GE Sensing ISX878 Operating Manual
GE
Sensing
DigitalFlow™ ISX878
Panametrics Ultrasonic Liquid Flow Transmitter
User’s Manual
GE
Sensing
DigitalFlow™ ISX878
Panametrics Ultrasonic Liquid Flow Transmitter
User’s Manual
910-270A
July 2006
DigitalFlow™ is a GE Panametrics product. GE Panametrics has joined other GE high-technology sensing
businesses under a new name—GE Industrial, Sensing.
July 2006
Warranty Each instrument manufactured by GE Sensing, Inc. is warranted to be
free from defects in material and workmanship. Liability under this
warranty is limited to restoring the instrument to normal operation or
replacing the instrument, at the sole discretion of GE. Fuses and
batteries are specifically excluded from any liability. This warranty is
effective from the date of delivery to the original purchaser. If GE
determines that the equipment was defective, the warranty period is:
• one year for general electronic failures of the instrument
• one year for mechanical failures of the sensor
If GE determines that the equipment was damaged by misuse,
improper installation, the use of unauthorized replacement parts, or
operating conditions outside the guidelines specified by GE, the
repairs are not covered under this warranty.
The warranties set forth herein are exclusive and are in lieu of
all other warranties whether statutory, express or implied
(including warranties of merchantability and fitness for a
particular purpose, and warranties arising from course of
dealing or usage or trade).
Return Policy If a GE Sensing, Inc. instrument malfunctions within the warranty
period, the following procedure must be completed:
1. Notify GE, 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 will issue a
RETURN AUTHORIZATION number (RA), and shipping instructions
for the return of the instrument to a service center will be
provided.
2. If GE instructs you to send your instrument to a service center, it
must be shipped prepaid to the authorized repair station indicated
in the shipping instructions.
3. Upon receipt, GE will evaluate the instrument to determine the
cause of the malfunction.
Then, one of the following courses of action will then be taken:
• If the damage is covered under the terms of the warranty, the
instrument will be repaired at no cost to the owner and returned.
• If GE determines that the damage is not covered under the terms
of the warranty, or if the warranty has expired, an estimate for the
cost of the repairs at standard rates will be provided. Upon receipt
of the owner’s approval to proceed, the instrument will be repaired
and returned.
iii
Table of Contents
Chapter 1: Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ISXDR Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electronics Enclosure Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Transducer Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Transducer Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Mounting the ISX878 Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Making the Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Preparing the Unit Before Making Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Intrinsically Safe Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safety Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Wiring the Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Determining the Number of Traverses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Installing the Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Small Pipe Transducer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Large Pipe Fixture and Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Mounting Transducers into the CF-ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
Wiring the Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Wiring the Option Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Wiring the RS232 Serial Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
Service Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
What’s Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
July 2006
Chapter 2: Programming Site Data
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unlocking and Locking the ISX878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unlocking the ISX878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Locking the ISX878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Activating a Channel/Path (Status) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Entering Transducer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Other Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Entering Pipe Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Entering the Pipe Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Entering Pipe Lining Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Entering Fluid Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Entering Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Entering Reynolds Correction Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Entering Path Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Entering Signal Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Entering the Meter Correction (K) Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Entering Error Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
What’s Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
v
July 2006
Table of Contents (cont.)
Chapter 3: Displaying Data
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Setting Up the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Changing the Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Changing the Measurement Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Adjusting the Numeric Display Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Changing the Measurement Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Interpreting the Error Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Setting Screen Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Setting the Number of Screen Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Chapter 4: Configuring Meter Data
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Entering Global Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Entering Base (Zero) and Span Output Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Entering Output Type and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Entering Base and Span Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Entering Error Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Entering RS232 Communication Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Resetting Forward and Reverse Totals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Handling Totalizer Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Configuring the Option Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Configuring the Totalizer Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Configuring the Alarm Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
What’s Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Chapter 5: Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Updating ISX878 Instrument Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Checking the Meter Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Checking Option Card Version Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Trimming 4-20 mA via the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
vi
Table of Contents (cont.)
Chapter 6: Error Codes and Diagnostics
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
E0: No Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
E1: Low Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
E2: Sound Speed Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
E3: Velocity Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
E4: Signal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
E5: Amplitude Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
E6: Cycle Skip, Accel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
E7: Analog Out Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
E30: Channel Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
E31: Invalid Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Displaying Diagnostic Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Fluid and Pipe Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Fluid Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Pipe Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Maintaining the ISXDR Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Transducer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Clamp-on Transducer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
July 2006
Chapter 7: Specifications
General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Measurement Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Flow Accuracy
(% of Reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Rangeability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Fluid Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Electrical Classification/Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Input/Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Transducer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Clamp-on Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Pipe Size and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Clamp-on Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
vii
July 2006
Table of Contents (cont.)
Appendix A: Menu Maps
Appendix B: CE Mark Compliance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
EMC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C: Data Records
Site Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D: Service Record
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Diagnostic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
viii
Chapter 1
Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ISXDR Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Mounting the ISX878 Electronics Enclosure. . . . . . . . . . . . . . . . . . . . . . . . 1-4
Making the Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installing the Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
July 2006
Introduction T o ensure safe and reliable operation of th e Model ISX878 Ultrasonic
Flowmeter, the system must be installed and programmed in
accordance with the guidelines established by GE Sensing’s
engineers. Those guidelines, explained in detail in this chapter,
include the following topics:
• Unpacking the Model ISX878 system
• Selecting suitable sites for the electronics enclosure and the
transducers
• Installing the transducers
• Installing the electronics enclosure
• Wiring the electronics enclosure
!WARNING!
Be sure to follow all applicable local safety codes and
regulations for installing electrical equipment. Consult
company safety personnel or local safety authorities to
verify the safety of any procedure or practice.
!ATTENTION EUROPEAN CUSTOMERS!
To meet CE Mark requirements, all cables
must be installed as described in
Appendix B, CE Mark Compliance.
ISXDR Transducers The ISXDR ultrasonic flow transducers are used exclusively with the
ISX878 ultrasonic flowmeter. These transducers measure the flow
rate of sonically-conductive liquids through pipes having diameters
between 1/2 in. (1.27 cm) and 16 in. (40.64 cm). Such measurements
are typically independent of the pipe material. The transducers
o
operate in process temperatures from -40 to 194
Each transducer assembly consists of the following components (see
Figure 1-1 on the next page):
F (-40 to 90oC)*.
• a stainless steel adapter with 3/4” NPT male thread for
attaching a junction box
• a transducer that consists of a piezoelectric element mounted on
a wedge and wired to the connector
• a connector for use in connecting the transducer to the
flowmeter.
*This temperature is for ATEX certified designs. Consult factory for
higher temperatures.
Installation 1-1
July 2006
ISXDR Transducers
(cont.)
Transducer Body
Figure 1-1: ISXDR Transducer Components
Connector
Adapter
Unpacking Carefully remove the electronics enclosure and the transducer/cable
assembly 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.
Site Considerations Because the relative location of the transducers and the electronics
enclosure is important, use the guidelines in this section to plan the
ISX878 installation.
Electronics Enclosure Location
The standard ISX878 electronics enclosure is epoxy-coated
aluminum rated for weatherproof NEMA T ype 4X, IP67 applications.
Typically, the enclosure is mounted as close as possible to the
transducers. When choosing a site, make sure the location permits
easy access to the electronics enclosure for programming,
maintenance and service.
Transducer Location Caution!
The Model ISX878’s accuracy and performance depends
primarily on the location, spacing and alignment of the
transducers. The transducer spacing is unique to your
installation.
In addition to accessibility, when planning for transducer location,
adhere to the following procedure:
1. Locate the transducer measurement point at least 3 ft (1 m) or
more from any butt welds or flanges, ideally in the center of a
20 ft (6 m) length of straight run of pipe. Keep appropriate
clearance on either side of the pipe for easy transducer installation:
• 6 in. (15 cm) if you are not using a junction box, or
• 9 in. (22.5 cm) if you are using a junction box.
1-2 Installation
July 2006
Transducer Location
(cont.)
Note: To guarantee the specified accuracy of the flowmeter there is
no substitute for a straight run pipe and fully-developed flow
profile. However, if straight run is not available, the
transducer location should be in a position such that the
acoustic signal travels through the full distribution of the
under-developed flow profile for best repeatability.
2. Place the transducers as close as possible to the horizontal plane.
(see Figure 1-2 below). Locate the transducers on opposite sides
o
of the pipe 180
apart, ideally at the 3 and 9 o’clock positions. Do
not place transducers on the top or bottom of the pipe.
Note: For best profile identification in limited straight run, place
transducers at 1 and 7 o’clock.
Pipe
Transducer
Signal Path
End View
Figure 1-2: Transducer Placement
Cable Lengths Locate the electronics enclosure as close as possible to the
transducers. GE Sensing can supply ISX878 transducer cables in
fixed lengths up to 100 ft (30 m) in length for remote location of the
electronics enclosure.
Transducer Cables When installing the transducer cables, always observe established
standard practices for the installation of electrical cables. 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. Do not run the transducer cables along a pipe with a
surface temperature over 75°C (167°F) for models ISXDR-407 and
ISXDR-408.
IMPORTANT: Use only the cables and transducers that have been
supplied with the ISX878.
Installation 1-3
July 2006
Mounting the ISX878 Electronics Enclosure
Making the Electrical Connections
The standard Model ISX878 electronics package is housed in a
epoxy-coated aluminum weatherproof NEMA4X, IP67 enclosure
suitable for indoor or outdoor use. Figure 1-27 on page 1-29 shows
the outline and installation drawing. Refer to Chapter 7,
Specifications, for the mounting dimensions and the weight of this
enclosure.
This section contains instructions for making all the necessary
electrical connections to the Model ISX878 flow transmitter . Refer to
Figure 1-31 on page 1-33 for a complete wiring diagram.
!ATTENTION EUROPEAN CUSTOMERS!
To meet CE Mark requirements, all cables
must be installed as described in
Appendix B, CE Mark Compliance.
!WARNING!
Always disconnect the input power from the Model ISX878
before removing the front cover.
Preparing the Unit Before
Making Electrical
Prepare the unit as described below before making any electrical
connections.
Connections
1. Disconnect any previously wired power line from the unit.
2. Remove the screws on the front cover.
3. Install any required cable clamps on the appropriate conduit holes
on the bottom of the enclosure.
Proceed to the next section to make the desired wiring connections.
Intrinsic Safety The ISX878 flowmeter is listed as “Intrinsically Safe” for hazardous
locations. “Intrinsically Safe” means that the circuits within this
flowmeter are designed to be incapable of producing a spark or
thermal effect that could ignite a mixture of flammable or
combustible gases when properly installed in a hazardous location.
However, it does not mean that the ISX878 is “Explosion-Proof.” If
proper safety precautions are not followed, or if the equipment is not
installed properly, there is a serious potential for possible explosion.
Be sure to review all safety precaution, installation, and wiring
directions throughout this manual prior to installing the ISX878
flowmeter. The ISX878 provides intrinsically safe outputs to the
transducers, allowing the transducers to be located in a hazardous
(Classified) location. The ISX878 electronics can be mounted in a
hazardous (classified) location when appropriate safety barriers are
used. See “Safety Barriers” on the next page.
1-4 Installation
July 2006
Intrinsically Safe Installation Requirements
Where possible, mount the associated apparatus in a non-hazardous
location as near as possible to the hazardous location. This will
minimize the length of intrinsically safe conductors within the nonhazardous location, thus decreasing the possibility of inadvertent
connection of non-intrinsically safe energy to the protected circuit.
!WARNING!
Intrinsically safe wiring must be separated from non-
intrinsically safe wiring to prevent the transfer of unsafe
levels of energy to the hazardous area. Consult local codes
and authorities having jurisdiction over the area.
Safety Barriers The Model ISX878 requires the use of a safety barrier(s). Refer to
Table 1-1 below for the required safety barrier specifications for use
with the Model ISX878.
Note: Safety barriers must be installed in accordance with the
barrier manufacturer’s specifications.
Table 1-1: Safety Barrier Specifications
Loop Power
Totalizer
Output
Alarm Switch
Output
MTL-7706 or
equivalent
Umax 28 VDC 28 VDC 10 VDC
Imax 93 mA 93 mA 19 mA
Rmax 300 ohm 300 ohm
Pmax 0.6 5 W 0.65 W 0.19 W
MTL-7787 or
equivalent
MTL-7741 or
equivalent
Installation 1-5
July 2006
Wiring the Input Power Note: If the input voltage needs to be adjusted, select “Voltage
Adjust” from the Service Menu and press [ENT]. Then adjust
the input voltage and press [ESC]. This procedure allows the
meter to correctly read the input voltage to adjust the power
management algorithm.
Refer to Figure 1-31 on page 1-33 to locate the power terminal block
and connect the input power as follows:
1. Follow the instructions on page 1-4 to prepare the unit before you
connect power.
!ATTENTION EUROPEAN CUSTOMERS!
To meet CE Mark requirements, all cables
must be installed as described in
Appendix B, CE Mark Compliance.
2. Connect the ISX878 case to the earth ground with a grounding
cable to the external ground screw found on either side of the
enclosure.
3. Strip 1/4-in. of insulation from the end of each of the two input
power leads.
4. Route the shielded cable through the conduit hole and connect the
power leads to the power terminal block as shown in Figure 1-31
on page 1-33. Tie the shield drain wire to the ground bus bar inside
the ISX878, but leave the shield wire open on the power supply
end (to avoid AC ground loops and for CE certification).
5. Leaving a small amount of slack, secure the power line with the
cable clamp.
6. Connect the two power leads to the safety barrier, as shown in
Figure 1-3 on the next page. Barriers must be installed in
accordance with the barrier manufacturer’s specifications.
1-6 Installation
Wiring the Input Power
(cont.)
Hazardous
Location
July 2006
Non-Hazardous Location
(Safe Area)
Determining the Number of Traverses
(+)
(-)
I.S. Ground
ISX878
1(+)
TB3
2(-)
Approved
Safety
Barrier
(See Note)
Figure 1-3: Power Lead Connection to Safety Barrier
7. If you are installing the ISX878 for the first time, refer to Chapter
2, Programming Site Data, and program the sections from page 24 to 2-14 (the Status, Transducer , Pip e, Fluid and Path options) to
determine the appropriate transducer spacing to position the
transducers (see page 1-9).
The next step in installation is to determine the number of traverses.
The transducers can be mounted using one of two methods (shown in
Figure 1-4 on the next page:
• Double-traverse method (“V” method) - transducers are mounted
on the same side of the pipe and the ultrasonic signal is bounced
from one transducer to the other, off the opposite pipe wall.
• Single-traverse method (“Z” method) - transducers are mounted
diagonally across from each other. The ultrasonic signal is
transmitted directly from one transducer to the other, across the
pipe.
You should always try the double-traverse method first, since it easier
to install and yields greater accuracy. Otherwise, the single-traverse
method is best for pipes with the following:
• poor inside surface conditions
• highly attenuating fluid
Note: You may want to try both configurations to see which yields
more accurate results.
Installation 1-7
July 2006
Determining the Number
of Traverses (cont.)
Double Traverse (“V” Method)
Transducers
Ultrasonic Signal Path
Single Traverse (“Z” Method)
Transducer
Transducer
Figure 1-4: Double- and Single-Traverse Installations
TOP VIEW
TOP VIEW
1-8 Installation
July 2006
Installing the Transducers
Small Pipe Transducer Installation
The transducers that have been specially designed for use with the
ISX878 are available in four models: 4 MHz for 1/2 to 2 in. pipes; 2
MHz for 1/2 to 8 in.; 1 MHz for 2 to 16 in.; and 500 kHz for 6 to 16
in. They typically support 2-traverse applications. Two styles of
transducer are available; one style, intended for smaller pipes,
integrates the cable and clamping fixture, while the other style
accommodates larger pipes. The preattached cables come in lengths
from 6 to 25 ft. (Longer lengths are available by special order. Please
consult the factory.) Figure 1-5 below shows a typical ISX878
transducer, while the outline and installation drawing for the
clamping fixture appears in Figure 1-30 on page 1-32.
Adjustment
Screws
Setting Transducer
Spacing
Figure 1-5: ISX878 Transducer/Cable Assembly
Note: If the calculated spacing exceeds the minimum allowed by the
transducers, set the transducers to minimum spacing, and
override the calculated value to the values measured on the
transducers
If you have not already obtained the transducer spacing, you must
program the Status, Transducer, Pipe, Fluid and Path options of the
Program menu (pages 2-4 to 2-14) to calculate the appropriate
setting. To set the desired transducer spacing:
1. Loosen the red screws on the adjustable transducer (shown in
Figure 1-5 above).
2. Slide the adjustable transducer on the rails until you have
positioned it at the desired spacing. Use the ruler on the rails and
the white tick mark on the transducer housing to assist in setting
the correct spacing.
3. Tighten the red screws to secure the transducer to the rails.
Installation 1-9
July 2006
Setting Transducer
Spacing (cont.)
Installing the Transducers
on the Pipe
Note: If your application requires one or three traverses, you can
remove the adjustable transducer fr om the rails and use it as a
separate transducer at a 180° angle from the stationary
transducer, as shown in Figure 1-6 below.
Figure 1-6: Positioning for 1 or 3-Traverse Applications
Note: Some pipe preparation may be required before securing the
transducers to the pipe. Remove any paint or coating from the
surface in contact with the transducers. A flat, smooth surface
is ideal.
1. Apply the supplied couplant to the transducer faces, as shown in
Figure 1-7 below.
Figure 1-7: The Transducer Faces
2. Put the transducer fixture at the desired location on the pipe.
Secure it with the supplied stainless steel clamps. Figure 1-8 on
the next page illustrates a typical installation.
Note: Installation on the sides (at 3 and 9 o’clock) of the pipe is
ideal. The top of the pipe might contain bubbles, while the
bottom might contain sediment.
1-10 Installation
Installing the Transducers
on the Pipe
July 2006
Figure 1-8: A Typical Transducer Installation
Once on the pipe, an internal spring mechanism ensures proper
mechanical pressure by “pressing” the transducer face against the
pipe surface. Refer to the next page to wire the transducer cables to
the ISX878.
Large Pipe Fixture and Transducer Installation
The CF-ES clamping fixture acts as a permanent transducer holder.
The fixture has two blocks that are used for double- and singletraverse methods. Steel straps secure the blocks to the pipe for a
permanent installation.
The blocks are positioned properly using the spacing dimension
calculated by the flowmeter. Then the transducers are mounted into
the blocks. Figure 1-9 below shows a long block.
The transducer installation consists of mounting the CF-ES to the
pipe and then mounting the transducers into the blocks. Refer to the
appropriate section that follows for instructions:
• Double-traverse Method - see the next page
• Single-traverse Method - see page 1-16.
End View
Side View
Figure 1-9: CF-ES Clamping Fixture Block
Installation 1-11
July 2006
The Double-Traverse
Method - CF-ES
Note: The instructions in this section can also be used for a
multiple-traverse method. However, you must use an EVEN
number of traverses. The distance the signal travels from one
side of the pipe wall to the opposite side of the pipe wall is
considered one traverse. For more than two traverses, consult
the factory.
There are three advantages in using the double-traverse method:
• Accuracy is improved because the signal is in the fluid longer than
with a single-traverse.
• This configuration can reduce some effects of an underdeveloped
flow profile.
• If there is enough pipe length available, the double-traverse fixture
is easier to install.
The procedure for mounting the CF-ES involves marking the pipe for
the desired spacing, fastening the clamping fixture on the pipe and
then mounting the transducers into the fixture.
Procedure:
You will need a level and a marker or scribe to locate and mark the
transducer locations on the pipe.
1. Obtain the transducer spacing dimension S.
2. Be sure the location you have chosen for the installation has at
least 10 pipe diameters of straight, undisturbed flow upstream and
5 pipe diameters downstream of the measurement point.
3. Prepare the pipe where you intend to place the clamping fixture by
making sure it is clean and free of loose material. Sanding, though
usually not required, may be necessary to take off any high spots.
Be careful to preserve the original curvature of the pipe.
4. Find the top of the pipe and use a level to draw a line parallel to
the pipe’s axis, as shown in Figure 1-10 below.
Line
Top of Pipe
Side View
Figure 1-10: Line Parallel to Pipe Axis
1-12 Installation
July 2006
The Double-Traverse
Method - CF-ES (cont.)
5. Make two marks (shown in Figure 1- 1 1 below) on the line equal to
the transducer spacing distance S, as calculated by the meter.
Spacing
Mark
Mark
Side View
Figure 1-11: Marks for Transducer Spacing on Inscribed Line
6. From each of the m a rks , m e as u r e a round the circumference of the
pipe in the same direction a distance equal to one quarter the
pipe’s circumference, as shown in Figure 1-12 below. Make a
crossmark with a marker or scribe.
Figure 1-12: Measuring a Quarter-Circumference
Installation 1-13
July 2006
The Double-Traverse
Method - CF-ES (cont.)
7. Center one of the blocks over one of the crossmarks on the pipe.
Align the block so that the pressure bolt is over the center of the
mark. Secure the block by wrapping the two straps around the
block and pipe and tightening them. Make sure the turnbuckles are
at least 1/2 pipe diameter away from the block, as shown in Figure
1-13 below.
Turnbuckles
Top View
Figure 1-13: Positioning Turnbuckles 1/2 Pipe Diameter
from Block
8. Repeat Step 7 to install the other block over the other crossmark
(Figure 1-14 below).
Note: Make sure both straps are perpendicular to the bottom of the
block. If the straps are slanted, the slack will cause the block
to slide. The slack may also change the transducer spacing
after the transducers are mounted.
Figure 1-14: Positioning Both Blocks
Figure 1-15 on the next page shows a double-traverse installation
without transducers. Proceed to Mounting Transducers into the CF-
on page 1-20.
ES
1-14 Installation
The Double-Traverse
Method - CF-ES (cont.)
July 2006
Top View
End View
Figure 1-15: A Double-Traverse CF-ES Installation without
Transducers
Installation 1-15
July 2006
The Single-Traverse
Method - CF-ES
Note: The instructions in this section can also be used for a
multiple-traverse method. However, you must use an ODD
number of traverses. The distance the signal travels from one
side of the pipe wall to the opposite side of the pipe wall is
considered one traverse.
The procedure for mounting the CF-ES involves marking the pipe for
the desired spacing, fastening the fixture to the pipe and then
mounting the transducers into the fixture.
Procedure:
You will need a level and marker or scribe to locate the transducers on
the pipe.
1. Obtain the transducer spacing dimension S, as described on pages
2-4 to 2-14.
2. Be sure the location you have chosen for the installation has at
least 10 pipe diameters of straight, undisturbed flow upstream and
5 pipe diameters downstream of the measurement point.
3. Prepare the pipe where you intend to place the CF-ES by making
sure it is clean and free of loose material. Sanding, though usually
not required, may be necessary to take off any high spots. Be
careful to preserve the original curvature of the pipe and not to
eradicate the marks on the pipe.
4. Find the top of the pipe and use a level to draw a line parallel to
the pipe’s axis, as shown in Figure 1-16 below.
Line
Top of Pipe
Side View
Figure 1-16: Drawing Line Parallel to Pipe Axis
1-16 Installation
July 2006
The Single-Traverse
Method - CF-ES (cont.)
5. Make two marks (shown in Figure 1-17 below) on the line equal to
the transducer spacing distance S, as calculated by the meter.
Spacing
Mark
Mark
Side View
Figure 1-17: Marking Transducer Spacing
6. From one of the marks, measure around the circumference of the
pipe a distance equal to one quarter the pipe’s circumference, as
shown in Figure 1-18 below. Make a crossmark with a marker or
scribe.
Figure 1-18: Measuring a Quarter of the Pipe’s Circumference
7. From the other mark, go in the opposite direction around the pipe
for one quarter the circumference and make another crossmark, as
shown in Figure 1-19 below.
Figure 1-19: Measuring the Second Quarter Circumference
Installation 1-17
July 2006
The Single-Traverse
Method — CF-ES (cont.)
8. Center one of the blocks over one of the crossmarks on the pipe.
Align the block so that the pressure bolt is over the center of the
crossmark. Secure the block by wrapping two straps around the
block and pipe and tightening them. Make sure the turnbuckles are
at least 1/2 pipe diameter away from the block, as shown in Figure
1-20 below.
Turnbuckles
Top View
Figure 1-20: Positioning Turnbuckles
9. Repeat Step 8 to install the other block over the other punch mark.
Note: Make sure both straps are perpendicular to the bottom of the
block (Figure 1-21 below). If the straps are slanted, the slack
will cause the block to slide. The slack may also change the
transducer spacing after the transducers are mounted.
Figure 1-21: Correct Strap Positioning
1-18 Installation
July 2006
The Single-Traverse
Method -CF-ES (cont.)
Figure 1-22 below shows a single-traverse installation without
transducers. Proceed to Mounting Transducers into the CF-ES
next page.
Top View
on the
End View
Figure 1-22: A Single-Traverse CF-ES Installation without
Transducers
Installation 1-19
July 2006
Mounting Transducers into the CF-ES
The last step of installation is mounting the transducers into the
clamping fixture.
IMPORTANT: To maintain ATEX certification, the transducer face
must be protected again st impact. This is provided by
properly installing the transducer into the clamping
fixture. All care must be taken during installation to
ensure all protection is afforded.
Procedure for Mounting Transducers
To mount the transducers into the CF-ES, use the following steps:
1. Apply a thread sealant to the transducer threads. A sealant is not
required within the US; however, a sealant must be used in the
European Community .
2. Before mounting the transducers, thread the junction box onto the
end of the transducer with the connector, as shown in Figure 1-23
below. Ensure that at least five full threads are engaged. Make sure
to orient the cover of the junction box so it is accessible to make
cable connections once the box is installed.
Figure 1-23: Threading the Junction Box
3. Take one of the transducers and apply a thin bead of couplant
down the center of its face approximately the size of a toothpaste
bead (Figure 1-24 below).
IMPORTANT: To prevent the loss of couplant, do not slide the
transducer with couplant along the surface of the
pipe when mounting.
Figure 1-24: Applying Couplant to Transducer
1-20 Installation
July 2006
Mounting Transducers
into the CF-ES (cont.)
4. Place the transducers in the appropriate blocks. Make sure the
transducers are oriented as shown in Figure 1-25 below.
Note: If the transducer cables are already connected, you must
determine the upstream and downstr eam directions of the pipe
and place the transducers into the appropriate blocks.
Locking Nut
Top View
Figure 1-25: Transducer Orientation
5. Use the pressure bolt to secure the transducer in place. The
pressure bolt should fit into the dimple. Hand-tighten enough to
hold the transducer in place. Do not overtighten so that the
fixture lifts off the pipe.
6. Tighten the locking nut on the pressure bolt (see above).
IMPORTANT: When using the CF-ES in a pipe location with
possible mechanical vibration, the locking nut must
be used to secure the position of the pressure bolt on
the transducer after the bolt has been hand-tightened
into the transducer dimple. For additional resistance
to vibration a thread lock compound or a stainless
steel washer and lock washer may also be used.
These items can be ordered from GE by requesting a
“special” clamping fixture and specifying either the
thread lock or the washers.
7. Repeat Steps 1 to 6 to mount the other transducer in the
remaining block. See Figure 1-26 on the next page for completed
installations.
Installation 1-21
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