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Technical content subject to change without notice.

910-176S Rev. E1

Customer Support Centers

U.S.A.

The Boston Center
1100 Technology Park Drive
Billerica, MA 01821
U.S.A.
Tel: 800 833 9438 (toll-free)

978 437 1000

E-mail: [email protected]

Ireland

Sensing House
Shannon Free Zone East
Shannon, County Clare
Ireland
Tel: +353 61 61470200
E-mail: [email protected]

Summary of Contents for DigitalFlow DF868

Page 1: ...GE Measurement Control Flow 910 176S Rev E1 August 2015 DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual ...

Page 2: ......

Page 3: ...015 General Electric Company All rights reserved Technical content subject to change without notice GE Measurement Control DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual 910 176S Rev E1 August 2015 ...

Page 4: ...ii no content intended for this page proceed to next page ...

Page 5: ...re followed carefully WARNING This symbol indicates a risk of potential serious personal injury unless these instructions are followed carefully 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 WARNING For installations in potentially hazardous...

Page 6: ...ipment WEEE take back initiative directive 2012 19 EU The equipment that you bought has required the extraction and use of natural resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the ap...

Page 7: ...s 5 1 4 1 Accessing the Calibration Menu 6 1 4 2 aLOW Option F1 6 1 4 3 aHIGH Option F2 6 1 4 4 4 mA Option F3 6 1 4 5 20 mA Option F4 6 1 5 Calibrating the RTD Inputs 8 1 5 1 Accessing the Calibration Menu 8 1 5 2 LOW Option F1 8 1 5 3 HIGH Option F2 8 1 6 Alarms Option Card 9 1 6 1 Accessing the Calibration Menu 9 1 6 2 Testing the Alarm Relays 10 1 7 Totalizer Frequency Option Card 11 1 7 1 Acc...

Page 8: ...emoving the Printed Circuit Board 29 4 4 Replacing the EPROM 30 4 5 Installing an Option Card 30 4 6 Replacing the LCD Display 31 4 7 Installing the Printed Circuit Board 32 4 8 Spare Parts 33 Appendix A Service Record A 1 Introduction 37 A 2 Data Entry 37 A 3 Diagnostic Parameters 39 Appendix B Optional Enclosures B 1 Introduction 41 B 2 Rack Mount Enclosure 41 B 3 Rack Mount Fuse Replacement 42 ...

Page 9: ...nvention in this manual identifies any expansion slot as Slot x where x is a number from 0 6 See Chapter 1 Installation of the Startup Guide for a complete description of the available option cards and the procedures for wiring them 1 2 Menu Map The Calibration Menu is accessed by pressing the CAL key on the keypad Use this menu to calibrate and test the Slot 0 analog outputs as well as to calibra...

Page 10: ...t of the analog output may be set for either 0 mA or 4 mA However the calibration procedure always uses the 4 mA point as the meter will extrapolate this value to obtain the 0 mA point Prepare for the calibration procedure by connecting an ammeter to analog output A of Slot 0 as shown in Figure 1 below Refer to the menu map in Figure 6 on page 13 Figure 1 Ammeter Connection Output A Press the CAL ...

Page 11: ...t be sure to reconnect the ammeter to the appropriate pins on terminal block I O See Figure 1 on page 2 or Figure 2 above for the correct pin numbers 1 3 2 Calibrating the Low End of the Output Range 1 Press F1 to calibrate the low end of the output range 2 Press F1 or F2 to adjust the ammeter reading UP or DOWN until a 4 mA reading is achieved If you press F3 Numer enter the numeric value and pre...

Page 12: ...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 above 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 contac...

Page 13: ...ot 0 analog output will supply the low reference high reference 4 mA and 20 mA signals at the appropriate times Note If a Slot 0 analog output will be used to calibrate the analog inputs make sure that the Slot 0 analog output calibration procedure has already been completed Connect the Slot X analog output s or an independent calibrated current source to the analog input s on the option card as s...

Page 14: ...ed F2 aHIGH proceed to aHIGH Option below If you selected F3 4 mA proceed to 4 mA Option below If you selected F4 20 mA proceed to 20 mA Option below 1 4 2 aLOW Option F1 1 Enter the low reference value and press the ENT key 2 Press F1 to store the current low reference value or press F2 to cancel the entry In either case the ANALOG INPUT prompt will reappear 3 Press F2 to proceed to the next sect...

Page 15: ...store the current 20 mA value or press F2 to cancel the entry In either case the ANALOG INPUT prompt reappears 3 Proceed to Procedure Options below Procedure Options You have completed calibration of the analog input Do one of the following To calibrate another input return to Step 3 in Accessing the Calibration Menu on the previous page To calibrate test additional slots press F4 EXIT and proceed...

Page 16: ...OW proceed to step 5 If you selected F2 HIGH proceed to step 8 1 5 2 LOW Option F1 5 Enter the low reference value and press the ENT key 6 Press F1 to STORE the low reference value or F2 to ABORT the calibration In either case the screen returns to the ANALOG INPUT prompt 7 Press F2 to proceed to the next section 1 5 3 HIGH Option F2 8 Enter the high reference value and press the ENT key 9 Press F...

Page 17: ...the option card terminal block as shown in Figure 4 below Refer to the menu map in Figure 6 on page 13 as a guide Figure 4 Typical Ohmmeter Connections For this discussion assume that the option card has been installed in Slot x 1 6 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to select Slot x The option bar will include a slot listing for each i...

Page 18: ... correct pin numbers on the option card terminal block 4 Pressing F1 CLOSE should yield an ohmmeter reading of about zero Pressing F2 OPEN should yield an infinite ohmmeter reading 5 Press F3 to EXIT 6 Repeat the above procedure until both the normally open and normally closed contacts for all three alarm relays have been tested Then proceed to Procedure Options below Procedure Options You have co...

Page 19: ... the menu map in Figure 6 on page 13 as a guide Figure 5 Frequency Counter Connections For this discussion assume that the option card has been installed in Slot x 1 7 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to select Slot x The option bar will include a slot listing for each installed option card 3 Press F1 F4 to select output A B C or D re...

Page 20: ...en be output at the specified frequency 6 Repeat steps 3 4 and 5 to test all four of the frequency totalizer outputs If any of the outputs fails to pass the test contact the factory for assistance Procedure Options You have completed testing the totalizer frequency outputs Do one of the following To calibrate test additional slots press F4 EXIT and proceed to the appropriate section To leave the C...

Page 21: ... REF LOW REFERENCE LOW REF ANALOG INPUT Slot x Inputs Analog Inputs F1 F2 A B F1 4 mA F2 20 mA F3 TEST F4 EXIT F1 UP F2 DOWN F3 STORE F4 ABORT Full Scale CALIBRATING ANALOG OUTPUT Slot 0 Outputs TB I O F1 F2 A B F1 4 mA F2 20 mA F3 TEST F4 EXIT F1 UP F2 DOWN F3 STORE F4 ABORT Full Scale CALIBRATING ANALOG OUTPUT Slot x Outputs Analog Outputs F3 F4 C D F1 F2 A B F1 aLOW F2 aHIGH F1 EXIT F1 STORE F2...

Page 22: ...Chapter 1 Calibration DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 14 ...

Page 23: ...ies the troubleshooting process All of the possible Model DF868 error code messages are discussed in this chapter along with the possible causes and the recommended actions When an error code is generated it will appear on the active pane of the display screen in the location shown in Figure 7 below Figure 7 A Typical Display Screen Note For a 2 Channel Model DF868 the channel number is displayed ...

Page 24: ...he error may be caused by incorrect programming poor flow conditions or poor transducer spacing Action Compare the measured sound speed to tabulated nominal values for the fluid being used and correct any programming errors Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems pages 3 5 to 3 8 E3 Velocity Range Problem The velocity exceeds the limits programmed in the S...

Page 25: ...ween transmitting device and input card broken transmitter or broken analog input on option card Action Test analog input verify wiring test transmitter E8 Temp In Supply Problem This message indicates a temperature input supply error Cause The temperature exceeds the specified limits for the analog inputs option card Action Check the temperature transmitter and the connecting cable Refer to Chapt...

Page 26: ...oo dissimilar Action Check the pipe and setup parameters and the transducer connections The process may not include enough two phase content switch to transit time mode E13 Over Range Problem This error code message indicates that the present measurement exceeds the capacity of the meter Cause A internal mathematical overflow has occurred in either the volumetric or mass flow calculations Action S...

Page 27: ...ng a log there are no more logs to clear 2 logging data user has hit ENT instead of selecting an old log or entering a new name 3 printing a log there are no logs to print 4 displaying a log there are no logs to display Hit any key to resume taking measurements All Sites Cleared hit key This message may appear during one of the following tasks 1 saving a new site a new site name was not entered or...

Page 28: ...wed Reduce the number of decimal digits or change the units P L Enter L again The entered path length P is less than the axial dimension L Enter a new value for L range is X XX to X XX When in the User Program this message indicates that the entered number is unacceptable Hit any key and enter a number within the allowable range Review calibration An option card error indicating a programming fail...

Page 29: ...he troubleshooting of flowcell transducer and or electrical problems The Diagnostics Menu may only be entered from the Big or Dual measurement mode display See Chapter 2 Displaying Data in the Programming Manual for instructions on setting the display screen to the desired format and enter the Diagnostics Menu as shown below Note For a 1 Channel Model DF868 the above prompt does not appear and the...

Page 30: ...N A N A Tup UP Transit S usec Displays the upstream transit time of the ultrasonic signal in microseconds N A N A Tdown DN Transit usec Displays downstream transit time of the ultrasonic signal in microseconds N A N A DELTA DeltaT usec Displays the difference in μsec between upstream and downstream transit times N A 10 000 nsec REYN Reynolds A number based on the kinematic viscosity and flow rate ...

Page 31: ... for the downstream transducer 100 2300 100 or 2300 NFup UP Norm Factor Displays the normalization factor for the upstream transducer 0 85 1 0 0 85 NFdn DN Norm Factor Displays the normalization factor for the downstream transducer 0 85 1 0 0 85 Cxdcr CEE1 Displays the speed of sound in the transducer clamp on only N A N A TEMPs Supply Temp deg F Displays the temperature for the supply input energ...

Page 32: ... solid or gas particles will absorb or disperse the ultrasound signals This interference with the ultrasound transmissions through the fluid will cause inaccurate flow rate measurements In addition temperature gradients in the fluid flow may result in erratic or inaccurate flow rate readings 2 The fluid must not cavitate near the flowcell Fluids with a high vapor pressure may cavitate near or in t...

Page 33: ...ipe these dimensions must be precisely measured See Appendix D Measuring P and L Dimensions of the Startup Guide for a thorough discussion of this topic 3 The inside of the pipe or flowcell must be relatively clean Excessive build up of scale rust or debris will interfere with flow measurement Generally a thin coating or a solid well adhered build up on the pipe wall will not cause problems Loose ...

Page 34: ...re must be applied to the transducer by its clamp to hold it firmly against the pipe 2 MISALIGNMENT The transducer transmits relatively narrow beams of ultrasound therefore transducer alignment is critical to assure that the beam can travel from one transducer to the other without undue attenuation Be sure to exactly follow the instructions that came with your transducers and clamping fixtures Als...

Page 35: ...the European Union s Low Voltage Directive 73 23 EEC this unit requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model DF868 An aluminum shroud over the printed circuit board shields the electrical components and serves as a location for the wiring di...

Page 36: ...e fuse holder cap counterclockwise about 1 4 turn The fuse holder cap with the captive fuse will be ejected from the fuse holder 4 Replace the defective fuse with a new one of the same rating and type Use only 1 1 4 x 1 4 Slo Blo fuses having a rating as indicated in Table 4 below and on the wiring diagram label 5 Press the new fuse into the fuse holder cap and insert the fuse into the fuse holder...

Page 37: ...ffs along the right side of the main circuit board 5 While supporting the printed circuit board remove the two screws or standoffs along the bottom edge of the printed circuit board Note For an LVD compliant meter with the clear plastic shroud over the electrical connectors there will be standoffs in these two locations For meters not equipped with this shroud there will be Phillips head screws in...

Page 38: ...he EPROM into the socket 5 By applying equal pressure on all four corners gently press the EPROM into the socket until it is fully seated Do not strike the EPROM or apply excessive force during this procedure Complete the EPROM replacement by proceeding to the Installing the Printed Circuit Board page 32 section of this chapter Note If you have installed a new EPROM upon reinitialization the DF868...

Page 39: ...ace the LCD display see Figure 8 on page 35 for the component locations and complete the following steps 1 Remove the printed circuit board as described in a previous section of this chapter 2 Using a 3 16 in nutdriver remove the four nut washer sets that secure the display shroud to the inside of the console cover Lift the display shroud off its mounting studs 3 Using a 1 4 nutdriver remove the f...

Page 40: ...hort standoffs on the left side of the printed circuit board 4 Insert the free end of the green grounding strap between the printed circuit board and the middle standoff beneath the left side of the board Making sure to capture the grounding strap lug between the printed circuit board and the standoff beneath it install the remaining short standoff on the left side of the printed circuit board Sec...

Page 41: ...d account of the service procedure performed on the Model DF868 in Appendix A Service Record 4 8 Spare Parts All of the necessary components to upgrade or repair the Model DF868 flowmeter are readily available from GE As a convenient reference some of the more common spare parts are listed below in Table 5 To purchase the parts listed in Table 5 above or any items not listed in the table contact t...

Page 42: ...Chapter 4 Parts Replacement 34 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual no content intended for this page ...

Page 43: ...pter 4 Parts Replacement DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 35 SIDE VIEW BOTTOM VIEW FRONT VIEW G DC G N L2 L1 AC Figure 8 Standard Model DF868 Electronics Console Assembly ...

Page 44: ...Chapter 4 Parts Replacement DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 36 G N L2 L1 AC G DC Figure 9 Standard Model DF868 Printed Circuit Board Assembly ...

Page 45: ... Model DF868 flowmeter the details of the service should be recorded in this appendix An accurate service history of the meter can prove very helpful in troubleshooting any future problems A 2 Data Entry Record complete and detailed service data for the Model DF868 in Table 6 below Make additional copies of the table as needed Table 6 Service Record Date Description of Service Performed By ...

Page 46: ...Appendix A Service Record 38 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Table 6 Service Record cont Date Description of Service Performed By ...

Page 47: ...nction is noticed the values for the diagnostic parameters should be entered in Table 7 below Table 7 Diagnostic Parameters Parameter Initial Current Parameter Initial Current SS up CNTup SS do CNTdn SNDSP P up Tup P dn Tdown NFup DELTA NFdn Reynolds Cxdr1 K RE TEMPs2 PEAK TEMPr2 THETA1 Ts Tr2 Qup DENSs2 Qdown DENSr2 AMPup DELTh2 AMPdn TW 1 available only for Clamp on transducers 2 available only ...

Page 48: ...Appendix A 40 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual no content intended for this page ...

Page 49: ...ons specific to that unit WARNING Prior to performing any maintenance procedures disconnect the main power from the unit Note For compliance with the European Union s Low Voltage Directive 73 23 EEC 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...

Page 50: ...over on the back panel at the bottom of the power cord receptacle and pull it straight out 3 Replace the defective fuse with a new one of the same rating and type Use only 5 x 20 mm Slo Blo fuses having a rating as indicated in Table 8 below and on the rear panel label 4 Reinstall the black plastic fuse cover and insert the power cord back into the receptacle Then position the power switch in the ...

Page 51: ...ar panel remove the appropriate option slot cover to make room for the external connector on the new option card 4 To install the option card insert its 32 pin connector into the chosen option card socket and gently press the card into place Make sure that the pins in the connector are straight and properly aligned with the socket and that the option card is oriented with its external connector po...

Page 52: ...ounded metal object to discharge any built up static electricity and avoid touching the leads on the side of the chip 2 Using a chip puller remove the EPROM from its socket If a chip puller is unavailable a straightened paper clip may be used in the notches at opposite corners of the socket Gently pry the EPROM up a little at a time at each notch until it comes free 3 Make sure that the beveled co...

Page 53: ...e connections to the printed circuit board Remove and discard the old LCD display 5 Place the new LCD display assembly over the mounting studs on the front panel and fasten it in place with the four standoffs Make sure that the LCD display assembly is oriented with the cables pointing toward the left side away from the keypad of the meter CAUTION Do not overtighten the standoffs or the display ass...

Page 54: ...t in reinstallation on the new circuit board 4 Remove the RS232 ANALOG OUT and TRANSDUCER connectors from the printed circuit board Use a marker to identify pin 1 on the right side keypad side of these connectors Note These connectors should be pulled straight up and off the printed circuit board DO NOT remove the leads from the screw terminals 5 Remove the flat KEYPAD CABLE connector from termina...

Page 55: ...RS232 ANALOG OUT and TRANSDUCER connectors onto the printed circuit board at the locations indicated in Figure 11 on page 50 Make sure the marked pin 1 sides of the connectors face the right side keypad side of the enclosure Note If any leads have come loose from the screw terminals on these connectors refer to Appendix C Optional Enclosures of the Startup Guide for wiring instructions 6 Reconnect...

Page 56: ...Appendix B 48 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual no content intended for this page ...

Page 57: ... Flowmeter Service Manual 49 DF868 A OUT ALARMS A IN RTD IN USE ONLY WITH A 250V FUSE 18 25 464 19 00 483 2 25 5 22 11 82 13 13 57 133 15 70 399 300 333 3 31 84 4 19 106 11 37 289 14 83 377 16 99 432 Fuse Figure 10 Model DF868 Rack Mount Enclosure Dimensions ref dwg 712 1076 ...

Page 58: ...Appendix B Optional Enclosures DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 50 Figure 11 Model DF868 Rack Mount Console Assembly ref dwg 705 849 ...

Page 59: ...ucers 25 D Diagnostic Parameters Listing 22 Record of Values 39 Diagnostics Menu Entering 21 Exiting 23 Dimensions Bench Mount 36 Rack Mount 35 49 Display Cable 29 LCD 31 Replacing 31 Display Screen 15 E EPROM Replacing 30 User Program 30 Error Codes 16 17 18 Error Message Display Screen 15 Expansion Slots 1 F Flowcell Problems Fluid 24 Pipe 25 Fluid Problems 24 Fuse Replacement 28 G Gas Contamina...

Page 60: ... Option Card Calibrating 8 S Safety Auxiliary Equipment vii General Issues vii Personal Equipment vii Screen Messages Table 19 Service Record 37 S cont Shroud Aluminum 27 32 LCD Display 31 LVD 32 Plastic 32 Signal Quality Error E4 16 Sockets Option Card 31 Soundspeed Error E2 16 Gas 24 Spare Parts List 33 Special Input E7 17 T Temperature Input Return Error E8 17 Temperature Input Supply Error E8 ...

Page 61: ...fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Sensing giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory ...

Page 62: ...Warranty 54 DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual no content intended for this page ...

Page 63: ...hanical or thermal stresses in excess of those permitted in the certification documentation and the instruction manual The product cannot be repaired by the user it must be replaced by an equivalent certified product Repairs should only be carried out by the manufacturer or by an approved repairer Only trained competent personnel may install operate and maintain the equipment The product is an ele...

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Page 65: ...61326 2 3 2006 EN 61010 1 2012 Overvoltage Category II Other standards Used EN 50014 1997 A1 A2 EN 50018 2000 A1 following the provisions of the 2004 108 EC EMC 2006 95 EC Low Voltage and 94 9 EC ATEX Directives Where products were initially assessed for compliance with the Essential Health and Safety Requirements of the ATEX Directive 94 9 EC using earlier harmonized standards a subsequent review...

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Page 68: ...echnical content subject to change without notice 910 176S Rev E1 Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com Ireland Sensing House Shannon Free Zone East Shannon County Clare Ireland Tel 353 61 61470200 E mail gesensingsnnservices ge com ...

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