 19 Totalizer Frequency Option Card Testing 13 Totals Overflow Error E14 21 Transducers Corrosion...

Page 67: ...ular 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 w...

Page 68: ...Warranty 58 DigitalFlow GS868 Service Manual no content intended for this page ...

Page 69: ...e entries must be sealed using a suitably certified threaded plug Modifications to any flameproof enclosure are not permitted The apparatus must be de energized before opening servicing and conducting any routine maintenance Installation shall be in accordance with the installation instructions and the National Electrical Code ANSI NFPA 70 the Canadian Electrical Code C22 1 or IEC EN 60079 14 as a...

Page 70: ...ounted for process temperatures up to 85 C and will be remotely mounted for process temperatures exceeding 85 C Markings Markings appear on the instrument label which identifies the product model serial number operating ranges hazardous area ratings entry thread type and warning and caution information EU EEA Installation Compliance The use of this apparatus is subject to the EU directive on minim...

Page 71: ...61326 2 3 2006 EN 61010 1 2012 Overvoltage Category II Other standards Used EN 50014 1997 A1 A2 EN 50018 2000 A1 following the provisions of the 2004 108 EC EMC 2006 95 EC Low Voltage and 94 9 EC ATEX Directives Where products were initially assessed for compliance with the Essential Health and Safety Requirements of the ATEX Directive 94 9 EC using earlier harmonized standards a subsequent review...

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Page 74: ...Certified Company www ge mcs com en about_us quality html 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 470200 E mail gesensingsnnservices ge com ...

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