GE Sensing GS868 Start-up Guide
GE
Measurement & Control Flow
DigitalFlow™ GS868
Panametrics Steam Ultrasonic Mass Flowmeter
Startup Guide
910-190U Rev. E1
February 2016
DigitalFlow™ GS868
Panametrics Steam Ultrasonic Mass Flowmeter
Startup Guide
910-190U Rev. E1
February 2016
www.gemeasurement.com
©2016 General Electric Company. All rights reserved.
Technical content subject to change without notice.
[no content intended for this page]
ii
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.
Safety Issues
WARNING! It is the responsibility 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.
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™ GS868 Startup Guide 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 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.
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.
http://www.ge-mcs.com/en/about-us/environmental-health-and-safety/weee.html for take-back instructions and
Visit
more information about this initiative.
iv DigitalFlow™ GS868 Startup Guide
Contents
Chapter 1. Installation
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Electronics Console Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2.2 Flowcell Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2.3 Transducer Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2.4 Cable Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2.5 Temperature and Pressure Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.6 Transducer Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 Installing a Flowcell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4 Installing Temperature and Pressure Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Mounting the GS868 Electronic Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.6 Making the Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6.1 Wiring the Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.2 Wiring the Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.6.3 Wiring the 0/4-20 mA Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.6.4 Wiring the Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.6.4a Wiring the RS232 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.6.4b Wiring the RS485 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.6.4c Wiring the Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.6.4d Wiring the MODBUS/TCP Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.6.5 Wiring the Foundation Fieldbus Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.6.6 Wiring an Alarms Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.6.7 Wiring a 0/4-20 mA Analog Inputs Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.6.8 Wiring a Totalizer/Frequency Outputs Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.6.9 Wiring an RTD Inputs Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.6.10 Wiring a 0/4-20 mA Analog Outputs Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
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Chapter 2. Initial Setup
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.2 Navigating Through the User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.3 Accessing the User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.4 Activating a Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.4.1 1-Channel Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.4.2 2-Channel Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.4.3 1 and 2-Channel Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.5 Entering System Data for a Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.5.1 A 1-Channel Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.5.2 A 2-Channel Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.5.3 1 and 2-Channel Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.6 Entering Pipe Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.6.1 Transducer Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.6.2 Pipe OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.6.3 Pipe Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.6.4 Path Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.6.5 Axial Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.6.6 Fluid Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.6.7 Reynolds Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.6.8 Calibration Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Chapter 3. Operation
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.2 Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.3 Using the Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3.4 Taking Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.4.1 Foundation Fieldbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
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Chapter 4. Specifications
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.1.1 Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.1.2 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.1.3 Flow Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.1.4 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.1.5 Rangeability (Overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.1.6 Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.1.7 Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2.2 Power Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2.3 Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2.4 European Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.2.5 Input/Output Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.3 Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.3.1 Flow Computer (Built-in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.3.2 Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.3.3 Display Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.3.4 Printer Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.4 Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.4.1 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.4.2 Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.4.3 Pressure Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.4.4 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.4.5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.5 Flowcell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Appendix A. CE Mark Compliance
A.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
A.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
A.3 External Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Appendix B. Data Records
B.1 Option Cards Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
B.2 Initial Setup Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Appendix C. Optional Enclosures
C.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
C.2 Rack Mount Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
C.3 Rack Mount Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
C.4 Rack Mount Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
DigitalFlow™ GS868 Startup Guide vii
Contents
Appendix D. Measuring P and L Dimensions
D.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
D.2 Measuring P and L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• Special Conditions for Safe Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 EU / EEA Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 Increased Safety Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 Power Connection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 All Other Screw Terminal Connections:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
viii DigitalFlow™ GS868 Startup Guide
Chapter 1. Installation
Chapter 1. Installation
1.1 Introduction
To ensure safe and reliable operation of the Model GS868 Steam Ultrasonic Mass Flowmeter, the system must be
installed in accordance with the guidelines established by GE’s engineers. Those guidelines, which are explained in
detail in this chapter, include the following specific topics:
• Unpacking the Model GS868 system
• Selecting a suitable site for the electronics console and the flowcell/transducers
• Installing a flowcell
• Installing temperature and pressure transmitters
• Installing the Electronics Console
• Wiring the Electronics Console.
WARNING!
which are potentially hazardous. In such cases, the importance of proper safety practices cannot
be overemphasized.
Be sure to follow all applicable local safety codes and regulations for installing electrical
equipment and working with hazardous gases or flow conditions. Consult company safety
personnel or local safety authorities to verify the safety of any procedure or practice.
ATTENTION EUROPEAN CUSTOMERS!
connections must be made in accordance with the instructions in Appendix A, CE Mark
Compliance.
The Model GS868 flowmeter can measure the flow rate of many gases, some of
In order to meet CE Mark requirements, all wiring
1.1.1 Unpacking
Carefully remove the electronics console, the transducers, and the cables from the shipping containers. Before
discarding any of the packing materials, account for all components and documentation listed on the packing slip. The
discarding of an important item along with the packing materials is all too common. If anything is missing or damaged,
contact the factory immediately for assistance.
DigitalFlow™ GS868 Startup Guide 1
Chapter 1. Installation
1.2 Site Considerations
Because the relative physical locations of the flowcell and the Model GS868 electronics console are important, use the
guidelines given in this section to plan the Model GS868 system installation.
1.2.1 Electronics Console Location
The standard Model GS868 electronics enclosure is a Type-4X weather-resistant, dust-tight, indoor/outdoor type.
Typically, the electronics console is mounted in a meter shed. When choosing a mounting site, make sure that the
location permits easy access to the console for programming, testing, and servicing.
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.
1.2.2 Flowcell Location
The pipeline flowcell consists of the flowmeter transducers and any pressure and/or temperature transducers employed
as part of the flowmeter system. Ideally, choose a section of pipe with unlimited access as the flowcell; for example, a
long stretch of pipe that is above ground. However, if the flowcell is mounted on an underground pipe, dig a pit around
the pipe to facilitate installation of the transducer mechanisms.
1.2.3 Transducer Location
For a given fluid and pipe, the Model GS868’s accuracy depends primarily on the location and alignment of the
transducers. In addition to accessibility, when planning for transducer location, adhere to the following guidelines:
1. Locate the transducers so that there are at least 20 pipe diameters of straight, undisturbed flow upstream and 10
pipe diameters of straight, undisturbed flow downstream from the measurement point. To ensure undisturbed flow,
avoid: sources of turbulence in the fluid such as valves, flanges, expansions and elbows; swirl; and dips or low
spots in which condensed liquid may collect.
2. Because condensate or sediment at the bottom of the pipe may cause attenuation of the ultrasonic signal, locate the
transducers on the side of a horizontal pipe, where possible. If limited pipe access necessitates top-mounted
transducers and the sound beam path includes a reflection, shift the transducers to at least 10° off top center. This
will minimize the influence of any sediment on the reflected ultrasonic signals.
1.2.4 Cable Lengths
Locate the flowcell/transducers as close as possible to the electronics console. The factory supplies transducer cables
up to 500 ft (153 m) in length. If longer cables are required, consult the factory for assistance.
1.2.5 Temperature and Pressure Transmitters
When installing temperature and/or pressure transmitters in the flowcell, locate them downstream of the flowmeter
transducers. These transmitters should be positioned no closer to the flowmeter transducers than 2 pipe diameters and
no further away from the flowmeter transducers than 20 pipe diameters.
2 DigitalFlow™ GS868 Startup Guide
Chapter 1. Installation
1.2.6 Transducer Cables
When installing the transducer cables, always observe established standard practices for the installation of electrical
cables. Specifically, do not route transducer cables alongside high amperage AC power lines or any other cables that
could cause electrical interference. Also, protect the transducer cables and connections from the weather and corrosive
atmospheres.
Note: When using non-GE cables to connect the flowmeter transducers to the Model GS868 electronics console, the
cables must have electrical characteristics identical to the GE cables. Type RG 62 a/u coaxial cable should be
used, and each cable must be the same length (within ±4 in.).
1.3 Installing a Flowcell
A flowcell is the section of pipe where the transducers are mounted. It can be created either by mounting the
transducers on the existing pipeline or by mounting them on a spoolpiece. A spoolpiece is a separately manufactured
pipe section, matched to the existing pipe, which contains ports for mounting the transducers. This approach allows the
transducers to be aligned and calibrated before inserting the spoolpiece into the pipeline.
Figure 1 on page 4 shows a block diagram of a typical Model GS868 system, including optional pressure and
temperature transmitters. For detailed instructions on installing the transducers and/or spoolpiece, refer to the supplied
drawings and the GE Gas Transducer Installation Guide for Ultrasonic Flowmeters.
DigitalFlow™ GS868 Startup Guide 3
Chapter 1. Installation
Transducer
Flowcell
Temperature Transmitter
Pressure Transmitter
Preamp
Transducer
Electronics Console
STEAM
FLOW
Figure 1: A Typical Model GS868 System
4 DigitalFlow™ GS868 Startup Guide
Chapter 1. Installation
Temperature Transmitter
Pressure Transmitter
Isolation Valve
Flowcell Wall
Coupling
Thermowell
RTD
1.4 Installing Temperature and Pressure Transmitters
Optional temperature and pressure transmitters may be installed as part of the flowcell, near the ultrasonic transducer
ports. Be sure to observe the siting requirements given earlier in this chapter. These transmitters must use a 0/4-20 mA
signal to transmit the temperature and pressure values to the Model GS868 electronics console. In turn, the electronics
console will provide a 24 VDC signal to power the transmitters. Any desired transmitters or sensors may be used, but
they must have an accuracy equal to 0.5% of the reading or better.
Note: Resistive Thermal Devices (RTDs) are a good choice for measuring the temperature.
Typically, a 1/2” or 3/4” NPT female threaded port is used to mount the transmitters on the flowcell. If the pipeline is
insulated, the coupling may need to be extended to provide convenient access. Of course, other types of mounting
ports, including flanged ports, may be used for the transmitters.
IMPORTANT: Under changing temperature and pressure conditions, the Model GS868 can calculate accurate steam
density and mass flow only if temperature and pressure transmitters have been installed.
Figure 2 below shows a typical mounting arrangement for the pressure and temperature transmitters. The temperature
sensor should protrude 1/4 to 1/2 way into the pipe.
Figure 2: Typical Temperature/Pressure Transmitter Mounting
DigitalFlow™ GS868 Startup Guide 5
Chapter 1. Installation
1.5 Mounting the GS868 Electronic Console
The standard model GS868 electronics package is housed in a Type-4X weather-resistant enclosure. Refer to Figure 9
on page 19 for the mounting dimensions of this enclosure.
IMPORTANT: For meters supplied in one of the optional enclosure styles, refer to Appendix C, Optional Enclosures, for
specific mounting dimensions and instructions.
WARNING!
electric shock. See Figure 10 on page 20 to locate the internal ground connection.
Proper grounding of the GS868 chassis is required to prevent the possibility of
1.6 Making the Electrical Connections
ATTENTION EUROPEAN CUSTOMERS!
connections must be made in accordance with the instructions in Appendix A, CE Mark
Compliance.
This section contains instructions for making all the necessary electrical connections to the Model GS868 flowmeter.
Refer to Figure 10 on page 20 for a complete wiring diagram of the unit.
IMPORTANT: For meters supplied in one of the optional enclosure styles, refer to Appendix C, Optional Enclosures, for
the appropriate wiring diagram and specific wiring instructions.
Except for the power connector, all electrical connectors are stored in their terminal blocks during shipment and may be
removed from the enclosure for more convenient wiring. Feed the cables through the conduit holes on the bottom of the
enclosure, attach the wires to the appropriate connectors and plug the connectors back into their terminal blocks.
Note: For compliance with the European Union’s Low Voltage Directive, a transparent plastic shroud protects the
electrical connections. The shroud must remain in place, except while wiring the unit. Reinstall the shroud
after the wiring has been completed.
In order to meet CE Mark requirements, all wiring
Once the Model GS868 is completely wired, proceed to Chapter 2, Initial Setup, to configure the unit for operation.
6 DigitalFlow™ GS868 Startup Guide
1.6.1 Wiring the Line Power
Chapter 1. Installation
ATTENTION EUROPEAN CUSTOMERS!
In order to meet CE Mark requirements, all wiring
connections must be made in accordance with the instructions in Appendix A, CE Mark
Compliance.
The Model GS868 may be ordered for operation with power inputs of 100-120 VAC, 220-240 VAC, or 12-28 VDC.
The label on the shroud inside the electronics enclosure, just above the
TB1 line power terminal block, lists the required
line voltage and the fuse rating for the unit (the fuse rating is also listed in Chapter 4, Specifications). Be sure to
connect the meter only to the specified line voltage.
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.
Note: Only use Class 2 Rated Power supply for line power connection to DC instrument.
Refer to Figure 3 on page 8 or Figure 10 on page 20 to locate terminal block
WARNING!
Improper connection of the line power leads or connecting the meter to the
TB1 and connect the line power as follows:
incorrect line voltage will damage the unit. It will also result in hazardous voltages at the flowcell
and associated piping and within the electronics console.
DigitalFlow™ GS868 Startup Guide 7
Chapter 1. Installation
1
TB1
N/L2
Gro
und
23
L1G
Internal
Ground
Connection
PC Board
Ground Wire
Cover
Ground Wire
G – +ACDC
AC Line Power
or DC +
AC Neutral/Line
or DC –
1.6.1 Wiring the Line Power (cont.)
1. Remove the plastic shroud that covers the terminal blocks. Be sure to reinstall the shroud after all of the wiring has
been completed.
2. Strip ¼” of insulation from the end of the power and neutral or line leads (or the positive and negative DC power
leads), and ½” from the end of the ground lead.
3. Connect the ground lead to the internal ground connection located on the side panel of the inclosure (see Figure 3
below).
IMPORTANT: The incoming ground lead must be connected to the internal ground connection.
4. Connect the neutral or line lead (or the negative – DC power lead) to
TB1-2 and the line power lead (or the positive
+ DC power lead) to TB1-3 as shown in Figure 3 below.
IMPORTANT: Do not remove the existing PC board ground wire or the cover ground wire.
Figure 3: Wiring the Line Power
8 DigitalFlow™ GS868 Startup Guide
1.6.2 Wiring the Transducers
Chapter 1. Installation
ATTENTION EUROPEAN CUSTOMERS!
connections must be made in accordance with the instructions in Appendix A, CE Mark
Compliance.
Wiring a typical Model GS868 ultrasonic natural gas flowmeter system requires interconnection of the following
components:
In order to meet CE Mark requirements, all wiring
• a pair of transducers (per channel) mounted in the flowcell
• a preamplifier for each channel
• a lightning protector (optional)
• the electronics console
To wire the transducers, complete the following steps:
WARNING!
static buildup by shorting the center conductor of the transducer cables to the metal shield on
the cable connector.
1. Using the pair of coaxial cables with BNC to BNC connectors supplied by the factory (or equivalent cables),
connect both transducers to the preamplifier.
Before connecting the transducers, take them to a safe area and discharge any
CAUTION!
2. If an optional lightning protector is being installed, connect it to the preamplifier.
3. Using the pair of coaxial cables with BNC to flying lead connectors supplied by the factory (or equivalent cables),
connect the preamplifier to terminal block
location of the terminal block and the terminal block pin assignments.
4. For a 2-channel Model GS868 flowmeter, repeat steps 1-3 to wire the Channel 2 transducer system to terminal
CH2.
block
Note: It is not required that Channel 2 of a 2-channel Model GS868 be used. This channel may be left inactive for
future use.
After the wiring has been completed, the transducer channel(s) must be activated before measurements can begin. See
Chapter 2, Initial Setup, for instructions.
As part of maintaining the FM/CSA environmental rating (TYPE 4) on the remote
preamplifier, thread sealant is required on all conduit entries.
CH1 in the electronics console. Refer to Figure 10 on page 20 for the
DigitalFlow™ GS868 Startup Guide 9
Chapter 1. Installation
1.6.3 Wiring the 0/4-20 mA Analog Outputs
The standard configuration of the Model GS868 flowmeter includes two isolated 0/4-20 mA analog outputs
(designated as A and B). Connections to these outputs may be made with standard twisted-pair wiring. The current loop
impedance for these circuits must not exceed 550 ohms.
Refer to Figure 10 on page 20 for the location of terminal block
I/O and wire the terminal block as shown.
1.6.4 Wiring the Serial Port
The Model GS868 is equipped with a built-in serial communications port. The standard port is an RS232 interface, but
an optional RS485 interface is available upon request. Proceed to the appropriate sub-section for wiring instructions.
For more information on serial communications, refer to the EIA-RS Serial Communications Manual (916-054).
1.6.4a Wiring the RS232 Interface
The RS232 communications port provides a serial interface for connecting the Model GS868 flowmeter to a printer, an
ANSI terminal or a personal computer.
The RS232 serial interface is wired as Data Terminal Equipment (DTE), and the signals available at the Model GS868
RS232 terminal block are shown in Table 1 below. Refer to Figure 8 on page 16 to locate terminal block RS232 and
complete the following steps to wire the terminal:
1. Use the information in Table 1 below to construct a suitable cable for connecting the Model GS868 to the external
device. If desired, an appropriate cable may be purchased from GE.
Table 1: RS232 Connection to DCE or DTE Device
RS232
Pin # Signal Description
DCE
DB25
Pin #
DTE
DB25
Pin #
DTE
DB9
Pin #
1 RTN (Return) 7 7 5
2 TX (Transmit) 3 2 3
3 RX (Receive) 2 3 2
4
DTR (Data Terminal Ready)
20 20 4
5 CTS (Clear to Send) 4 5 8
2. Wire the flying leads end of the cable to terminal block
RS232 and connect the other end of the cable to the printer,
ANSI terminal or personal computer.
After the wiring has been completed, consult the User’s Manual for the external device to configure it for use with the
Model GS868.
10 DigitalFlow™ GS868 Startup Guide
Chapter 1. Installation
NC 6
NC 7
RX 8
TX 9
1 TD OUT
2
3
4 RD IN
GS868 Converter
1.6.4b Wiring the RS485 Interface
Use the optional RS485 serial port to network multiple GS868 flowmeters to a single computer terminal. Upon request,
the standard RS232 port on the GS868 may be configured as a two-wire, half-duplex RS485 interface, through a device
such as the INMAC Model 800052 RS232-RS422/RS485 converter.
To wire the RS485 serial port, refer to Figure 10 on page 20 and complete the following steps:
1. Disconnect the main power to the unit and remove the cover.
2. Install the required cable clamp in the chosen conduit hole on the side of the electronics enclosure.
3. Feed one end of the cable through the conduit hole, wire it to terminal block J1 and secure the cable clamp.
Connect the other end of the cable to the converter, as shown in Figure 4 below.
Figure 4: Typical RS485 Connections
ATTENTION EUROPEAN CUSTOMERS!
connections must be made in accordance with the instructions in Appendix A, CE Mark
Compliance.
4. If wiring of the unit has been completed, reinstall the rear cover on the enclosure and tighten the set screw.
In order to meet CE Mark requirements, all wiring
DigitalFlow™ GS868 Startup Guide 11
Chapter 1. Installation
1.6.4c Wiring the Ethernet Interface
A modified GS868 can use the Ethernet interface to communicate to an internal network. An optional Ethernet card
with a unique MAC (IP) address (installed only in slots 5 or 6) includes an RJ45 connector. To connect the Ethernetenabled GS868 to the network, insert the jack of an RJ45 cable into the RJ45 connector, route the cable through the
bottom of the GS868, and wire the other end of the cable to the Ethernet network according to the manufacturer’s
instructions. An external connection is required between the Ethernet option card and the GS868’s RS232 connector, as
shown in Table 2 below.
Note: The MAC address for a specific GS868 is included with customer documentation. For more information on
setting up the MAC address, refer to Chapter 6 of the Programming Manual.
Table 2: RS232 to Ethernet Interconnections
GS868 Type Terminal Block Terminal Block
RS232 on Main Board TB1 on Ethernet Card
Wall Mount
TX Pin 1
RX Pin 2
RTN Pin 3
RS232 on Main Board TB2 on Ethernet Card
Rack Mount
TX Pin 1
RX Pin 2
RTN Pin 3
1.6.4d Wiring the MODBUS/TCP Interface
Customers can also use a modified GS868 that provides a MODBUS/TCP interface to communicate to an internal
network. An optional MODBUS/TCP card with a unique MAC (IP) address (installed only in slots 5 or 6) includes an
RJ45 connector. To connect the MODBUS/TCP-enabled GS868 to the network, insert the jack of an RJ45 cable into
the RJ45 connector, route the cable through the bottom of the GS868, and wire the other end of the cable to the Ethernet
network according to the manufacturer’s instructions.
Note: The MAC address for a specific GS868 is included with customer documentation. For more information on
setting up the MAC address, refer to Chapter 6 of the Programming Manual.
12 DigitalFlow™ GS868 Startup Guide
Chapter 1. Installation
1
9
J8
1
9
J9
1.6.5 Wiring the Foundation Fieldbus Network
Fieldbus network connections are made at J8/J9, pins 1 and 2 (see Figure 5 below). Optionally, a shield can be
connected to J8/J9 pin 3, depending on the network wiring. Connector J8 or J9 will be installed depending on the
option ordered by the customer.
No connections are made to J8/J9, pins 7 and 9, under normal operation. If it is desired to reset the network board to
factory defaults:
1. Connect a jumper between J8/J9 pin 7 and pin 9.
2. Power cycle the instrument.
3. Ten seconds after the power has been restored to the unit, remove the jumper to return the network board to normal
operation.
Figure 5: Network Connections - Standard Option Interior
DigitalFlow™ GS868 Startup Guide 13
Chapter 1. Installation
C
NO
NC
NC
C
NO
NC NC
C
NO
C
NO
Monitoring
Alarm
Device
Monitoring
Alarm
Device
Monitoring
Alarm
Device
Monitoring
Alarm
Device
not triggered
Conventional,
not triggered
Fail-Safe,
triggered
Conventional,
triggered or power failure
Fail-Safe,
1.6.6 Wiring an Alarms Option Card
The Model GS868 flowmeter can accommodate up to 4 alarms option cards. Each alarms option card includes three
Form C relays (designated as A, B and C).
The alarm relays on the option card are available in two types:
• general purpose
• hermetically sealed for Class I, Division 2 hazardous areas.
The maximum electrical ratings for the relays are listed in Chapter 4, Specifications. Each of the three alarm relays can
be wired either as Normally Open (NO) or Normally Closed (NC).
In setting up an alarm relay, it may be wired for either conventional or fail-safe operation. In fail-safe mode, the alarm
relay is constantly energized, except when it is triggered or a power failure or other interruption occurs. See Figure 6
below for the operation of a NO alarm relay in both conventional and fail-safe mode.
Connect the two wires required for each alarm relay in accordance with the pin number assignments shown in
Figure 10 on page 20.
14 DigitalFlow™ GS868 Startup Guide
Figure 6: Conventional and Fail-Safe Operation
Chapter 1. Installation
+24V 1
INHI 2
INLO 3
+–
+ IN
– OUT
+ IN
– OUT
Sensor
Sensor
Transmitter
Transmitter
Analog Input
Analog Input
24 VDC
POWER SUPPLY
With External Power Supply
With Internal Power Supply
RTN 4
Jumper
+24V 1
INHI 2
INLO 3
RTN 4
1.6.7 Wiring a 0/4-20 mA Analog Inputs Option Card
To calculate the standard mass flow rates of the steam, the Model GS868 requires accurate temperature and pressure
data from the measurement site. Transmitters installed in the flowcell can provide this information via an optional 0/4-
20 mA analog inputs card. This option card includes two isolated 0/4-20 mA analog inputs (designated as A and B),
each of which includes a 24 VDC power supply for loop-powered transmitters. Either input may be used to process the
temperature signal, while the other input is used to process the pressure signal.
Note: To enter programming data during operation of the meter, it will be necessary to know which input is assigned
to which process parameter. This information should have been entered in Appendix B, Data Records.
The analog inputs, which have an impedance of 118 ohms, should be connected with standard twisted-pair wiring.
Power to the transmitters may be supplied either by the integral 24 VDC power supply on the analog input card or by
an external power supply. Figure 7 below shows typical wiring diagrams, with and without an external power supply,
for one of the analog inputs.
DigitalFlow™ GS868 Startup Guide 15
Figure 7: Analog Input Wiring Diagram
Chapter 1. Installation
NO
C
IN
Common
Volts –
(Common)
Volts +
(Int. Pwr. Sup.)
NO
C
+5V
200
:
Model GS868
Model GS868
Pulse Counter
Frequency Counter
Totalizer Output
Frequency Output
Load
Max. Current: 4A
Max. Voltage: 150V
Isolation Voltage: 500V
Max. Load Power: 10W In
C = Isolated Return
C = Isolated Return
1.6.7 Wiring a 0/4-20 mA Analog Inputs Option Card (cont.)
Wire the analog input terminal block in accordance with the pin number assignments shown in Figure 10 on page 20.
The standard Model GS868 has at least one analog inputs option card, which is used to supply the live pressure reading
required for accurate mass flow calculations. These option cards are identical to the temperature/pressure card
described above and they should be wired in the same manner (see Figure 6 on page 14).
Note: The analog inputs option card can be calibrated with the Model GS868’s built-in analog outputs. However, be
certain that the analog outputs have been calibrated first. See Chapter 1, Calibration, in the Service Manual
for the appropriate procedures.
1.6.8 Wiring a Totalizer/Frequency Outputs Option Card
The Model GS868 can accommodate up to four totalizer/frequency outputs option cards. Each totalizer/frequency
outputs option card provides four outputs (designated as A, B, C, and D) that can be used as either totalizer or
frequency outputs.
Each totalizer/frequency output requires two wires. Wire this terminal block in accordance with the pin number
[no content intended for this page]
assignments shown in Figure 10 on page 20. Figure 8 below shows sample wiring diagrams of a totalizer output circuit
and a frequency output circuit.
16 DigitalFlow™ GS868 Startup Guide
Figure 8: Totalizer/Frequency Outputs Wiring
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