GE Sensing XGS868i User Manual

Oil & Gas Flow

DigitalFlow™ XGS868i

Startup Guide

910-196U Rev. H

May 2017

Oil & Gas

DigitalFlow™ XGS868i

Panametrics Steam Ultrasonic Flow Transmitter

Startup Guide

910-196U Rev. H May 2017

www.gemeasurement.com

Technical content subject to change without notice.

[no content intended for this page]

Preface

Product Registration

Thank you for purchasing a model DigitalFlow™ XGS868i from GE. Please register your product at

www.gemeasurement.com/productregistration

product information and special promotions.

for product support such as the latest software/firmware upgrades,

Services

GE provides customers with an experienced staff of customer support personnel ready to respond to technical inquiries, as well as other remote and on-site support needs. To complement our broad portfolio of industry-leading solutions, we offer several types of flexible and scalable support services including: Training, Product Repairs, Service Agreements and more. Please visit www.gemeasurement.com/services

for more details.

Terms and Conditions

GE’s sales Terms and Conditions for your recent purchase of a GE product, including the applicable product Warranty, can be found on our website at the following link: www.gemeasurement.com/sales-terms-and-conditions

Typographical Conventions

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 that emphasizes instructions that are essential to proper setup of

the equipment. Failure to follow these instructions carefully may cause unreliable performance.

CAUTION! This symbol indicates a risk of potential minor personal injury and/or severe damage to the equipment, unless these instructions are followed carefully.

WARNING! This symbol indicates a risk of potential serious personal injury, unless these instructions are followed 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.

Attention European Customers! To meet CE Marking requirements for all units intended for use in the EU, all electrical cables must be installed as described in this manual.

DigitalFlow™ XGS868i Startup Guide iii

Preface

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 this equipment.

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.

iv DigitalFlow™ XGS868i Startup Guide

Environmental Compliance

RoHS

The DigitalFlow™ XGS868i fully complies with RoHS regulations (Directive 2011/65/EU).

Waste Electrical and Electronic Equipment (WEEE) Directive

GE 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.

Preface

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.

Please visit http://www.gemeasurement.com/environmental-health-safety-ehs information about this initiative.

for take-back instructions and more

DigitalFlow™ XGS868i Startup Guide v

Preface

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vi DigitalFlow™ XGS868i Startup Guide

Contents

Product Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Terms and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Auxiliary Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Environmental Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Chapter 1. Installation

1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.3 Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.3.1 Electronics Enclosure Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3.2 Flowcell Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.3.3 Transducer Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.3.4 Cable Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.3.5 Temperature and Pressure Transmitters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.6 Transducer Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.4 Installing a Flowcell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5 Installing Temperature and Pressure Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.6 Mounting the XGS868i Electronics Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.7 Making the Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.7.1 Wiring the Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.7.2 Wiring the Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.7.3 Wiring Std 0/4-20 mA Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.7.4 Wiring the Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.7.5 Wiring the Option Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Chapter 2. Initial Setup

2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

2.2 Programming Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

2.3 The XGS868i Enclosure Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

2.4 Entering Data in the Global Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

2.4.1 Entering Global System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

2.5 Activating a Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

2.6 Entering System Data for the Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

2.6.1 Accessing the Channelx-System Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

2.7 Entering Transducer and Pipe Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

2.7.1 Special Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

2.7.2 Pipe Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

DigitalFlow™ XGS868i Startup Guide vii

Contents

Chapter 3. Operation

3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

3.2 Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.2.1 The LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.3 The Optional PanaView Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4 Taking Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

3.4.1 Programming the LCD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

3.4.2 Using the LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

3.4.3 The PanaView Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

3.4.4 Pausing Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Chapter 4. Specifications

4.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4.1.1 Hardware Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4.1.2 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4.1.3 Velocity Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4.1.1 Velocity Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.1.2 Rangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.1.3 Repeatability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.2 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.2.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.2.2 Power Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.2.3 Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.2.4 European Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.2.1 Input/Output Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

4.2.2 Preamplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

4.3 Flow Transducer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.3.1 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.3.2 Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.3.3 Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.3.4 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.3.5 Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.4 Flowcell Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

4.4.1 Spoolpiece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

4.4.2 Cold Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

4.4.3 Pipe Size & Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Appendix A. CE Mark Compliance

A.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

A.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

viii DigitalFlow™ XGS868i Startup Guide

Contents

Appendix B. Data Records

B.1 Available Option Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

B.2 Option Cards Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

B.3 Setup Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Appendix C. Measuring P and L Dimensions

C.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

C.2 Measuring P and L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

DigitalFlow™ XGS868i Startup Guide ix

Contents

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x DigitalFlow™ XGS868i Startup Guide

Chapter 1. Installation

1.1 Introduction

To ensure safe and reliable operation of the Model XGS868i Ultrasonic Flow Transmitter, the system must be installed in accordance with the guidelines established by GE engineers. Those guidelines, which are explained in detail in this chapter, include the following topics:

• “Unpacking” on page 1

• “Site Considerations” on page 2

• “Installing a Flowcell” on page 4

• “Installing Temperature and Pressure Transmitters” on page 4

• “Mounting the XGS868i Electronics Enclosure” on page 5

• “Making the Electrical Connections” on page 5

WARNING! The Model XGS868i flow transmitter can measure the flow rate of many gases, some of which are potentially hazardous. In such cases, the importance of proper safety practices cannot be overemphasized.

WARNING! 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! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance.

1.2 Unpacking

Carefully remove the electronics enclosure, 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.

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Chapter 1. Installation

1.3 Site Considerations

Because the relative location of the flowcell and the electronics enclosure is important, use the guidelines in this section to plan the XGS868i installation. Figure 1 below shows a typical XGS868i flowcell ready for insertion into a process line.

Figure 1: A Typical Model XGS868i System

1.3.1 Electronics Enclosure Location

The standard Model XGS868i electronics enclosure is a powder-coated, cast-aluminum, Type-7/4X explosion-proof enclosure. An optional stainless-steel enclosure is available. 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.

Attention European Customers! 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 unit.

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1.3.2 Flowcell Location

The pipeline flowcell consists of the flow rate transducers and any pressure and/or temperature transducers employed as part of the flow measurement system. Ideally, choose a section of pipe with unlimited access to the flowcell. For example, a long stretch of pipe that is above ground. However, if the flowcell is to be mounted on an underground pipe, dig a pit around the pipe to facilitate installation of the transducers.

1.3.3 Transducer Location

For a given fluid and pipe, the Model XGS868i’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, 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, when 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 dead center. This will minimize the influence of any sediment on the reflected ultrasonic signals.

1.3.4 Cable Lengths

Locate the electronics enclosure as close as possible to the flowcell/transducers, preferably directly on the flowcell. However, the factory can supply transducer cables up to 1,000 ft (300 m) in length for remote location of the electronics enclosure. If longer cables are required, consult the factory for assistance.

1.3.5 Temperature and Pressure Transmitters

When installing temperature and/or pressure transmitters in the flowcell, locate them downstream of the transducers. These transmitters should be positioned no closer to the Model XGS868i transducers than 2 pipe diameters and no further away from the transducers than 20 pipe diameters.

1.3.6 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 flow transducers to the Model XGS868i electronics enclosure, 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 to within ±4 in. (10 cm).

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Chapter 1. Installation

Temperature Transmitter

RTD

Thermowell

Coupling

Pressure Transmitter

Isolation Valve

Flowcell Wall

1.4 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 2 shows a typical Model XGS868i spoolpiece, with a mounting bracket to hold the electronics enclosure. For detailed instructions on installing the transducers and/or spoolpiece, refer to the supplied drawings and the appropriate GE Transducer Installation Guide.

1.5 Installing Temperature and Pressure Transmitters

Optional temperature and pressure transmitters may be installed near the ultrasonic transducer ports as part of the flowcell. Be sure to observe the siting requirements given earlier in this chapter. These transmitters should send a 0/4-20 mA signal to the Model XGS868i. In turn, the Model XGS868i must be fitted with a suitable option card to process the signals and to provide the required 24 VDC power to the transmitters. Any desired transmitters or sensors may be used, but they must have an accuracy equal to 0.5% of the flow rate 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.

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

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1.6 Mounting the XGS868i Electronics Enclosure

The standard Model XGS868i electronics package is housed in a Type-4X weather-resistant enclosure suitable for indoor or outdoor use. Refer to Figure 8 on page 21 for the mounting dimensions and the weight of this enclosure.

The Model XGS868i electronics enclosure is fitted with a mounting boss that has a single 3/4” NPTF threaded hole at its center and four 1/4-20 tapped holes at its corners. By using this mounting boss, the electronics enclosure may be mounted by any of the typical methods shown in Figure 9 on page 22.

WARNING! Proper grounding of the XGS868i chassis is required to prevent the possibility of electric shock. See Figure 9 on page 22 for the location of the chassis grounding screw.

WARNING! Always disconnect the line power from the Model XGS868i before removing either the front cover or the rear cover. This is especially important in a hazardous environment.

1.7 Making the Electrical Connections

This section contains instructions for making all the necessary electrical connections to the Model XGS868i flow transmitter. Refer to Figure 10 on page 23 for a complete wiring diagram.

Except for the power connector, all electrical connectors are stored on their terminal blocks during shipment and may be removed from the enclosure for more convenient wiring. Simply, feed the cables through the conduit holes on the side of the enclosure, attach the wires to the appropriate connectors and plug the connectors back onto their terminal blocks.

Attention European Customers! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance.

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Chapter 1. Installation

Power ConnectionsOption Card Connections

Wiring Label

Slots

Set Screw

Inside View

Outside View

1.7 Making the Electrical Connections (cont.)

Refer to Figure 3 on page 6 and prepare the Model XGS868i for wiring by completing the following steps:

1. Disconnect any existing power line from its source.

2. Loosen the set screw on the rear cover.

3. Place a rod or long screwdriver across the cover in the slots provided, and rotate the cover counterclockwise

until it comes free from the enclosure.

4. Install any required cable clamps in the appropriate conduit holes around the side of the enclosure.

5. Note the labels inside the rear cover to assist in wiring the power and option card connections. Also, Figure 11

on page 24 shows the rear cover option card labels for every available option card configuration.

Proceed to the appropriate section of this chapter to make the desired wiring connections.

Figure 3: Rear Cover with Connection Labels

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1.7.1 Wiring the Line Power

The Model XGS868i may be ordered for operation with power inputs of 100-120 VAC, 220-240 VAC, or 12-28 VDC. The label on the side of the electronics enclosure lists the meter’s required line voltage and power rating. The fuse size is listed in Chapter 4, Specifications. Be sure to connect the meter only to the specified line voltage.

1.8 m (6 ft) of the unit.

WARNING! Only use Class 2 Rated Power supply for line power connection to a DC instrument.

Refer to Figure 10 on page 23 to locate terminal block TB5 and connect the line power as follows:

WARNING! Improper connection of the line power leads or connecting the meter to the incorrect

line voltage may damage the unit. It may also result in hazardous voltages at the flowcell and associated piping as well as within the electronics enclosure.

Attention European Customers! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance.

1. Prepare the line power leads by trimming the line and neutral AC power leads (or the positive and negative DC power leads) to a length 0.5 in. (1 cm) shorter than the ground lead. This ensures that the ground lead is the last to detach if the power cable is forcibly disconnected from the meter.

2. Install a suitable cable clamp in the conduit hole indicated in Figure 10 on page 23. If possible, avoid using the other conduit holes for this purpose to minimize any interference in the circuitry from the AC power line.

3. Strip 1/4 in. of insulation from the end of each of the three power line leads.

4. Route the cable through the conduit hole and connect the line power leads to terminal block TB5, using the pin

number assignments shown in Figure 10 on page 23.

5. Leaving a bit of slack, secure the power line with the cable clamp.

WARNING! Make sure both covers, with their o-ring seals, are installed and the set screws tightened before applying power in a hazardous environment.

CAUTION! The transducers must be properly wired, as described in the next section, before applying power to the meter.

Proceed to the next section to continue the initial wiring of the Model XGS868i flow transmitter.

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Chapter 1. Installation

1.7.2 Wiring the Transducers

Before wiring the XGS868i transducers, complete the following steps:

• Disconnect the main power from the electronics enclosure.

• Remove the rear cover and install all required cable clamps.

Based on the location of the electronics enclosure, proceed to the appropriate sub-section for detailed instructions.

Attention European Customers! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance.

1.7.2a Flowcell-Mounted Enclosure

For an electronics enclosure mounted directly on the flowcell, wire the transducers as follows:

WARNING! Before connecting the transducers, take them to a safe area and discharge any static buildup by shorting the center conductor of the transducer cables to the metal shield on the cable connector.

IMPORTANT: For transducer frequencies below 2 MHz, the cable lengths for a pair of transducers must be within

4 in. (10 cm) of each other. If the transducer frequency exceeds 2 MHz, the cable lengths must be within

0.5 in. (1.25 cm) of each other.

1. Locate the CH1 transducer cables and connect them to the two CH1 transducers in the flowcell. Feed the free

ends of the cables through the selected conduit hole in the electronics enclosure.

2. Refer to the wiring diagram in Figure 10 on page 23 and connect the transducer cables to terminal block Then, secure the cable clamp.

IMPORTANT: The RED cable leads are the SIG(+) leads and the BLACK cable leads are the RTN(-) leads.

3. For a 2-Channel XGS868i, repeat steps 1 and 2 to connect the CH2 transducers to terminal block

Note: It is not

4. If wiring of the unit has been completed, reinstall the rear cover on the enclosure and tighten the set screw.

Note: A channel must be activated before it can begin taking measurements. See Chapter 2, Initial Setup, for

instructions.

required that both channels of a 2-Channel unit be connected.

J4.

J3.

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1.7.2b Remote-Mounted Enclosure

For a remote mounted enclosure, refer to the wiring diagram in Figure 10 on page 23 and the remote transducer wiring in Figure 12 on page 25, and complete the following steps:

1. Using the pair of coaxial cables with BNC to BNC connectors supplied by the factory (or equivalent cables),

connect both

CAUTION! As part of maintaining the FM/CSA environmental rating (TYPE 4) on the remote preamplifier, thread sealant is required on all conduit entries.

2. If an optional lightning protector is being installed, connect it to the preamplifier as shown.

3. Using the supplied coaxial cables with BNC to flying lead connectors (or equivalent cables), route the cables

through one of the conduit holes in the electronics enclosure and connect the preamplifier to terminal block J3. Secure the cable clamp.

CH1 transducers to the preamplifier.

IMPORTANT: The RED cable leads are the SIG(+) leads and the BLACK cable leads are the RTN(-) leads.

4. For a 2-Channel XGS868i, repeat steps 3-5 to connect the CH2 transducers to terminal block J4 in the

electronics enclosure. It is not

required that both channels of a 2-Channel unit be connected.

5. If wiring of the unit has been completed, reinstall the rear cover on the enclosure and tighten the set screw.

Note: A channel must be activated before it can begin taking measurements. See Chapter 2, Initial Setup, for

instructions.

Proceed to the next section to continue the initial wiring of the unit.

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Chapter 1. Installation

1.7.3 Wiring Std 0/4-20 mA Analog Outputs

The standard configuration of the Model XGS868i flow transmitter includes two isolated 0/4-20 mA analog outputs (designated as Outputs 1 and 2). Connections to these outputs may be made with standard twisted-pair wiring, but the current loop impedance for these circuits must not exceed 600 ohms.

Attention European Customers! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance.

To wire the analog outputs, complete the following steps:

1. Disconnect the main power and remove the rear cover.

2. Install the required cable clamp in the chosen conduit hole on the side of the electronics enclosure.

3. Refer to Figure 10 on page 23 for the location of terminal block J1 and wire the analog outputs as shown.

Secure the cable clamp.

IMPORTANT: Analog outputs 1 and 2 in the wiring diagram correspond to analog outputs A and B in Slot 0 in the

XGS868i software.

4. If wiring of the unit has been completed, reinstall the rear cover on the enclosure and tighten the set screw.

WARNING! Make sure both covers, with their o-ring seals, are installed and the set screws tightened before applying power in a hazardous environment.

Note: Prior to use, the analog outputs must be set up and calibrated. See Chapter 1, Calibration, of the Service

Manual for detailed instructions.

Proceed to the next section to continue the initial wiring of the unit.

1.7.4 Wiring the Serial Port

The Model XGS868i flow transmitter is equipped with an RS232 or an RS485 serial interface. An RS485 option is also available with MODBUS capability. When the MODBUS option is present, the XGS868i may also have the standard RS232 serial interface.

The serial port is used to transmit stored data and displayed readings to a personal computer by connecting the meter’s serial interface to the serial port of the PC. In addition, the Model XGS868i can receive and execute remote commands, using GE’s PanaView software via this link.

Note: For more information on serial communications refer to the GE EIA-RS Serial Communications manual

(916-054).

Attention European Customers! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance.

Proceed to the appropriate sub-section for wiring instructions.

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Chapter 1. Installation

1.7.4a Wiring the RS232 Interface

Use the serial port to connect the Model XGS868i flow transmitter to a printer, an ANSI terminal or a personal computer. The RS232 interface is wired as Data Terminal Equipment (DTE). Tab le 1 below lists the standard cables available from GE for this purpose.

Table 1: GE Serial Cables

Part Number PC Connector XGS868i Connector

704-659 DB-25 Male Flying Leads (5) 704-660 DB-9 Male Flying Leads (5) 704-661 DB-25 Female Flying Leads (5) 704-662 DB-9 Female Flying Leads (5)

Each of the cables listed inTa bl e 1 above is available in several standard lengths. A user-supplied cable may be used, if preferred. In either case, wire the XGS868i end of the serial cable using the pin designations listed in Tab le 2 below.

WARNING! Dangerous voltages exist within the electronics enclosure. Do not attempt to wire the unit until the main power has been disconnected.

WARNING! The XGS868i must be moved to a safe environment before removing either cover.

Refer to Figure 10 on page 23 to complete the following steps:

1. Disconnect the main power and remove the rear cover.

2. Install the required cable clamp in the chosen conduit hole on the side of the electronics enclosure.

3. Use the information in Tab le 2 below to construct a suitable cable for connecting the Model XGS868i to the

external device. If desired, an appropriate cable may be purchased from GE.

Table 2: RS232 Connection to DCE or DTE Device

Pin #

Signal

Description

DCE DB25

Pin #

DCE DB9

Pin #

DTE DB25

Pin #

DTE DB9

Pin #

5 DTR (Data Terminal Ready) 20 4 20 4 6CTS (Clear to Send)4758 7COM (Ground) 7575 8RX (Receive) 2332 9TX (Transmit) 3223

4. Feed the cable’s flying leads through the conduit hole and wire it to terminal block J1. Connect the other end of

the cable to the external serial device and secure the cable clamp.

After the wiring is complete, consult the external device’s User’s Manual to configure it for use with the XGS868i.

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1.7.4b Wiring the RS485 Interface

Use the optional RS485 serial port to network multiple XGS868i flow transmitters to a single control system. As an option, the standard RS232 port on the XGS868i may be configured as a two-wire, half-duplex RS485 interface.

IMPORTANT: The Model XGS868i must be configured at the factory for RS485 operation.

WARNING! Dangerous voltages exist within the electronics enclosure. Do not attempt to wire the

unit until the main power has been disconnected.

WARNING! The XGS868i must be moved to a safe environment before removing either cover.

To wire the RS485 serial port, refer to Figure 10 on page 23 and complete the following steps:

1. Disconnect the main power and remove the rear 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.

Use the information in Tab le 3 below to wire a suitable cable for connecting the XGS868i to the external device.

Table 3: RS485 Connections

J1 Pin # Signal Description

9 Data + 8Data – 7Shield 6Not Used 5Not Used 4Not Used

4. If wiring of the unit has been completed, reinstall the rear cover on the enclosure and tighten the set screw.

Proceed to the next section to continue the initial wiring of the unit.

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1.7.5 Wiring the Option Cards

The Model XGS868i can accommodate one option card in Slot 1 and one option card in Slot 2. The following option card functions are available only in the combinations listed in Table 14 on page 61:

• Alarm Relays (Slot 1)

• Analog Inputs (Slot 1)

• Totalizer/Frequency Outputs (Slot 1)

• RTD Inputs (Slot 1)

• Analog Outputs (Slot 1)

• MODBUS Communications (Slot 2)

• MODBUS/TCP Communications (Slot 2)

• Ethernet (Slot 2)

• Foundation Fieldbus (Slot 2)

• Data Logging (Slot 2) - no wiring required

Wiring any option card installed in Slot 1 proceed to the following sub-sections.

Attention European Customers! To meet CE Mark requirements, all cables must be installed as

described in Appendix A, CE Mark Compliance.

1.7.5a Preparing for Wiring

1. Disconnect the main power and remove the rear cover.

2. Install a cable clamp in the chosen conduit hole on the side of the electronics enclosure and feed a standard

twisted-pair cable through this conduit hole.

3. Locate the 12-pin terminal block (J2) in Figure 10 on page 23 and wire the option card as indicated on the

label inside the rear cover (see Figure 3 on page 6 and Figure 11 on page 24). Secure the cable clamp.

IMPORTANT: Because of the attached wiring label, all rear covers must

4. If wiring of the unit has been completed, reinstall the rear cover on the enclosure and tighten the set screw.

Note: Prior to use, the option card must be set up and calibrated. See Chapter 1, Programming Site Data, in the

Programming Manual and Chapter 1, Calibration, in the Service Manual for detailed instructions.

remain with their original meters.

For more specific instructions on particular option cards, proceed to the appropriate sections that follow.

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Chapter 1. Installation

NC NC

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,

1.7.5b Wiring an Alarms Option Card

Each alarms option card includes two or four general-purpose Form C relays (designated as A, B, C and D).

The maximum electrical ratings for the relays are listed in Chapter 4, Specifications. Each of the alarm relays can be wired as either 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 4 below for the operation of a NO alarm relay in both conventional and fail-safe mode.

Before making any connections, complete the steps in “Preparing for Wiring” on page 13. Connect each alarm relay in accordance with the wiring instructions shown on the label inside the rear cover (see Figure 3 on page 6 and Figure 11 on page 24).

Figure 4: Conventional and Fail-Safe Operation

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Chapter 1. Installation

+24V

INPUT +

+24V

+–

+ IN

– OUT

+ IN

– OUT

Sensor

Transmitter

Analog Input

24 VDC

POWER SUPPLY

With External Power Supply

With Internal Power Supply

1.7.5c Wiring a 0/4-20 mA Analog Inputs Option Card

To calculate the standard flow rates, the Model XGS868i 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 option card. This option card includes two or four isolated 0/4-20 mA analog inputs (designated as A, B, C and D), 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 properly enter programming data into the meter, it is necessary to know which input is assigned to which

process parameter. This information should be 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 option card or by an external power supply. Figure 5 below shows typical wiring diagrams, with and without an external power supply, for one of the analog inputs.

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Figure 5: Analog Input Wiring Diagram

+ 63 hidden pages

GE Sensing XGS868i User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1. Installation

1.1 Introduction

1.2 Unpacking

1.3 Site Considerations

1.3.1 Electronics Enclosure Location

1.3.2 Flowcell Location

1.3.3 Transducer Location

1.3.4 Cable Lengths

1.3.5 Temperature and Pressure Transmitters

1.3.6 Transducer Cables

1.4 Installing a Flowcell

1.5 Installing Temperature and Pressure Transmitters

1.6 Mounting the XGS868i Electronics Enclosure

1.7 Making the Electrical Connections

1.7.1 Wiring the Line Power

1.7.2 Wiring the Transducers

1.7.3 Wiring Std 0/4-20 mA Analog Outputs

1.7.4 Wiring the Serial Port

1.7.5 Wiring the Option Cards