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DigitalFlow™ DF868 Multipurpose Ultrasonic Liquid

1. Figure 3 Analog Input Calibration Connections For this discussion assume that the option card has been installed in Slot x Note The zero point of the analog input 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 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 5 Chapter 1 Calibration 1 4 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press F1 to select the desired input The procedure for calibrating Input A is identical to that for calibrating Input B However when calibrating Input B be sure a calibrated current source is connected to the appropriate pins on the terminal block See Figure 3 on page 5 for the correct pin numbers 4 Press F1 F4 to select the reference point to be calibrated Do one of the following If you selected F1 aLOW proceed to aLOW Option below If you selected F2 laHIGH 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
2. 1 6 2 Testing the Alarm Relays Note The procedure for testing Alarm Relay A is identical to that for testing Alarm Relays B and C However make sure that the ohmmeter is connected to the desired normally open or normally closed contact of the currently selected relay See Figure 4 on page 9 for the 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 completed testing the alarm relays Do one of the following To calibrate test additional slots press F4 EXIT and proceed to the appropriate section To leave the Calibration Menu press EXIT twice 10 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 1 Calibration 1 7 Totalizer Frequency Option Card Totalizer Frequency outputs may be added to the Model DF868 by installing a Totalizer Frequency Option Card in one or more of the six expansion slots Each option card includes four outputs which are designated as A B C and D To test the outputs connect a frequency counter to the card s terminal block as shown in Figure 5 below Refer to the menu map in Figure 6 on page 13 as a
3. DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual V Contents Chapter 3 Diagnostics 3 11 14 02100 4 Ilo eoa teca Le ter LLENO LEER MS Re RD CU LETRA RN 21 3 2 Displaying Diagnostic Parameters S io eel tasca ete Rute re Ro Oleg dr sete 21 33 DIGGHOSHE RECON e ees tatto EROR RES RENS EREMO ba oa vine d d EG Ld OR ao t em tates 23 A a esi tian eed codecs ten eae cad career tUe Kio beh ud os ere Mts ect ufui 24 S201 BIO PEFOBISITIS eua pres Die ie Red eet A rd wie tee E 24 A oD Pe Eure eC cte i eto ERE e E 25 5 53 Transducer PROBS Se oe ndo ore Mtt eerte M din ou te Mert e e Eos lur eels t 25 3 51 Wetted Iransd cerProblemlis cue dao iet Coe C A aio p FER DERE sa 25 one oampsenThnsudecenProblemis s ceat c op EO ET OCT E tas 26 Chapter 4 Parts Replacement AI as oco e Erde s one Eta PEPPER HEREIN TIPP Eo Led esr hee ta bebe 27 epos usc Replacertie lbi cs oeste den es er Dh Eten LL npe qu 28 AS Removing th Printed Circuit BOON conet Leon eer Longit rah haat ce ertet Mti 29 4 Replacing the EPROM essei cereo uae De rele a xoa paie ts ta quati es atn t tus 30 45 ls A Wie ice ana Mord RES MO Seta aa Ae etat TRAE 30 46 Replacing the CD DISDIO 3 reei iere pa PERRO A ead UE PI ee ake ES 31 4 amp 7 installing the Printed lat AAA A E erect 32 ALO Spare A RS aa e a res ea hes ek Se e m erar I 33 Appendix A Service Record AL a osocena ibit o nene AS UM REIR AR aie Rs tags Dae Co e ae Haa aora el d at eee e
4. EXIT twice and proceed to the appropriate section To leave the Calibration Menu press F4 EXIT three times 4 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 1 Calibration 1 4 Calibrating the Analog Inputs Analog inputs may be added to the Model DF868 flowmeter by installing an Analog Inputs Option Card in one or more of the six expansion slots The option card contains two analog inputs which are designated as A and B Each of the inputs must be calibrated at both the zero point and full scale values After calibrating the inputs their linearity should be tested 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 O 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 Note IfaSlot0 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 shown in Figure 3 below Refer to the menu map in Figure 6 on page 13 as a guide Analog Input Option Card Terminal Block I O Slot 0
5. Screw typical Standoffs typical Display Shroud LCD Display Nuts amp Washers typical PC Board Main Shroud Standoffs typical Option Card Socket Metal Bracket Fasteners Option Card LVD Shroud SIDE VIEW Figure 8 Standard Model DF868 Electronics Console Assembly DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 35 Chapter 4 Parts Replacement LCD Display Display Cable J2 Connector Vertical Components Optional WI FI Antenna Long Standoff 3 places Keypad Cable X Short Standoff 3 places Backlight Cable EY AR ae TERN PC Board Ground Wire z a Screws or Standoffs EPROM U4 4 Metal Bracket Option Card Connectors Keypad Connector J50 Beveled Corner of Socket Display Connector J52 Fastener 4 places Figure 9 Stand
6. 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 failure or a loss of memory Contact the factory Review parameters An option card error indicating a programming failure or a loss of memory Contact the factory Staring time must exceed current time This message appears when in the LOG menu STD option Enter a start time that is later than the current time Write error 20 An option card error indicating a programming failure or a loss of memory Contact the factory DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 3 Diagnostics Chapter 3 Diagnostics 3 1 Introduction This chapter explains how to troubleshoot the Model DF868 if problems arise with the electronics console the flowcell or the transducers Indications of a possible problem include display of an error message on the active display screen e erratic flow readings readings of doubtful accuracy i e readings that are not consistent with readings from another flow measuring device connected to the same process If any of the above conditions occurs proceed with the instructions presented in this chapter 3 2 Displaying Diagnostic Parameters The Model DF868 has a built in Diagnostics Menu to aid in the troubleshooting of flowcell
7. Chapter 4 Parts Replacement 4 5 Installing an Option Card cont 3 There are six 32 pin option card sockets J41 J46 on the rear of the printed circuit board To install an option card insert its 32 pin connector into any available 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 connector is positioned on the right side of the option card CAUTION Do notforce the option card into the socket If the card does not enter the socket easily check for and straighten any bent pins in the connector and try again 4 Repeat step 3 to install any additional option cards 5 Place the metal bracket over the option cards making sure that all option cards are aligned with the plastic card guides in the bracket Secure the metal bracket to the printed circuit board with the snap rivets provided See the installed assembly in Figure 8 on page 35 Complete the option card installation by proceeding to Installing the Printed Circuit Board on page 32 4 6 Replacing the LCD Display The Model DF868 s measurements are displayed on a a two pane LCD graphic display panel The LCD display normally provides years of dependable service but it is easily field replaceable when necessary To replace 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 desc
8. Fx represent function keys to select option bar choices Figure 6 Calibration Menu Map DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 13 Chapter 2 Error Codes and Screen Messages Chapter 2 Error Codes and Screen Messages 2 1 Introduction The Model DF868 ultrasonic flowmeter is a reliable easy to maintain instrument When properly installed and operated as described in the Startup Guide the meter provides accurate flow rate measurements with minimal user intervention However if a problem should arise with the electronics console the transducers or the flowcell a built in error code message system greatly simplifies 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 Prompt Area Locator Bar Pointer Velocity 6 95 Chi E1 Low Signal Option Bar Error Message Figure 7 A Typical Display Screen Note Fora 2 Channel Model DF868 the channel number is displayed in front of the error message Only the error message appears with a 1 Channel Model DFS amp 68 If an
9. 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 Ch1 label SENE Press the or keys until the desired channel option appears on the option Velocity Ft s bar Press the appropriate Fx key to select this option 6 95 error codes appear here CH1 J cHe J sum oF Note Fora I Channel Model DF868 the above prompt does not appear and the following prompt is the initial screen Ch1 label PSIE Press the or keys until DIAG appears on the option bar Press the Velocity Ft s appropriate Fx key to select this option 6 95 error codes appear here TIME Di c Note Chl or Ch2 which is shown in parentheses above appears in the locator bar only with a 2 Channel Model DF868 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 21 Chapter 3 Diagnostics 3 2 Displaying Diagnostic Parameters cont For example pressing F1 displays the Tdown parameter as shown in the following prompt Ch1 label MEN Press the and keys and the appropriate Fx key to display a different Ch1 DN Transit usec diagnostic parameter or to EXIT the Diagnostics Menu 019 7 error codes appear here Tdown DELTA SA Qup Table 3 below l
10. Action Select larger measurement units or a shorter time interval for the current measurement parameter For example choose KSCF M instead of SCF M See the Startup Guide for instructions E14 Totals Overflow Problem Cause Action 18 The totalizers are unable to keep up with the total flow signals The programmed units pulse value is too small Select a larger number of units pulse value DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 2 Error Codes and Screen Messages 2 5 Screen Messages A variety of messages may appear on the display screen during the performance of a task Since the error codes have already been discussed in this chapter and the locator bar messages are discussed in detail in Chapter 3 Operation of the Startup Guide they will not be repeated here All other messages are listed in Table 2 below Table 2 Screen Messages C CN NNNM ONE Backup Battery FAIL Power Up Messages he backup battery that powers the non volatile RAM has failed Contact the factory Backup Battery OK The backup battery that powers the non volatile RAM has passed DSP Processor OK DSP RAM Failed he DSP digital signal processor has passed he DSP digital signal processor RAM has failed Contact the factory DSP RAM OK he DSP digital signal processor RAM has passed EPROM sum XXXX FRIGID_INIT Executed Record the EPROM sum at initial power up and p
11. C RA 31 R placing 2245 tng Ses ey eS dU dtekE PES 31 Display Screen iesse tane oy eee REPRE RS 15 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Index E EPROM Replacing este sce pe Ses QE RR EX RS 30 User Program ssi ses AA eiui eva oae a 30 Error Codes veo oan eer eR REA 16 17 18 Error Message Display Screen 15 Expansions los es eam aree rn P PISA IER eae ees 1 F Flowcell Problems A Boke Recah ws Saosin UR TEE Seen 24 Piper AA A ba rd ids 25 Fluid Problems 528 dead 24 Fuse Replacement uns save sed C SEES CIN 28 G Gas CONAN ALIE cz oe y SOS aun a eg e 24 Physical Requirements 04 24 Soundspeed ipsi cards ie DR AE aG 24 Grounding Strap ys 5e eto vedete veh 32 Guides Option Card 31 Incoherent Signal Error E12 18 Information Paragraphs lt Lu ove RIS ae ERE vii K Keypad Cable cua e rue X RU 20 L EGDSIDISBISV dedu eMe dau c un 21 Leaks Transducers 1 0 0 0 0 ccc eee eee 25 Low Signal Error El 0 2 2 2 0 000 0000s 16 EVD Siatemelil v Gand oe SA ere en ao ode 27 N No Error BO seio he eri Gey dias kanes 16 Numer Option for RTD Option Card 8 51 Index O Option Card Brackets t vrar taaan Suv v de A aA 30 A A ou eS eis etat ai bs 1 Guides yu Sect eh Ree ec Miers hada Pad 31 Installing i osa unr ean CARLA EP Ex 30 Sockets 3 vases te CE SUR Ud epu e 31 Outline Bench Mount 0 0 00 cece eee ees 3
12. already installed remove the four fasteners that secure the metal bracket to the printed circuit board Lift the metal bracket straight up and away from the printed circuit board Note The fasteners may be either plastic snap rivets or metal hardware in some older meters In either case they may be discarded as new plastic snap rivets are provided 3 There are six 32 pin option card sockets J41 J46 on the rear of the printed circuit board By removing the screw on the rear 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 positioned in the opening on the rear panel CAUTION Do not force the option card into the socket If the card does not enter the socket easily check for and straighten any bent pins in the connector and try again 5 Repeat steps 3 and 4 to install any additional option cards 6 Place the metal bracket over the option cards making sure that all installed option cards are inserted into the plastic card guides in the bracket The bracket must be oriented so that the six card guides are directly above the six sockets on the printed circuit board do not install the bracket rota
13. error message appears on the display screen during operation of the Model DF868 refer to the appropriate section of this chapter for instructions on how to proceed DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 15 Chapter 2 Error Codes and Screen Messages 2 2 Error Codes E0 No Error Problem No error condition currently exists Cause This message appears briefly to confirm that the response to another error message has corrected the problem Action No action is required E1 Low Signal Problem Poor ultrasonic signal strength or the signal exceeds the limits entered via the User Program Cause Poor signal strength may be caused by a defective cable a flowcell problem a defective transducer or a problem in the electronics console A signal that exceeds the programmed limits is probably caused by the entry of an improper value in the SETUP SIGNL submenu of the User Program Action Using the procedures in Chapter 3 Diagnostics check the components listed above Also check the value programmed into the SETUP SIGNL submenu as described in the Programming Manual page 1 31 for the 1 channel DF868 or page 1 25 for the 2 channel DF868 E2 Sound Speed Error Problem The sound speed exceeds the limits programmed in the SETUP SIGNL submenu of the User Program Cause The error may be caused by incorrect programming poor flow conditions or poor transducer spacing Action Compare the measured sou
14. guide Terminal Block Option Card Frequency Counter 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 respectively 1 7 2 Entering Frequency 4 Entera new frequency in the range of 1 10 000 Hz and press the ENT key Verify that the frequency counter reads the correct value DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 11 Chapter 1 Calibration 1 7 3 Entering Pulse Number 5 Enter the number of pulses desired between 1 and 10 000 and press the ENT key That number of pulses will then 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 Calibration Menu press EXIT twice 12 DigitalFlow Multipurpose Ultras
15. message appears when in the LOG menu Enter an end time that is at least five minutes later than the start time Header invalid Log Active END only hit any key An option card error indicating a programming failure or a loss of memory Contact the factory When in the LOG menu this message indicates that the log is still compiling data Only the End Time may be edited Log DONE When in the LOG menu this message indicates that the log is complete Hit any key to display to inspect hit any key the log DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 19 Chapter 2 Error Codes and Screen Messages Table 2 Screen Messages EN RSEN HN Log hasn t started hit key When in the LOG menu this message indicates that the log has not yet started OK settling The measurement has not stabilized Wait before taking a reading Outside limits value rejected When in the CAL menu this message indicates that the calibration of the analog output is invalid Hit any key to clear the message and the DF868 will default to the last valid calibration The message will also appear if there is no ammeter connected to the analog output during calibration Overflow The display value overflowed 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
16. nnn cece ene ea 3 1 3 3 Calibrating the High End of the QUIERES ec tes en debi obe te te tern 4 1 35 45 Testingth Analog QUEUE Lihiedtby o set ted ost uda te tt a e e cte Mete eds 4 Calibrating the Analog put vse acai beide to fone Peleo Fade aed o D Ead Ral eeu RIDE ASTE 5 T 41 Accessing The CAMA Ml t IRE bot pde 6 1 4 2 ALWAYS LN tcd eese etd ue Pd cid cast heeled me Mie vr HOdeq Se ory 6 145 OIGA Opos oar Sete RR a eb ten Du tento e O 6 quA AMA UPON Ae n hri tub e tre ee pets Dele d ie LU tA ad 6 15 20 MA CODITOR s Uc 4 A moo meat eia Ree ALR Eee Oe P ERR DU T RIA eo Ns e 6 Calibrating tbe STD THUS e ERN EUNDO eb in 8 1 5 1 Accessing th Calibration Mem cure 5040 Deb dense QuwiG o 8 A LOW Option SEU Weis cept oa o A Ba Td e le ol al a a Se 8 T53 pli oC UOMO ont eon aid dide Ree AA A ta io RR eo TA BR CORE 8 AS oido o REI EE REN 9 1 6 1 ACCESO Tie calibration M BOE sa oett ut esa toes eed eS CER ERU det aad ba Bes tne 9 L52 Testing tie AlarmmiReldyss Socr a rh booed S ede eee ddd eee 10 Tot lizer Freg eney O e tot nak 11 1 7 1 Accessing the Calibration MEET a accio pror ir ctn a oae Ee lee EE EEEE EE ORAE RP ERE 11 1572 EnteningiF rede ies siet t toU ne o RR atto etie Et e el E D TUER 11 1737 Unten Pulse NUmbGE scs ote A vtae Bare eta e abu eo D OR etc eh E 12 Chapter 2 Error Codes and Screen Messages requise ca A A AA eae 15 Error CodeS A A REDE MS 16 Screen Messi A AA Oe A II tae A eae dad Dp qan dear ee 19
17. on the pipe wall will not cause problems Loose scale and thick coatings such as tar or oil will interfere with ultrasound transmission and may result in incorrect or unreliable measurements 3 5 Transducer Problems Ultrasonic transducers are rugged reliable devices However they are subject to physical damage from mishandling and chemical attack Clamp on transducers are also subject to installation variables such as physical misalignment and faulty coupling to the pipe on which they are mounted Because transducer problems are largely dependent on the type of transducers used wetted or clamp on the following list of potential problems is grouped according to transducer type Contact the factory if you cannot solve a transducer related problem 3 5 1 Wetted Transducer Problems 1 LEAKS Leaks may occur around the transducer and or the flowcell fittings Repair such leaks immediately If the leaking fluid is corrosive carefully check the transducer and cables for damage after the leak has been repaired 2 CORROSION DAMAGE If the transducer material was not properly chosen for the intended application the transducers may suffer corrosion damage The damage usually occurs either at the electrical connector or on the transducer face If corrosion is suspected remove the transducer from the flowcell and carefully inspect the electrical connector and the transducer face for roughness and or pitting Any transducer damaged in this manner mu
18. 6 Rack Mount essere 35 49 Over Range Error El3 o o oo oooooo o 18 P Pipe Measurements sees hh 25 Problems cided det des ELE be as 25 Poor Signal Error E11 vou neg eene Read 18 Printed Circuit Board EPROM 100 JR ONG a OSS Ba A 30 Replica as al es oC heel A cO MET 29 Problems Plowc ll uc So Ges e ex 24 O Cae Rd 25 TransduCers see ie D reden S 25 R Rack Mount Dimensions es emere eto is 35 49 OTI MP 35 49 Reboot Automatic l l 1 Replacing See Part Name R tu rn Policy acoge set pe ad woe wap ee ik 51 RTD Option Card Calibrating 8 S Safety Auxiliary Equipment sir vil General Issues ooooooooooooooo vii Personal Equipment 00000 eee vii Screen Messages Table o ooooo o 19 Service Record oooooooooooooo 37 52 S cont Shroud AI s Leer Sce o eV eoe En 27 32 LCD Disp os ovatis eva ka E 31 ENV Die eo Pt EORR a tease 32 Plastic il 32 Signal Quality Error EA 0 04004 a 16 Sockets Option Cards eese t OR eT 31 Soundspeed Errors 25 uiu eui e Mu tag E td aa 16 GS rock rad tes 24 Spare Parts List cse ciccate RA e ER IA ts 33 Special Input By 5 5 ts ev orte pus 17 T Temperature Input Return Error EB 17 Temperature Input Supply Error ES 17 Totalizer Frequency Option Card Testing 11 Totals Overflow Error El4 o oo oooo 18 Transducers COMOSION 00 rs aia 25 Internal Da
19. Card Ammeter Figure 2 Ammeter Connection Output A 1 Press the CAL key to enter the Calibration Program 2 Press FX to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press FX to select the desired output IMPORTANT The procedure for calibrating all outputs is the same However when calibrating a different output 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 press ENT 3 Press F4 to STORE the setting or press and F1 to ABORT the calibration Note If the ammeter reading cannot be adjusted within 5 0 uA of the 4 mA setting contact the factory for assistance DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 3 Chapter 1 Calibration 1 3 3 Calibrating the High End of the Output Range 1 Press F2 to calibrate the high end of the output range 2 Press F1 or F2 to adjust the ammeter reading UP or DOWN until a 20 mA reading is achieved If you press F3 Numer ente
20. GE Measurement amp Control Solutions Flow DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual f k 910 1765 Rev E Imagination at wor March 2011 GE Measurement amp Control Solutions DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual 910 176S Rev E March 2011 WWW ge mcs com 2011 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page proceed to next page Preface 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 e 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 Itis 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 m
21. NDSP Tup Tdown DELTA Reynolds K RE PEAK THETA Qup Qdown AMPup AMPdn available only for Clamp on transducers available only if Energy ON DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 39 Appendix A no content intended for this page 40 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Appendix B Optional Enclosures Appendix B Optional Enclosures B 1 Introduction The Model DF868 is available in optional enclosure types each of which has been designed to permit easy on site upgrades and parts replacement See the foldout drawings at the end of this appendix for details of the applicable DF868 electronics console assembly The instructions in this appendix along with a few common tools are all that is required to perform the following tasks fuse replacement option card installation e EPROM replacement LCD display replacement e printed circuit board PCB replacement IMPORTANT For meters supplied in the standard Type 4X enclosure see Chapter 4 Parts Replacement for instructions 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 de
22. andoffs 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 these two locations 6 Carefully lift the printed circuit board out of the enclosure Continue to support the printed circuit board as the keypad and display cables are still connected to the rear of the board CAUTION During this procedure be very careful not to damage the upright components along the top edge of the printed circuit board see Figure 9 on page 36 Severe or repeated bending will break the component leads 7 Tilt the top of the printed circuit board forward and mark the top edges of the two ribbon cable connectors Then remove these cables from their connectors on the rear of the board 8 The printed circuit board is now free and may be removed to a clean work area If the printed circuit board is being replaced proceed to the section on Installing the Printed Circuit Board page 32 now Otherwise refer to the appropriate section for instructions on nstalling an Option Card page 30 Replacing the EPROM below or Replacing the LCD Display page 31 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 29 Chapter 4 Parts Replacement 4 4 Replacing the EPROM The Model DF868 s User Program is stored on an er
23. anty no content intended for this page 54 DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual M DECLARATION Sensing OF CONFORMITY DOC 0013 Rev A We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the DigitalFlow DF8688 Liquid Ultrasonic Flowmeter DigitalFlow GC868 Clamp On Gas Ultrasonic Flowmeter DigitalFlow GF868 Flare Gas Mass Ultrasonic Flowmeter DigitalFlow GM868 General Purpose Gas Ultrasonic Flowmeter DigitalFlow GS868 Steam Mass Ultrasonic Flowmeter to which this declaration relates are in conformity with the following standards e EN 60079 0 2007 EN 60079 1 2004 e EN50281 1 1 1998 e 2 G EExd IIC T6 ISSePO3ATEX113 ISSeP B7340 Colfontaine Belgium NoBo 492 e EN 61326 1 2006 Class A Table 2 Industrial Locations e EN 61326 2 3 2006 EN 61010 1 2001 Overvoltage Category II Pollution Degree 2 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 has determined that technical knowledge is unaffected by the current harmonized standards listed above The unit listed above and any ancillary
24. ard Model DF868 Printed Circuit Board Assembly DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 36 Appendix A Service Record Appendix A Service Record A 1 Introduction Whenever any service procedure is performed on the 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 Description of Service Performed By DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 37 Appendix A Service Record Aa ee eun D RO ume Ecce I UE LLLLLLLLLUU SSS B MMMPPPPPPPPPPPPUPPEEEEEEUUUuuuuuuuuuuuu i Table 6 Service Record cont Description of Service Performed By 38 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Appendix A Service Record A 3 Diagnostic Parameters After a successful initial installation of the Model DF868 and whenever any system malfunction 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 SS do S
25. asable programmable read only memory EPROM chip The EPROM which is designated as component U4 is located in the top left corner of the rear of the printed circuit board See Figure 9 on page 36 for a rear view of the printed circuit board EPROM replacement may be required to replace a defective chip or to upgrade to a newer software version To replace the EPROM complete the following steps 1 Remove the printed circuit board as described in a previous section of this chapter 2 Place the printed circuit board face down on a clean flat surface Locate the EPROM socket in the top left corner of the board CAUTION The EPROM is easily damaged by static electricity Before handling the new chip touch a grounded metal object to discharge any built up static electricity and avoid touching the leads on the side of the chip 3 Usinga 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 the upper right and lower left corners of the socket Gently pry the EPROM up a little at a time at each notch until it comes free 4 Make sure that the beveled corner on the new EPROM is aligned with the beveled corner of the socket and place the EPROM into the socket 5 Byapplying 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 r
26. cessary To replace the LCD display refer to Figure 11 on page 50 and complete the following steps WARNING The main power to the Model DF868 must be disconnected before proceeding 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated 2 Using a 3 16 in nutdriver remove the four nut washer sets that secure the display shroud to the inside of the front panel Pull the display shroud off its mounting studs 3 Using a 1 4 nutdriver remove the four standoffs that secure the LCD display assembly to the front panel Pull the LCD display assembly off its mounting studs 4 Place the new display in the enclosure and replace the circuit board connections of the data and power cables of the old display with those of the new display Be sure to orient the new cables in the same way as the old ones when making the 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 assembly may be damaged 6 Position the LCD display cables between the two mounting studs and install the display shroud over the mounting studs The top and bott
27. connecting cable Refer to Chapter 1 Calibration and recalibrate the analog inputs on the option card page 1 6 E10 Weak Signal Problem This message indicates a weak signal Cause The magnitude of the two phase signal is not large enough or the flow rate in the pipe is out of range 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 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 17 Chapter 2 Error Codes and Screen Messages E11 Poor Signal Problem This message indicates a poor signal Cause The shape of the processed signal is not good enough to formulate a flow measurement 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 E12 Incoherent Signal Problem This message indicates an incoherent signal Cause The flow measurements as determined by the two Repetition Periods are too 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
28. cuit board Plug all other electrical connectors into the appropriate sockets on the printed circuit board and option cards See Chapter 1 Installation of the Startup Guide for instructions on proper wiring of the Model DF868 Note Foran LVD compliant meter with the clear plastic shroud over the electrical connectors there are standoffs in the two mounting locations along the bottom edge of the printed circuit board For meters not equipped with this shroud there are Phillips head screws in these two locations 32 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 4 Parts Replacement 4 7 Installing the Printed Circuit Board cont 9 ForLVD compliant units position the clear plastic LVD shroud over the electrical connections so that the two holes in the shroud align with the standoffs on the printed circuit board Secure the shroud to the standoffs with the two sets of screws and washers 10 After carefully checking for and removing any loose hardware in the enclosure close the electronics console and reconnect the main power to the Model DF868 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 of the Model DF868 Before taking measurements with the Model DF868 ref
29. ducers must be replaced in pairs Refer to Chapter 2 Initial Setup of the Startup Guide to program the replacement transducer data into the meter 5 CYCLE SKIP CONDITION A cycle skip is usually caused by a distorted or altered signal due to poor couplant bad wall or unusual fluid disturbances To resolve a cycle skip recouple both transducers with proper couplant Check your couplant for temperature ranges In addition make sure the pipe wall is free of paint and rust Contact the factory if you cannot solve a transducer related problem 26 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 4 Parts Replacement Chapter 4 Parts Replacement 4 1 Introduction The electronics console of the Model DF868 has been designed to permit easy on site upgrades and parts replacement See Figure 8 on page 35 and Figure 9 on page 36 for details of the standard DF868 electronics console assembly The instructions in this chapter along with a few common tools are all that is required to perform the following tasks e fuse replacement printed circuit board PCB removal and installation e EPROM replacement e option card installation LCD display replacement IMPORTANT For meters supplied in any of the optional enclosure types see Appendix B Optional Enclosures for instructions specific to that unit WARNING Prior to performing any maintenance procedures be sure to disconnect the main power from the un
30. eS 37 A 2 Data Entrys S EE E RADI md Dni de do tado IRI MM 37 AS DiagnosticiParameters cons elu icem DAS LV ened ook e ebbe b uer eu Neb ed Deb FE 39 Appendix B Optional Enclosures BT virer o a nee eter ree ts dl dl a E 41 Bie ROCK PGIBITICEBEIBS ME Laie Dales cela dida eia die Mtis Lebe Mr ES iei dri ME 41 B 3 Rack Mount Fuse Replacement sos take ad er a pd er ead 0b ERE pe FERAIS ERG 42 BA v Rack Mount Option Card MStallati N es sssktas sacas o SP ae meme scene ana coment 43 B 5 R ck Mount EPROM Replacement cc52 4 pne OEpULO ERR PD RI a M rarere 44 B 6 Rack Mount LCD Display Replacement or cities Code te hA o t eR C CU E RR I OE 45 B 7 Rack Mount Printed Circuit Board Replacement 5 1x ure p itat et ite t aree dtc s 46 B 7 1 Circuit Board Removal us o eee eee ORR ets ette tete Lr RN tK ese Lud eT 46 Bro Gcultbogdradinstalloliois eoe catu cete aestuat eras aaa etin olds Cu te ere eee ae 47 vi DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 1 Calibration Chapter 1 Calibration 1 1 Introduction Calibrating the Model DF868 s analog outputs and inputs is explained in this chapter In addition testing the optional totalizer frequency and alarm relay outputs is discussed The following specific topics are included calibrating the built in Slot 0 analog outputs calibrating optional Slot 1 through Slot 6 analog outputs calibrating optional Slot 1 through Slot 6 analog inputs e te
31. eam transducer 400 to 400 UP Amp Discrim Displays the value for the amplitude discriminator of lt 19 or gt 29 upstream transducer DN Amp Discrim Displays the value for the amplitude discriminator of the 19 or gt 29 downstream transducer Counts up Displays automatic gain control setting for the A N A upstream signal CNTdn Counts down Displays automatic gain control setting for the downstream signal 22 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 3 Diagnostics Table 3 Available Diagnostic Parameters cont Option Bar Screen Display Description UP Peak Displays signal peaks for the upstream transducer 100 2300 DN Peak Displays signal peaks for the downstream transducer 100 2300 UP Norm Factor Displays the normalization factor for the upstream 0 85 1 0 transducer DN Norm Factor Displays the normalization factor for the downstream 0 85 1 0 transducer CEE1 Displays the speed of sound in the transducer N A clamp on only Supply Temp deg F Displays the temperature for the supply input energy N A measurement Return Temp deg F Displays the temperature for the return input energy N A measurement Supply Rtn Difference between supply input and return input N A measurement energy measurement Supply Dens Displays the density for the supply input energy N A management Retur
32. efore handling the new chip touch a grounded metal object to discharge any built up static electricity and avoid touching the leads on the side of the chip 2 Usinga 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 corner on the new EPROM is aligned with the beveled corner of the socket and place the EPROM into the socket 4 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 5 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model DF868 flowmeter may now be placed back into service Reconnect the main power and resume taking measurements Note Be sure to record the EPROM replacement in Appendix A Service Record 44 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Appendix B Optional Enclosures B 6 Rack Mount LCD Display Replacement The Model DF868 measurements are displayed on a two pane LCD graphic display panel The LCD display normally provides years of dependable service but it is field replaceable when ne
33. en the transducer and the pipe and must be firmly coupled or bonded to both the pipe and the transducer The pipe and transducer must be clean and dry for permanent couplant such as grease or epoxy to adhere properly Enough pressure 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 Also be sure that the transducer spacing agrees with the calculated spacing S 3 INTERNAL DAMAGE Ultrasonic transducers consist of a ceramic crystal bonded to the transducer case The bond between the crystal and the case may be damaged by extreme shock and by temperature extremes The crystal itself can also be damaged by the same conditions The internal wiring can be corroded or shorted if contaminants enter the transducer housing 4 PHYSICAL DAMAGE Transducers may be physically damaged by dropping them onto a hard surface or striking them against another object Usually the connector on the transducers is the part that is damaged as it is the most fragile Minor damage may be repaired by carefully bending the connector back into shape If the connector cannot be repaired replace the transducers IMPORTANT Trans
34. eplacement 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 displays a message Slot x Params appended This message directs users to check the slot error handling on the option cards and appears on power up until you review the parameters in the I O submenu OPTN option 4 5 Installing an Option Card The Model DF868 flowmeter can accommodate up to six option cards The option cards are installed into sockets on the rear of the printed circuit board and they are held in place with a metal bracket A single metal bracket is used to secure all the installed option cards Note If the Model DF868 presently has no option cards installed be sure to purchase the metal mounting bracket along with the first option card To install an option card refer to Figure 9 on page 36 and complete the following steps 1 Remove the printed circuit board as described on page 29 2 Ifone or more option cards are already installed remove the four fasteners that secure the metal bracket to the printed circuit board Lift the metal bracket straight up and away from the printed circuit board Note The fasteners may be either plastic snap rivets or metal hardware in some older meters In either case they may be discarded as new plastic snap rivets are provided 30 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual
35. equipment supplied with it do not bear CE marking for the Pressure Equipment Directive as they are supplied in accordance with Article 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN 25 A A Perf pid i Billerica August 2010 Issued Mr Gary Kozinski Certification amp Standards Lead Engineer e CE TUV 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 4353 61 61470291 E mail gesensingsnnservices ge com An ISO 9001 2008 Certified Company www ge mcs com en about us quality html 910 176S Rev E www ge mcs com 2011 General Electric Company All rights reserved Technical content subject to change without notice
36. er to Chapter 2 Initial Setup of the Startup Guide and Chapter 1 Calibration of this Service Manual for instructions on setting up the meter for accurate flow rate measurements Note Be sure to enter a complete and detailed 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 Table 5 Spare Parts List Part Number Description Part Number Description 703 1127 02 Option Card Alarms Hermetically Sealed 417 027 Card Guide Nylon 703 1127 03 Option Card Alarms General Purpose 703 1247 Printed Circuit Board 703 1145 02 703 1126 02 Option Card Analog Inputs Option Card Analog Outputs 705 671 147 744 LCD Display Assembly EPROM 703 1145 03 Option Card RTD Inputs 421 700 Conduit Plate 1 2 703 1144 02 Option Card Totalizer Frequency Outputs 421 701 Conduit Plate 3 4 703 1358 Option Card MODBUS 421 702 Conduit Plate Blank 703 1476 02 Option Card Ethernet Only 421 946 LVD Plastic Shroud 703 1476 05 703 1476 10 Option Card MODBUS over Ethernet Option Card MODBUS over WI FI 421 686 Main Aluminum Shroud 421 703 purchase Card Cage Metal Brac
37. eriodically thereafter The NVR non volatile RAM was automatically initialized due to a memory fault Contact the factory NVR FAIL he non volatile RAM has failed Contact the factory NVR OK All Logs Cleared hit key The non volatile RAM has passed Measurement Mode Messages This message may appear during one of the following tasks 1 clearing 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 Do you want to SAVE This message may appear during one of the following tasks 1 saving a new site a new site name was not entered or overwrite existing site was not selected recalling a site there are no site files to recall clearing a site there are no sites to delete printing a site there are no sites to print displaying a site there are no sites to display Hit any key to resume taking measurements This message appears upon exiting the User Program if the new site data has not been saved Failure to save will result in loss of the new data next time the site data is changed or recalled Duplicate name Enter another The site file or log name is already in use Enter a different name End Time must exceed Start Time by 5 min This
38. et 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 DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual iii Preface Environmental Compliance Waste Electrical and Electronic Equipment WEEE Directive GE Measurement amp Control Solutions is an active participant in Europe s Waste Electrical and Electr
39. he User Program Cause Excessive levels of an attenuating gas such as CO are present in the flowcell Solid or liquid particulates may be present in the flowcell Action Refer to Chapter 3 Diagnostics to correct any flowcell problems page 3 5 E6 Cycle Skip Accel Problem The acceleration exceeds the limits programmed in the SETUP submenu of the User Program Cause This condition is usually caused by poor flow conditions or improper transducer spacing Action Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems pages 3 5 to 3 8 E7 Special Input Problem This message indicates a 4 20 mA input programmed for a special diagnostic is out of valid input range Cause Bad connection between 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 Chapter 1 Calibration and recalibrate the analog inputs on the option card page 1 6 E9 Temp In Return Problem This message indicates a temperature input return error Cause The temperature exceeds the specified limits for the analog inputs option card Action Check the pressure transmitter and the
40. ing warranties or merchantability and 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 service GE Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Sensing instructs you to send your instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 3 Upon receipt GE Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken e Ifthe damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e If GE Sensing determines that the damage is not covered under the terms of the warranty or if the warranty has expired an estimate for the cost of the repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual 53 Warr
41. ists the available diagnostic parameters for the Model DF868 The first column in the table shows the parameter as it appears on the option bar while the second column shows the parameter as it appears in the prompt area after it has been selected Table 3 Available Diagnostic Parameters Option Bar Screen Display Description UP Sig Strength Displays signal strength for the upstream transducer lt 50 or gt 75 DN Sig Strength Displays signal strength for the downstream transducer 50 or 75 Soundspeed Ft s Displays the measured sound speed of the fluid A N A UP Transit S usec Displays the upstream transit time of the ultrasonic A N A signal in microseconds DN Transit usec Displays downstream transit time of the ultrasonic A N A signal in microseconds DeltaT usec Displays the difference in usec between upstream and A gt 10 000 downstream transit times nsec REYN Reynolds A number based on the kinematic viscosity and flow rate of the fluid K RE K RE K factor based on Reynolds number PEAK PEAK Displays the percentage of peak set to 50 by default Theta 3 degrees Theta 3 is the angle between the ultrasonic beam and the normal to pipe wall It is calculated from the measured transit time and clamp on parameters clamp ons only UP Signal Q Displays the signal quality for the upstream transducer S 400 to 400 DN Signal Q Displays signal quality for the downstr
42. it 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 of the Model DF868 An aluminum shroud over the printed circuit board shields the electrical components and serves as a location for the wiring diagram label All of the procedures discussed in this chapter except for fuse replacement require removal of this shroud Note For compliance with the European Union s Low Voltage Directive 73 23 EEC a transparent plastic shroud protects the electrical connections The shroud must remain in place except while wiring the unit Reinstall the shroud after the wiring has been completed Use the foldout drawings at the end of this chapter to locate the relevant components while completing the following procedures IMPORTANT Keep a detailed record all service procedures performed on the Model DF868 in Appendix A Service Record This service history may prove very helpful in diagnosing any future problems DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 27 Chapter 4 Parts Replacement 4 2 Fuse Replacement If it has been determined that the fuse in the Model DF868 requires replacement complete the following steps WARNING The main power to the Model DF868 must be disconnected bef
43. ket DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 442 484 Label Wiring Diagram To purchase the parts listed in Table 5 above or any items not listed in the table contact the factory for assistance To make sure the proper components are obtained be sure to specify the serial number of the Model DF868 at the time of 33 Chapter 4 Parts Replacement no content intended for this page 34 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 4 Parts Replacement FRONT VIEW Keypad Cable Display Cable Mounting Screw 8 places Main Shroud n _ Optional WI FI Antenna Nut amp Washer AS L 4 places Display Shroud Backlight Cable LVD Shroud Cover Ground Wire Internal Ground Connection PC Board gt Power Ground Wire Fuse Holder Connector Option Cards Fuse Holder Cap Card Guide Metal Bracket BOTTOM VIEW
44. le 8 below and on the rear panel label Table 8 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 100 120 VAC 1 0 A Slo Blo 220 240 VAC 0 5 A Slo Blo 12 28 VDC 3 0 A Slo Blo 4 Reinstall the black plastic fuse cover and insert the power cord back into the receptacle Then position the power switch in the ON position The Model DF868 flowmeter may now be placed back into service Reconnect the main power and resume taking measurements Note Be sure to record the fuse replacement in Appendix A Service Record 42 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Appendix B Optional Enclosures B 4 Rack Mount Option Card Installation The Model DF868 flowmeter can accommodate up to six option cards in a manner similar to that used in a PC The option cards are installed into sockets on the printed circuit board and they are held in place with a metal bracket A single metal bracket is used to secure all the installed option cards Note Jf the Model DF868 presently has no option cards installed be sure to purchase the metal mounting bracket along with the first option card Refer to Figure 11 on page 50 and complete the following steps 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated WARNING The main power to the Model DF868 must be disconnected before proceeding 2 If one or more option cards are
45. mage 06m VS EVEN 26 Led A E bei uu E ees 25 Physical Damage V ca sa a ae wares xS 26 Placement 55 V nrg cec RR EN Ade XT 25 Problems da de da eod due do 25 U User Program ERPOM Pt lts sv 30 Upgrading s peu qu E eased REP ERG Iu 30 V Velocity Range Error E3 ooooo 16 W NATA cups Ss Sor e e orte e Ett 53 Weak Signal Error E10 o oooooooo o 17 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Warranty Warranty Each instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period is one year from delivery for electronic or mechanical failures one year from delivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied includ
46. n Dens Displays the density for the return input energy N A management Delta h Displays the delta enthalpy which is the difference N A between the supply and return Enthalpy is a measure of energy contained in the fluid energy measurement Transmit Wedge Displays the current adjustment in transit time measurements due to signal delay in transducers 3 3 Diagnostic Record Upon leaving the Diagnostic Menu via the EXIT key or the EXIT option on the option bar the display screen will continue to show the last diagnostic parameter that was selected To return to normal measurement mode select a channel to display for a 2 Channel meter only and then select the desired display parameter See Chapter 3 Operation of the Startup Guide for detailed instructions The values for the diagnostic parameters immediately after initial installation of the meter and verification of proper operation should be entered in Table 7 on page 39 These values can then be compared to future values to help diagnose any future malfunction of the system DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 23 Chapter 3 Diagnostics 3 4 Flowcell Problems If preliminary troubleshooting with the Error Code Messages and or the Diagnostic Menu indicates a possible flowcell problem proceed with this section Flowcell problems fall into two categories e liquid problems pipe problems Read the followi
47. nd 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 SETUP submenu of the User Program Cause This error may be caused by the entry of improper programming data or by poor flow conditions and or excessive turbulence Action Make sure the actual flow rate is within the programmed limits See the Programming Manual for details Refer to Chapter 3 Diagnostics to correct any flowcell and or transducer problems pages 3 5 to 3 8 E4 Signal Quality Problem The signal quality is outside the limits programmed in the SETUP submenu of the User Program Cause Too high a signal strength may be caused by the failure of an electronic component Too low a signal strength may be caused by a flowcell or electrical problem Action Check for sources of electrical interference and verify the integrity of the electronics console by temporarily substituting a test flowcell that is known to be good Check the transducers and relocate them if necessary See Chapter 3 Diagnostics for instructions 16 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 2 Error Codes and Screen Messages E5 Amplitude Error Problem The signal amplitude exceeds the limits programmed in the SETUP submenu of t
48. ng sections carefully to determine 1f the problem is indeed related to the flowcell If the instructions in this section fail to resolve the problem contact the factory for assistance 3 4 1 Fluid Problems Most fluid related problems result from a failure to observe the flowmeter system installation instructions as described in the Startup Guide Refer to Chapter 1 Installation of the Startup Guide to correct any installation problems If the physical installation of the system meets the recommended specifications it is possible that the fluid itself may be preventing accurate flow rate measurements The fluid being measured must meet the following requirements 1 The fluid must be homogeneous single phase and relatively clean Although a low level of entrained particles may have little effect on the operation of the Model DF868 excessive amounts of 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 the flowcell This causes problems resulting from gas bubbles in the fluid Cavitation can usually be controlled through proper installation design 3 The fluid must not excessively attenuate ultras
49. nto service Reconnect the main power and resume taking measurements Note Be sure to record the fuse replacement in Appendix A Service Record 28 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 4 Parts Replacement 4 3 Removing the Printed Circuit Board All of the remaining maintenance procedures discussed in this chapter require removal of the printed circuit board Refer to Figure 8 on page 35 and Figure 9 on page 36 while completing the following tasks 1 Remove the main power to the electronics console WARNING The main power to the Model DF868 must be disconnected before proceeding 2 Open the electronics console For LVD compliant units remove the two mounting screws and lift the clear plastic shroud out of the electronics console Remove the six mounting screws and lift the main aluminum shroud out of the electronics console 3 Disconnect the main power leads and the PC board ground wire from terminal block TB1 on the PC board Remove the electrical connectors from all installed option cards and terminal blocks Disconnect the twisted pair display backlight cable from connector J2 on the left side of the PC board 4 Using a 3 8 in nutdriver or open end wrench remove the three short standoffs along the left side of the main circuit board and the three long standoffs along the right side of the main circuit board 5 While supporting the printed circuit board remove the two screws or st
50. om edges of the shroud are bent at a 90 angle to the main surface and these edges must face inwards toward the display assembly Note One edge of the display shroud is covered with a piece of black electrical tape This side of the shroud should be over the cables to protect them against abrasion 7 Fasten the display shroud to the front panel with the four sets of nuts washers CAUTION Do not overtighten the nuts or damage to the mounting threads may occur 8 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model DF868 flowmeter may now be placed back into service Reconnect the main power and resume taking measurements Note Be sure to record the LCD Display replacement in Appendix A Service Record DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 45 Appendix B Optional Enclosures B 7 Rack Mount Printed Circuit Board Replacement If troubleshooting procedures have indicated a defective printed circuit board follow the instructions in this section to replace the defective board with a new one B 7 1 Circuit Board Removal Refer to Figure 11 on page 50 and complete the following steps 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated WARNING The main power to the Model DF868 mus
51. onic Equipment WEEB 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 http www ge mcs com en about us environmental health and safety 1741 weee reg html for take back instructions and more information about this initiative iv DigitalFlow DF868 Multipurpose Ultrasonic Liquid Flowmeter Service Manual Contents Chapter 1 Calibration 11 1 2 1 5 1 4 1 5 1 6 1 7 2 1 2 2 2 3 cidvelslESi al ewes c tht ae ee eke See Te ete ne Cae SES STMT ELIS ae D I CA Re M CE 1 MEN Dee ies Me Erde re atm ELM e LE Oe a Ae Dia teat adc An Pts Nal 1 Calibrating the Analog Outputs area Ion eo Vete Slo tfl etie rte CON ECRIRE CE ARUL RAS 2 1 34L Aecessina tie Calibration Menu s ep A o lid 3 1 3 2 Calibrating the Low End of the Output Range 0 6 cece
52. onic Liquid Flowmeter Service Manual Chapter 1 Calibration CAL Cal F1 F2 F3 F4 F1 F2 F3 stoto sLor store stots stor4 sLors store Slot x Option Card Slot 0 Outputs TB 1 0 Slot x Inputs Analog Inputs Slot x Outputs Alarms F1 F2 F1 F2 F1 F2 F3 a lt a B gt 8 Ca a Ce ANALOG OUTPUT ANALOG INPUT ALARMS Fr F2 F3 F4 F1 F2 F3 F4 F1 Fi F2 F3 4m 20mA TEST EXIT J aow aHiGH 4mA 20ma ExT Lose open ex Full Scale CALIBRATING LOW REFERENCE HIGH REFERENCE A ES ES LOW REF HIGH REF CALIBRATING Cue pown srore fasort F1 F2 F3 F4 STORE ABORT STORE ABORT Slot x Outputs Analog Outputs Slot x Inputs RTD Inputs Slot x Outputs Freq Total F1 F2 F3 F4 F1 F2 F1 F2 F3 F4 C2 e C CAJ eB a C8 9 o ANALOG OUTPUT ANALOG INPUT FREQUENCY F1 F2 F3 F4 Fi F2 F1 a n PULSES ama 20ma resT exit aow aHiGH exit Full Scale GALIBHATING LOW REFERENCE HIGH REFERENCE F1 F2 F3 F4 LOW REF HIGH REF S SAS up Down TorE fasort Fl F2 TORE faBoRT NOTE Plain text represents prompt area messages and sd boxed text represents option bar choices
53. ore proceeding 1 Open the cover on the electronics console For LVD compliant units remove the two mounting screws and lift the clear plastic shroud out of the electronics console 2 Locate the black plastic fuse holder that is mounted on the printed circuit board between the power terminal block TB1 and the RS232 terminal block As shown in Figure 8 on page 35 the fuse holder extends below the main aluminum shroud and the fuse holder cap is located on the bottom of the fuse holder 3 Using a small standard screwdriver turn the 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 Table 4 Line Voltages amp Fuse Ratings Line Voltage Fuse Rating 100 120 VAC 1 0 A Slo Blo 220 240 VAC 0 5 A Slo Blo 12 28 VDC 3 0 A Slo Blo 5 Press the new fuse into the fuse holder cap and insert the fuse into the fuse holder While applying a slight pressure with the screwdriver twist the fuse holder cap 1 4 turn clockwise 6 ForLVD compliant units place the clear plastic shroud over the standoffs in the electronics console and secure it in place with its two mounting screws Close the cover on the electronics console The Model DF868 flowmeter may now be placed back i
54. ound signals Some fluids particularly those that are very viscous readily absorb ultrasound energy In such a case an E1 error code message will appear on the display screen to indicate that the ultrasonic signal strength is insufficient for reliable measurements 4 The fluid sound speed must not vary excessively The Model DF868 will tolerate relatively large changes in the fluid sound speed as may be caused by variations in fluid composition and or temperature However such changes must occur slowly Rapid fluctuations in the fluid sound speed to a value that is considerably different from that programmed into the Model DF868 will result in erratic or inaccurate flow rate readings Refer to Chapter 2 Initial Setup of the Startup Guide and make sure that the appropriate sound speed is programmed into the meter 24 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 3 Diagnostics 3 4 2 Pipe Problems Pipe related problems may result either from a failure to observe the installation instructions as described in the Startup Guide or from improper programming of the meter By far the most common pipe problems are the following 1 The collection of material at the transducer location s Accumulated debris at the transducer location s will interfere with transmission of the ultrasound signals As a result accurate flow rate measurements are not possible Realignment of the flowcell or transducers often cu
55. page 50 Make sure the marked pin 1 sides of the connectors face the right side keypad side of the enclosure Note Jf 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 the main POWER LEADS to the screw terminals at the rear of the printed circuit board When properly installed the lead colors should be green white and black from left to right as viewed from the front of the enclosure 7 Reinstall all option cards as described earlier in this chapter Insert all external option card connectors at the rear panel of the meter 8 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model DF868 flowmeter may now be placed back into service Reconnect the main power and refer to Chapter 2 Initial Setup of the Startup Guide and Chapter 1 Calibration of this Service Manual for instructions on properly setting up the meter for accurate flow rate measurements Note Be sure to record the printed circuit board replacement in Appendix A Service Record DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 47 Appendix B no content intended for this page 48 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Appendix B Optional Enclosu
56. pose Ultrasonic Liquid Flowmeter Service Manual 31 Chapter 4 Parts Replacement 4 7 Installing the Printed Circuit Board Whether the printed circuit board was removed for replacement or for one of the other procedures discussed in this chapter reinstallation of the printed circuit board is the final step in the process Refer to Figure 8 on page 35 and complete the following steps CAUTION During this procedure be very careful not to damage the vertical components along the top edge of the printed circuit board see Figure 9 on page 36 Severe or repeated bending of these components will break their leads 1 Position the printed circuit board within the electronics console with the top edge tilted forward Insert the display ribbon cable and keypad ribbon cable connectors into their sockets on the rear of the printed circuit board See Figure 8 on page 35 and Figure 9 on page 36 to identify the cables and sockets Note that the keypad cable connects to the upper socket and the display cable connects to the lower socket IMPORTANT The ribbon cables must be installed with the edges that were marked during removal oriented toward the top of the printed circuit board 2 Carefully position the printed circuit board up against the eight standoffs in the enclosure Do not damage the transformers and any installed option cards as they are maneuvered between the standoffs 3 Loosely install the three long standoffs on the right side of the p
57. previous page To calibrate test additional slots press F4 EXIT and proceed to the appropriate section To leave the Calibration Menu press F4 EXIT twice DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 7 Chapter 1 Calibration 1 5 Calibrating the RTD Inputs Calibrating an RTD option card involves a slightly different procedure than for other analog input cards However you access the card in the same manner 1 5 1 Accessing the Calibration Menu 1 Press the CAL key to enter the Calibration Program 2 Press Fx to calibrate the desired slot The option bar will include a slot listing for each installed option card 3 Press F1 to select Input A or F2 to select Input B 4 Press F1 F2 to select the reference point to be calibrated Do one of the following If you selected F1 LOW 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 5 HIGH Option F2 8 Enter the high reference value and press the ENT key 9 Press F1 to STORE the current high reference value or press F2 to ABORT the entry In either case the ANALOG INPUT prompt will reappear 10 Proceed to Proced
58. r of Socket Keypad Cable Standoff typical LCD Display Display Shroud Option Card Bracket PCB Mounting Screw typical EPROM U4 Figure 11 Model DF868 Rack Mount Console Assembly ref dwg 705 849 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 50 A Acceleration Error E6 o oooooooo 17 Alarms Option Card Testing oooooo o 9 Amplitude Error s B55 o ooo A V ERA V 17 Analog Inputs Option Card Calibrating 5 Analog Outputs Slot 0 As Calibrated Current Source 3 Calibrating oo huey scooter Ite eene aes 2 Linearity AA e na ER Lone ede 2 Resolutions usu vienaa nE AE EESE SM 2 B Bench Mount Diin nsiolS a wae Ru T E S 36 Outline oes eaka a Pe tee ERE x 36 Bracket Option Card usais x De a 30 C Cable Backlighlit i noie pepe eR EAR 29 32 Display oath sedit eee tiende tu 29 31 Keypad lt lt cad ee eee eek a cen es 29 Calibrating See Parameter Name Calibration Menu Entering 1 Contamination Gas 24 Corrosion Transducers 000 000 cee eee 25 D Diagnostic Parameters EASUBE Sd sore dew Ape ei aret tendra PR rel a 22 Record of Valle e PERO 39 Diagnostics Menu Enterinie secos e andis Ga SM Aes c t us 21 EXi ng Locaciones ok 23 Dimensions Bench Mounts creo ed dex NR ERES 36 Rack Mount vss VES ex ind EVE 35 49 Display Cable tin iiie eie pA EE ER DOR ES 29 LGD cuc Eu pep an AR
59. r the numeric value and press ENT 3 Press F4 to STORE the setting or press and F1 to ABORT the calibration Note If the ammeter reading cannot be adjusted within 5 0 yA of the 20 mA setting contact the factory for assistance 1 3 4 Testing the Analog Output Linearity 1 Press F3 to TEST the linearity of the currently selected analog output 2 Check the ammeter reading at the 50 output level 3 Then enter a different output level 0 100496 and press ENT 4 Check the ammeter reading at this setting Press ENT when done Table 1 below 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 Table 1 Expected Ammeter Readings 96 Full Scale 4 20 mA Scale 0 20 mA Scale All ammeter readings should be 0 005 mA If the linearity test readings are not within 5 uA 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 contact the factory for assistance Procedure Options You have completed calibration of the analog output Do one of the following To calibrate or test another output press F4 EXIT and return to Accessing the Calibration Menu Step 3 page 3 To calibrate test additional slots press F4
60. re is no keypad activity for two minutes the Model DF868 will automatically reboot and return to measurement mode DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 1 Chapter 1 Calibration 1 3 Calibrating the Analog Outputs Every Model DF868 flowmeter includes two built in analog outputs A and B at terminal block I O which is designated as Slot 0 Both the zero point and full scale values for each output must be calibrated After calibrating the outputs which have a resolution of 5 0 uA 0 03 full scale their linearity should be tested Note The zero point 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 Terminal Block I O Slot 0 4 1 B B A A RTN SIG RTN SIG ELI Ammeter Figure 1 Ammeter Connection Output A Press the CAL key to enter the Calibration Program Press F1 to calibrate Slot 0 The option bar will include a slot listing for each installed option card last slot selected Se IS D BUE 2 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 1 Calibration 1 3 1 Accessing the Calibration Menu Terminal Block Option
61. 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 section 1 4 3 aHIGH Option F2 1 Enter the high reference value and press the ENT key 2 Press F1 to store the current high reference value or press F2 to cancel the entry In either case the ANALOG INPUT prompt will reappear 3 Proceed to Procedure Options on page 7 1 44 4mA Option F3 1 Connect the 4 mA current source to the currently selected analog input as shown in Figure 3 on page 5 2 Press F1 to store the current 4 mA value or press F2 to cancel the entry In either case the ANALOG INPUT prompt reappears 3 Press F4 to proceed to the next section 6 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 1 Calibration 1 4 4 Accessing the Calibration Menu cont 1 4 5 20mA Option F4 1 Connect the 20 mA current source to the currently selected analog input as shown in Figure 3 on page 5 2 Press F1 to 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
62. res 4 19 106 x D rege bum qp 97 emen n 7 FIL L ET Mo 9 o e 14 83 377 L 16 99 432 s AA ds Q Ta T i i d e amp 11 82 11 37 289 300 13 13 333 L e e Y n 15 70 399 l 1 5 ODE EEE Ze E 57 133 DEA E DF868 18 25 464 19 00 483 Figure 10 Model DF868 Rack Mount Enclosure Dimensions ref dwg 712 1076 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 49 Appendix B Optional Enclosures Fuse Ground Lead Green Top Panel Mounting Hole 4 places Printed Circuit Board Snap Rivets typical Display Cable Red Lead Backlight Cable Black Lead Nut amp Washers typical Line Lead Black Neutral Lead White Option Card Socket RS232 Connector Power Terminal Block Option Card Slot Cover Analog Output Connector CH1 Transducer Connector CH2 Transducer Connector JJ i S 5 Beveled Corne
63. res such problems and in some cases transducers that protrude into the flow stream may be used Refer to Chapter 1 Installation of the Startup Guide for more details on proper installation practices 2 Inaccurate pipe measurements The accuracy of the flow rate measurements is no better than the accuracy of the programmed pipe dimensions For a flowcell supplied by GE the correct data will be included in the documentation For other flowcells measure the pipe wall thickness and diameter with the same accuracy desired in the flow rate readings Also check the pipe for dents eccentricity weld deformity straightness and other factors that may cause inaccurate readings Refer to Chapter 2 Initial Setup of the Startup Guide for instructions on programming the pipe data In addition to the actual pipe dimensions the path length P and the axial dimension L based on the actual transducer mounting locations must be accurately programmed into the flowmeter For a GE flowcell this data will be included with the documentation for the system If the transducers are mounted onto an existing pipe 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
64. ribed 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 four standoffs that secure the LCD display assembly to the console cover Lift the LCD display assembly off its mounting studs 4 Place the new LCD display assembly over the mounting studs on the console cover and fasten it in place with the four standoffs Make sure that the LCD display assembly is oriented as shown in Figure 9 on page 36 CAUTION Do not overtighten the standoffs or the display assembly may be damaged 5 Position the LCD display cables between the two right side mounting studs and install the display shroud over the mounting studs The top and bottom edges of the shroud are bent at a 90 angle to the main surface and these edges must face inwards toward the display assembly Note One edge of the display shroud is covered with a piece of black electrical tape This side of the shroud should be on the right to protect the cables against abrasion 6 Fasten the display shroud to the console cover with the four sets of nuts washers CAUTION Do not overtighten the nuts or damage to the mounting threads may occur Complete the LCD display replacement by proceeding to the Installing the Printed Circuit Board page 4 7 section of this chapter DigitalFlow Multipur
65. rinted circuit board and the two short standoffs or screws along the bottom edge of the printed circuit board Then install only the top and bottom short 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 Securely tighten all eight standoffs and or screws IMPORTANT Correctly installing the grounding strap may require some patience but resist the temptation to place the grounding strap on top of the printed circuit board 5 Connect the twisted pair backlight cable to socket J2 on the left edge of the printed circuit board This plug is polarized so that it can only be installed in the proper orientation with the black wire above the red wire 6 Check for and remove any loose hardware that may have fallen into the electronics console during the maintenance procedure 7 Place the main shroud over the six upper standoffs on the printed circuit board Making sure that the shroud is oriented with the wiring diagram label upright fasten the shroud to the standoffs with the six sets of screws and washers 8 Reconnect the power line wires and the PC board ground wire to terminal block TB1 on the printed cir
66. screws along each side of the printed circuit board Carefully lift the printed circuit board out of the enclosure Proceed to the next section for instructions on installing the new printed circuit board 46 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Appendix B Optional Enclosures B 7 2 Circuit Board Installation Refer to Figure 11 on page 50 and complete the following steps 1 Position the new printed circuit board within the electronics console so that it rests on the six standoffs in the base of the enclosure and the option card sockets are located near the rear of the enclosure Secure the circuit board in place with the six screws previously removed 2 Connect the flat LCD DISPLAY CABLE connector to terminal J52 near the option card sockets Make sure the marked pin 1 side of the cable connector is located nearer the front of the enclosure 3 Connect the twisted pair DISPLAY BACKLIGHT cable to connector J2 beneath the left side of the printed circuit board This connector is polarized and can only be installed with the red wire closer to the rear of the enclosure 4 Connect the flat KEYPAD CABLE connector to terminal J50 near the front of the printed circuit board Make sure the marked pin 1 side of the cable connector is located nearer the rear of the enclosure 5 Install the RS232 ANALOG OUT and TRANSDUCER connectors onto the printed circuit board at the locations indicated in Figure 11 on
67. st be replaced Contact the factory for information on transducers in materials suitable for the application DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 25 Chapter 3 Diagnostics 3 5 1 Wetted Transducer Problems cont 3 INTERNAL DAMAGE An ultrasonic transducer consists of a ceramic crystal bonded to the transducer case The bond between the crystal and the case or the crystal itself may be damaged by extreme mechanical shock and or temperature extremes Also the internal wiring can be corroded or shorted if contaminants enter the transducer housing 4 PHYSICAL DAMAGE Transducers may be physically damaged by dropping them onto a hard surface or striking them against another object The transducer connector is the most fragile part and is the one most subject to damage Minor damage may be repaired by carefully bending the connector back into shape If the connector cannot be repaired the transducers must be replaced IMPORTANT Transducers must be replaced in pairs Refer to Chapter 2 Initial Setup of the Startup Guide to program the replacement transducer data into the meter If the instructions in this section fail to resolve the problem contact the factory for assistance 3 5 2 Clamp on Transducer Problems 1 POOR COUPLING TO PIPE Clamp on transducers must be in close contact with the pipe Make sure the pipe wall is smooth and generally free of paint The couplant material must fill voids betwe
68. sting optional Slot 1 through Slot 6 alarm relays e testing optional Slot 1 through Slot 6 totalizer frequency outputs The Model DF868 electronics console includes six expansion slots for the installation of option cards These slots are numbered 1 6 from right to left In addition every Model DF868 flowmeter includes two built in analog outputs A and B at terminal block I O which is designated as Slot 0 Note Convention 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 calibrate and test any option cards that are installed in the expansion slots Refer to the menu map in Figure 6 on page 13 as a guide in following the calibration instructions Note The same instructions apply to both the 1 Channel and 2 Channel versions of the Model DF 868 flowmeter The following discussion assumes that the left screen pane is active If the right screen pane is active only the function key designations change That is replace F1 F4 with F5 F8 Proceed to the appropriate sections of this chapter to calibrate and test all of the installed inputs and or outputs Note While in the Calibration Menu if the
69. t be disconnected before proceeding 2 Disconnect all external option card connectors at the rear panel of the meter Then remove all installed option cards from the printed circuit board as described earlier in this chapter 3 Disconnect the main POWER LEADS from the screw terminals at the rear of the printed circuit board Make a sketch of the terminal block and the locations of the black white and green power leads to assist 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 terminal J50 near the front of the printed circuit board Mark pin 1 of the cable connector which is located nearer the rear of the enclosure 6 Disconnect the twisted pair DISPLAY BACKLIGHT cable from connector J2 beneath the left side of the printed circuit board Although this connector is polarized it will help to note that the red wire is closer to the rear of the enclosure 7 Remove the flat LCD DISPLAY CABLE connector from terminal J52 near the option card sockets Mark pin 1 of the cable connector which is located nearer the front of the enclosure 8 Using a slotted screwdriver remove the three mounting
70. ted 180 out of position Secure the metal bracket to the printed circuit board with the four plastic snap rivets provided 7 After checking for any loose hardware that may have fallen into the enclosure reinstall the top panel on the meter and secure the panel in place with the four screws previously removed The Model DF868 flowmeter may now be placed back into service Reconnect the main power and refer to Appendix C Optional Enclosures of the Startup Guide for instructions on wiring the new option card s Note Be sure to record the option card installation in Appendix A Service Record DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 43 Appendix B Optional Enclosures B 5 Rack Mount EPROM Replacement The Model DF868 s User Program is stored on an erasable programmable read only memory EPROM chip The EPROM which is designated as component U4 is located on the corner of the printed circuit board just behind the keypad on the front panel EPROM replacement may be required to replace a defective chip or to upgrade to a newer software version To replace the EPROM refer to Figure 11 on page 50 and complete the following steps WARNING The main power to the Model DF868 must be disconnected before proceeding 1 After disconnecting the main power to the meter remove the top panel from the enclosure by removing the four screws indicated CAUTION The EPROM is easily damaged by static electricity B
71. ure Options below Procedure Options You have completed calibration of the RTD input Do one of the following To calibrate another input press EXIT To calibrate additional slots press EXIT and then F4 EXIT and proceed to the appropriate section To leave the Calibration Menu press F4 EXIT twice 8 DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual Chapter 1 Calibration 1 6 Alarms Option Card Alarm relays may be added to the Model DF868 by installing an Alarms Option Card in one or more of the six expansion slots Each option card includes three alarm relays which are designated as A B and C To test the alarm relays connect an ohmmeter to 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 Terminal Block Option Card Ohmmeter 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 installed option card 3 Press F1 F3 to select alarm relay A B or C respectively DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 9 Chapter 1 Calibration
72. vice must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the Model DF868 B 2 Rack Mount Enclosure Refer to Figure 10 on page 49 and Figure 11 on page 50 for the location of the relevant components while completing the following procedures If the top panel of the meter is accessible service may be performed without removing the meter from the rack Otherwise disconnect all rear panel electrical connections and remove the meter from the rack before proceeding IMPORTANT Keep a detailed record of all service procedures in Appendix A Service Record This record may prove very helpful in diagnosing any future problems DigitalFlow Multipurpose Ultrasonic Liquid Flowmeter Service Manual 41 Appendix B Optional Enclosures B 3 Rack Mount Fuse Replacement If it has been determined that the fuse in the Model DF868 requires replacement refer to Figure 10 on page 49 and Figure 11 on page 50 and complete the following steps 1 Onthe rear panel of the meter set the power switch to the OFF position and pull the power cord out of its receptacle WARNING The main power to the Model DF868 must be disconnected before proceeding 2 Locate the black plastic fuse cover 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 Tab

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