Panametrics DigitalFlow XGS868i User manual

panametrics.com
Flow
910-196S G
Jul 2021
DigitalFlow™ XGS868i
Panametrics Steam Ultrasonic Mass Flow Transmitter
(1 & 2 Channel)
Service Manual

Flow
panametrics.com
Copyright 2021 Baker Hughes company.
This material contains one or more registered trademarks of Baker Hughes Company and its subsidiaries
in one or more countries. All third-party product and company names are trademarks of their respective
holders.
DigitalFlow™ XGS868i
Panametrics Steam Ultrasonic Mass Flow Transmitter
(1 & 2 Channel)
Service Manual
910-196S Rev. G
Jul 2021

ii
[no content intended for this page]

DigitalFlow™ XGS868i Service Manual iii
Information Paragraphs
•Note paragraphs provide information that provides a deeper understanding of the situation, but is not essential
to the proper completion of the instructions.
•Important 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! paragraphs provide information that alerts the operator to a hazardous situation that can cause
damage to property or equipment.
•Warning! paragraphs provide information that alerts the operator to a hazardous situation that can cause injury
to personnel. Cautionary information is also included, when applicable.
Safety Issues
WARNING! It is the responsibility of the user to make sure all local, county, state and national codes, regulations,
rules and laws related to safety and safe operating conditions are met for each installation.
Auxiliary Equipment
Local Safety Standards
The user must make sure that he operates all auxiliary equipment in accordance with local codes, standards,
regulations, or laws applicable to safety.
Working Area
WARNING! Auxiliary equipment may have both manual and automatic modes of operation. As equipment can
move suddenly and without warning, do not enter the work cell of this equipment during automatic
operation, and do not enter the work envelope of this equipment during manual operation. If you do,
serious injury can result.
WARNING! Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform
maintenance procedures on the equipment.
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 Service Manual
Environmental Compliance
Waste Electrical and Electronic Equipment (WEEE) Directive
Panametrics Solutions is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE)
take-back initiative, directive 2002/96/EC.
The equipment that you bought has required the extraction and use of natural resources for its production. It may
contain hazardous substances that could impact health and the environment.
In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the
natural resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle
most of the materials of your end life equipment in a sound way.
The crossed-out wheeled bin symbol invites you to use those systems.
If you need more information on the collection, reuse and recycling systems, please contact your local or regional
waste administration.
Visit www.bakerhughesds.com/health-safetyand-environment-hse for take-back instructions and more information
about this initiative.

DigitalFlow™ XGS868i Service Manual v
Contents
Chapter 1. Calibration
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Accessing the Calibration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Calibrating and Testing Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.2 Calibrating the Low End of the Output Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.3 Calibrating the High End of the Output Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.4 Testing Output Linearity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Calibrating Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.1 Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.2 Accessing the Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Calibrating RTD Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5.1 Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5.2 Accessing the Calibration/Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5.3 Entering the Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5.4 Entering the Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Testing Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.1 Preparing for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.2 Testing the Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 Testing Totalizer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7.1 Preparing for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7.2 Testing the Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.8 Testing the Frequency Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8.1 Preparing for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8.2 Testing the Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2. Error Codes
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Chapter 3. Diagnostics
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2 Displaying Diagnostic Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3 Flowcell Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.3.1 Gas Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.2 Pipe Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.4 Transducer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 4. Parts Replacement
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Removing the Circuit Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Replacing the LCD Display/Interconnect Board Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4 Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.5 Replacing the User Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.6 Installing an Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6.1 Attaching an Optional Heat Sink to an I/O Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.7 Assembling/Installing the Circuit Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7.1 Assembling the Circuit Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7.2 Installing the Circuit Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Appendix A. Service Record
A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
A.2 Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A.3 Diagnostic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Appendix B. Calibration and Testing with PanaView
B.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
B.2 Accessing the Calibration/Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
B.3 Calibrating Slot 0 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents
vi DigitalFlow™ XGS868i Service Manual
B.4 Calibrating Slot 1 Option Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
B.4.1 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
B.4.2 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
B.4.3 RTD Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
B.4.4 Entering the Set Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
B.4.5 Entering the Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
B.4.6 Testing Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
B.4.7 Testing Totalizer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
B.4.8 Testing Frequency Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
B.5 Testing XGS868i Software and Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
B.5.1 Uploading Signal Array Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
B.5.2 Uploading XGS868i Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
B.5.3 Testing XGS868i Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Appendix C. Factory Tests
C.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
C.2 Resetting the Number of Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
C.1 Resetting the XGS868i to Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

DigitalFlow™ XGS868i Service Manual 1
Chapter 1. Calibration
Chapter 1. Calibration
1.1 Introduction
Calibrating the Model XGS868i’s analog outputs and inputs is explained in this chapter. In addition, testing the
optional totalizer, frequency and alarm relay outputs is discussed. The chapter includes the following specific topics:
• calibrating the Slot 0 and Slot 1 analog outputs - page 2.
• calibrating option card analog inputs - page 4.
• calibrating option card RTD inputs - page 6.
• testing option card alarm relays - page 7.
• testing option card totalizer outputs - page 8.
• testing option card frequency outputs - page 10.
Note:
Convention in this manual identifies any expansion slot as Slot x , where x is a number from 0-2. Slot 2 is used
only for data logging, MODBUS or HART option cards.
See Chapter 1, Installation , and Appendix B, Data Records , in the Startup Guide for a complete description of the
available option cards and the procedures for wiring them.
1.2 Accessing the Calibration Menu
The Calibration menu is accessible through the Keypad Program , as well as through PanaView™ software. (If you are
using PanaView to calibrate the XGS868i, refer to Appendix B.) Use this menu to calibrate and test the Slot 0 analog
outputs, as well as to calibrate and/or test any option cards that are installed in expansion Slot 1. Refer to the menu
maps in Figure 3 on page 11 as a guide in following the calibration instructions.
1. Power up the XGS868i and wait until it has initialized.
2. Press the [Escape], [Enter], [Escape] keys. The
Keypad Program appears on the screen.
3. Press the right arrow key to scroll to the
CALIB menu. Press [Enter]. The Cal window opens.
Proceed to the appropriate sections of this chapter to calibrate and/or test any of the installed inputs and/or
outputs.
Note:
The Calibration menu never returns to the Keypad Program. Pressing [Escape] to exit the menu causes the
XGS868i to restart.

Chapter 1. Calibration
2 DigitalFlow™ XGS868i Service Manual
1.3 Calibrating and Testing Analog Outputs
Every Model XGS868i flowmeter includes two built-in analog outputs (A and B) at terminal block J1, which is
designated as Slot 0. Additional analog outputs may be added to the Model XGS868i by installing an appropriate
option card in Slot 1. This option card contains two analog outputs, which are also designated as A and B.
Before beginning calibration, an ammeter must be connected to the desired analog output. Both the zero-point and
full-scale values for all of these outputs must be calibrated. After calibrating the outputs, which have a resolution of
5.0 A (0.03% full scale), their linearity should be tested.
Note:
The zero point of the analog output may be set at either 0 mA or 4 mA. However, the calibration always uses
the 4 mA point, as the meter extrapolates this value to obtain the 0 mA point.
1.3.1 Preparing for Calibration
Prepare for calibration by inserting an ammeter in series with the load on the desired output. Refer to Figure 1 and
Figure 4 on page 12 to identify the OUT(+) and RTN(-) pins for the desired output.
Figure 1: Ammeter Connection (Output A)
Terminal Block J1 (Slot 0)
B
RTN
B
SIG
A
RTN
A
SIG
41
+
-
Ammeter
Load

DigitalFlow™ XGS868i Service Manual 3
Chapter 1. Calibration
1.3.2 Calibrating the Low End of the Output Range
1. From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter].
2. In the
Cal menu, scroll to the Slot 0 or Slot 1 option, and press [Enter].
Note:
The Slot 1 option only appears in the menu if an option card has been installed in this slot.
3. Scroll to either Output A or Output B to open the Analog Output menu. (Output A will be used as an example in
this manual.) Press [Enter].
IMPORTANT: The procedure for calibrating Output B is identical to that for calibrating Output A. However, when
calibrating Output B, be sure to reconnect the ammeter on terminal block J1. See Figure 1 on page 2 for
the correct pin numbers.
4. Scroll to
4 mA to calibrate the low end of the output range. Press [Enter].
5. Scroll to
UP or DOWN to adjust the ammeter reading UP or DOWN, until a 4 mA reading is achieved,
or
Scroll to
Numer, and directly enter the mA reading. In either case, press [Enter] to confirm the entry.
6. Once you have achieved a 4 mA reading, scroll to either
STORE to store the calibration, or to ABORT to exit the
menu without storing the calibration. In either case, press [Enter].
Note:
If the ammeter reading cannot be adjusted within 5.0  A of the 4 or 20 mA setting, contact the factory for
assistance.
1.3.3 Calibrating the High End of the Output Range
7. The XGS868i returns to the Analog Output window. Scroll to 20 mA , and repeat steps 4 and 5 to calibrate the high
end of the output range.
Note:
Skip the following prompt, if linearity testing of the output will not be performed at this time.
1.3.4 Testing Output Linearity
8. Scroll to TEST to test the linearity of the currently selected analog output. Press [Enter].
9. Check the ammeter reading at
50% Full Scale . Then, use the arrow keys to enter a different % Full Scale (0-100%).
Press [Enter] when done.

Chapter 1. Calibration
4 DigitalFlow™ XGS868i Service Manual
1.3.4 Testing Output Linearity (cont.)
Table 1 lists the expected ammeter readings at various % Full Scale settings, for both 4-20 mA and 0-20 mA scales.
Refer to this table to verify the accuracy of the ammeter readings taken above.
If the linearity test readings are not within 5 A of the values listed in Table 1, check the accuracy and wiring of the
ammeter. Then, repeat the low and high end calibrations. If the analog output still does not pass the linearity test,
contact the factory for assistance.
10. Scroll to
EXIT and press [Enter] to return to the Cal menu. Then choose another output to calibrate or press [Escape]
to leave the
CALIB menu.
This completes calibration of the Slot 0 analog outputs. Proceed to the appropriate section to calibrate additional
inputs/outputs.
1.4 Calibrating Analog Inputs
Analog inputs may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option card
contains two or four analog inputs, which are designated as A, B, C and D. Both the zero-point and full-scale values
for each input must be calibrated.
Calibration of the analog inputs requires the use of a calibrated current source. If an independent calibrated current
source is not available, one of the Slot 0 analog outputs may be used for the calibration. During the analog input
calibration, the Slot 0 analog output will supply the low reference, high reference, 4 mA and 20 mA signals at the
appropriate times.
IMPORTANT: If a Slot 0 analog output will be used to calibrate the analog inputs, the Slot 0 analog output calibration
procedure must be completed first.
Table 1: Expected Ammeter Readings
% Full Scale 4-20 mA Scale* 0-20 mA Scale*
0 4.000 0.000
10 5.600 2.000
20 7.200 4.000
30 8.800 6.000
40 10.400 8.000
50 12.000 10.000
60 13.600 12.000
70 15.200 14.000
80 16.800 16.000
90 18.400 18.000
100 20.000 20.000
* all ammeter readings should be ±0.005 mA

DigitalFlow™ XGS868i Service Manual 5
Chapter 1. Calibration
1.4.1 Preparing for Calibration
Prepare for the calibration procedure by connecting a Slot 0 analog output (or an independent calibrated current
source) to the desired input on the option card. See Figure 4 on page 12 to identify the IN(+) and RTN(-) pins for the
desired input on terminal block J2.
Note:
The zero point of the analog input may be set for either 0 mA or 4 mA. However, the calibration always uses
the 4 mA point, as the meter extrapolates this value to obtain the 0 mA point.
1.4.2 Accessing the Calibration Menu
1. From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter].
2. In the
Cal window, scroll to Slot 1 . Press [Enter].
3. Scroll to the desired Input to open the
ANALOG INPUT menu. (Input A will be used as an example in this manual.)
Press [Enter].
IMPORTANT: Calibrating Input B, C or D is identical to calibrating Input A. However, be sure to reconnect the current
source on terminal block J2. Refer to Figure 4 on page 12 for the correct pin numbers.
4. Scroll to the appropriate option to select the reference point to be calibrated. Press [Enter].
IMPORTANT: The procedure for calibrating all the inputs is the same. However, when calibrating a different input, be
sure to reconnect the current source at terminal block J2. See Figure 4 on page 12 for the correct pin
numbers.
5. Do one of the following:
• Proceed to4 mA Option below.
• Proceed to20 mA Option below.
1.4.2.1 4 mA Option
Set the calibrated current source to 4 mA.
•If you selected the 4 mA option in the ANALOG INPUT menu, scroll to STORE to accept the current 4 mA value or
on ABORT to cancel the entry. Press [Enter]. In either case, the XGS868i returns to the Analog Input window.
1.4.2.2 20 mA Option
Set the calibrated current source to 20 mA.
• If you selected the
20 mA option in the ANALOG INPUT option, scroll STORE to accept the current 20 mA value or to
ABORT to cancel the entry. Press [Enter]. In either case, the XGS868i returns to the ANALOG INPUT window.
• Press [Escape] to return to the
Slot 1 window and calibrate additional inputs/outputs, or press [Escape] again to
close the
CALIB menu.

Chapter 1. Calibration
6 DigitalFlow™ XGS868i Service Manual
1.5 Calibrating RTD Inputs
RTD analog inputs may be added to the XGS868i by installing an appropriate option card in Slot 1. The option card
contains two or four RTD inputs that are designated as A, B, C and D. Both the set point and slope point values for
each input must be specified prior to use.
1.5.1 Preparing for Calibration
Prepare for the calibration procedure by connecting the RTD temperature transmitter to the desired input (A, B, C or
D) on the option card. See Figure 4 on page 12 to identify the RTD(+) and COM(-) pins for the desired input on
terminal block J2.
1.5.2 Accessing the Calibration/Test Menu
1. From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter].
2. In the
Cal window, scroll to Slot 1 . Press [Enter].
Note:
The Slot 1 option only appears at the above prompt if an option card is installed in this slot.
3. Scroll to the desired Input. (Input A will be used as an example in this manual.) Press [Enter].
IMPORTANT: When calibrating the other inputs, be sure to reconnect the current source at terminal block J2. See
Figure 4 on page 12 for the correct pins.
1.5.3 Entering the Set Point
1. Before proceeding, place the RTD in a temperature bath and allow it to stabilize at the desired set point
temperature.
2. Scroll to
Set to program the RTD set point. Press [Enter].
3. Use the arrow keys to enter the desired set point temperature and press [Enter].
4. Scroll to
STORE to accept the new set point value or ABORT to cancel the entry. Press [Enter].
1.5.4 Entering the Slope
1. Scroll to Slope to program the RTD slope point. Press [Enter].
2. Use the arrow keys to enter the desired slope point temperature and press [Enter].
3. Press
STORE to accept the new slope point value or ABORT to cancel the entry. Press [Enter].
Note:
If an error message appears, verify that the RTD is at the programmed temperature. Also, if you replace the
set/slope range with a different range, be sure to recalibrate the set and slope points.
Procedure Options
This completes calibration of the Slot 1 RTD input. Do one of the following:
• To calibrate or test another input, press [Escape] and return to Step 3 in
Accessing the Calibration/Test Menu .
• To leave the
Keypad Program , press [Escape] twice.

DigitalFlow™ XGS868i Service Manual 7
Chapter 1. Calibration
1.6 Testing Alarm Relays
Alarm relays may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option card
contains two or four alarm relays, which are designated A, B, C and D.
1.6.1 Preparing for Testing
Prepare for the testing procedure by connecting an ohmmeter to the NO and COM pins of the desired alarm on the
option card. Refer to Figure 4 on page 12 to identify the NO, NC and COM pins for the desired alarm on terminal block
J2.
1.6.2 Testing the Relay
1. From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter].
2. In the
Cal window, scroll to Slot 1 . Press [Enter].
Note:
The Slot 1 option only appears at the above prompt if an option card is installed in this slot.
3. Scroll to the desired Output. (Output A will be used as an example in this manual.) Press [Enter].
IMPORTANT: The procedure for testing all the alarms is the same. However, when testing a different output, be sure to
reconnect the ohmmeter at terminal block J2. See Figure 4 on page 12 for the correct pin numbers.
4. Do one of the following:
• Press [Enter] on
Close . The ohmmeter should yield a reading of about zero.
• Press [Enter] on Open . The ohmmeter should yield an infinite reading.
Note: To test the NC relay position, move the ohmmeter lead from the NO pin to the NC pin and repeat the above
test. In this case, the ohmmeter readings will be infinite when
Close Alarm is selected and zero when Open
Alarm
is selected.
Procedure Options
This completes testing of the Slot 1 alarm relays. Do one of the following:
• To test the
normally-open and normally-closed contacts for another alarm relay, return to Step 3 in Testing the
Relay
above.
• To calibrate/test additional inputs/outputs, proceed to the appropriate section.
• To leave the
Keypad Program , press [Escape] twice.

Chapter 1. Calibration
8 DigitalFlow™ XGS868i Service Manual
1.7 Testing Totalizer Outputs
Totalizer outputs may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option
card contains two or four totalizer outputs, which are designated A, B, C and D.
1.7.1 Preparing for Testing
Prepare for the testing procedure by connecting a pulse counter to the desired output of the option card. See Figure 2
for totalizer and frequency wiring output, and Figure 4 on page 12 to identify the OUT(+) and RTN(-) pins for Output A
on terminal block J2.
Figure 2: Totalizer and Frequency Wiring
OUT
RTN
IN
Common
Load
Volts -
(Common)
Volts +
(Int. Pwr. Sup.)
OUT
RTN
+5V
200
:
Transmitter
Transmitter
Pulse Counter
Frequency Counter
Totalizer Output
Frequency Output

DigitalFlow™ XGS868i Service Manual 9
Chapter 1. Calibration
1.7.2 Testing the Output
1. From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter].
2. In the
Cal window, scroll to Slot 1 . Press [Enter].
Note:
The Slot 1 option only appears at the above prompt if an option card is installed in this slot.
3. Scroll to the desired Output . (Output A will be used as an example in this manual.) Press [Enter].
IMPORTANT: The procedure for testing all the outputs is the same. However, when testing another output, be sure to
reconnect the pulse counter at terminal block J2. See Figure 4 on page 12 for the correct pins.
4. Use the arrow keys to enter a value for the minimum pulse on time (between 1 sec and 10,000 sec) for the
frequency of the totalizer pulses and press [Enter].
Note:
A complete pulse consists of equal amounts of ON and OFF times. Choose a value that is compatible with the
pulse counter to be used.
5. Use the arrow keys to enter a value for the number of measurement units represented by each pulse (between 1
and 10,000) and press [Enter]. That number of pulses will then be output at the specified frequency.
6. Verify that the pulse counter reads the correct value.
Procedure Options
This completes testing of the Slot 1 totalizer outputs. Do one of the following:
• To test another of the available totalizer outputs, return to Step 3 in
Testing the Output above. If any of the
totalizer outputs fails the test, contact the factory for assistance.
• To calibrate/test additional inputs/outputs, proceed to the appropriate section.
• To leave the
Keypad Program , press [Escape] twice.

Chapter 1. Calibration
10 DigitalFlow™ XGS868i Service Manual
1.8 Testing the Frequency Outputs
Frequency outputs may be added to the Model XGS868i by installing an appropriate option card in Slot 1. This option
card contains two or four frequency outputs, which are designated A, B, C and D.
1.8.1 Preparing for Testing
Prepare for the testing procedure by connecting a frequency counter to the desired output on the option card. See
Figure 4 on page 12 to identify the OUT(+) and RTN(-) pins for the desired output on terminal block J2.
1.8.2 Testing the Output
1. From the Keypad Program , press the right arrow key to scroll to the CALIB menu. Press [Enter].
2. In the
Cal window, scroll to Slot 1 . Press [Enter].
Note:
The Slot 1 option only appears at the above prompt if an option card is installed in this slot.
3. Scroll to the desired Output. (Output A will be used as an example in this manual.) Press [Enter].
IMPORTANT: The procedure for testing all the outputs is the same. However, when testing another output, be sure to
reconnect the frequency counter at terminal block J2. See Figure 4 on page 12 for the correct pins.
4. Enter a frequency (between 1 and 10,000 Hz) and press [Enter].
5. Verify that the frequency counter reads the correct value.
Procedure Options
This completes testing of the Slot 1 frequency outputs. Do one of the following:
• To test another of the available frequency outputs, return to Step 3 in
Testing the Output above. If any of the
frequency outputs fails the test, contact the factory for assistance.
• To calibrate/test additional inputs/outputs, proceed to the appropriate section.
• To leave the
Keypad Program , press [Escape] twice.

DigitalFlow™ XGS868i Service Manual 11
Keypad Pgm.
[Esc][Enter][Esc]
PROG RESET CALIB CNTRS
NO YES
Reset Totals
See Programming Manual
DARKN LITEN
STORE ABORT
SLOT0 SLOT1
UP DOWN Numer STORE ABORT
AB
4 mA 20 mA %TEST EXIT
ANALOG OUTPUT
Slot 0 Analog Outputs
CALIBRATING
mA Reading
% Full Scale
UP DOWN Numer STORE ABORT
AB
4 mA 20 mA %TEST EXIT
ANALOG OUTPUT
Slot 1 Analog Outputs
CALIBRATING
mA Reading
% Full Scale
STORE ABORT
AC
4 mA 20 mA
ANALOG INPUT
Slot 1 Analog Inputs
CALIBRATING
BD
press [EXIT] key
STORE ABORT
AC
SetPt Slope
RTD INPUT
Slot 1 RTD Inputs
CALIBRATING
BD
press [EXIT] key
SLOPE TEMP.SET POINT TEMP.
AC
OPEN EXIT
ALARMS
Slot 1 Alarm Relays
BD
CLOSE
AC
Slot 1 Totalizer Outputs
BD
PULSES TIME
AC
Slot 1 Frequency Outputs
BD
FREQUENCY
NOTE: Plain text represents prompt area meassages
and boxed text represents option bar choices.
Fx represent function keys to select option bar choices.
Slot 1 Option Card
Figure 3: Calibration Menu Map

DigitalFlow™ XGS868i Service Manual 12
-01 (AA,HH) -02 (FF,TT,FT,CT,CF) -03 (FO,TO,CO) -04 (FA,FH,TA,TH,CA,CH) -05 (CI,TI,FI) -06 (CR,FR,TR)
-07 (CIR) -11 (AR,HR)-09 (OI)-08 (AI,HI) -10 (OR) -12 (II)
-13 (RR) -14 (IR)
Pin 1
2
3
4
5
6
7
8
9
10
11
12
11
12
9
10
7
8
2
4
5
6
3
Pin 1
9
11
12
10
7
8
6
5
3
4
Pin 1
2
11
12
9
10
7
8
2
4
5
6
3
Pin 1
9
11
12
10
7
8
6
5
4
3
Pin 1
2
12
11
10
9
8
7
2
4
5
6
3
Pin 1
9
10
12
11
10
11
12
Pin 1
7
8
6
5
4
3
2
9
8
7
Pin 1
2
4
5
6
3
9
11
12
10
7
8
6
5
Pin 1
4
3
2
12
11
10
9
8
7
2
4
5
6
3
Pin 1
9
11
12
10
7
8
6
5
4
3
Pin 1
2
12
11
10
9
8
7
2
4
5
6
3
Pin 1
9
10
12
11
2
Pin 1
3
4
5
6
8
7
7
8
9
10
11
12
Pin 1
3
6
5
4
2
R = RTD Input
A = Standard Alarm
H = Hermetic Alarm
F = Frequency Output
T = Totalizer Output
I = Current Input
C = Current Output
O = Blank/No Connection
NOTE:
-17 (HART/OI)-15 (FHII) -16 (HART) -18 (F(F)HH)
9
11
12
10
7
8
6
5
3
4
Pin 1
2
9
11
12
10
7
8
6
5
4
3
Pin 1
2
9
10
12
11
Pin 1
7
8
6
5
4
3
2
9
11
12
10
7
8
6
5
Pin 1
4
3
2
-19 (HART/RI)
9
10
12
11
Pin 1
7
8
6
5
4
3
2
Figure 4: Option Card I/O Connections