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GE DigitalFlow DF868 Startup Manual

Multipurpose ultrasonic liquid flowmeter
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GE
Measurement & Control
Flow
DigitalFlow™ DF868
Multipurpose Ultrasonic Liquid Flowmeter
Startup Guide (1- and 2-Channel)
910-176U Rev.E1
February 2016

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  • Page 1 Measurement & Control Flow DigitalFlow™ DF868 Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 910-176U Rev.E1 February 2016...
  • Page 3 Measurement & Control DigitalFlow™ DF868 Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 910-176U Rev. E1 February 2016 www.gemeasurement.com ©2016 General Electric Company. All rights reserved. Technical content subject to change without notice.
  • Page 4 [no content intended for this page]...
  • Page 5 Preface Information Paragraphs Note: These paragraphs provide information that provides a deeper understanding of the situation, but is not essential to the proper completion of the instructions. IMPORTANT: These paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment.
  • Page 6 Environmental Compliance Waste Electrical and Electronic Equipment (WEEE) Directive GE Measurement & Control is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-back initiative, directive 2012/19/EU. The equipment that you bought has required the extraction and use of natural resources for its production. It may contain hazardous substances that could impact health and the environment.

  • Page 7: Table Of Contents

    Contents Chapter 1. Installation 1.1 Introduction ................... .1 1.2 Unpacking .
  • Page 8 Contents Chapter 2. Initial Setup 2.1 Introduction...................17 2.2 Navigating Through the User Program .
  • Page 9 Contents Chapter 4. Specifications 4.1 General Specifications ................39 4.1.1 Hardware Configuration.
  • Page 10 Contents Appendix C. Optional Enclosures C.1 Introduction...................55 C.2 Rack Mount Enclosure .

  • Page 11: Chapter 1. Installation

    To ensure safe and reliable operation of the Model DF868 Ultrasonic Liquid Flowmeter, the system must be installed in accordance with the guidelines established by GE engineers. Those guidelines, which are explained in detail in this chapter, include the following specific topics: •...

  • Page 12: Site Considerations

    Chapter 1. Installation 1.3 Site Considerations Because the relative physical locations of the flowcell and the Model DF868 electronics console are important, use the guidelines given in this section to plan the Model DF868 system installation. 1.3.1 Electronics Console Location The standard Model DF868 electronics enclosure is a Type-4X weather-resistant, dust-tight, indoor/outdoor type.

  • Page 13: Transducer Cables

    When using non-GE cables to connect the flow transducers to the Model DF868 electronics console, the cables must have electrical characteristics identical to the GE cables. Type RG 62 a/u coaxial cable should be used, and each cable must be the same length (within ±4 in.).

  • Page 14: Installing Temperature Transmitters

    Chapter 1. Installation 1.5 Installing Temperature Transmitters Optional temperature transmitters may be installed as part of the flowcell, near the ultrasonic transducer ports. Be sure to observe the siting requirements given earlier in this chapter. These transmitters must use a 0/4-20 mA signal to transmit the temperature values to the Model DF868 electronics console.

  • Page 15: Making Electrical Connections

    Chapter 1. Installation 1.7 Making Electrical Connections !ATTENTION EUROPEAN CUSTOMERS! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance. This section contains instructions for making all the necessary electrical connections to the Model DF868 flowmeter. Refer to Figure 10 on page 16 for a complete wiring diagram of the unit.
  • Page 16 Chapter 1. Installation 1.7.1 Wiring the Line Power (cont.) 1. Remove the plastic shroud that covers the terminal blocks. Be sure to reinstall the shroud after all of the wiring has been completed. 2. Strip ¼” of insulation from the end of the power and neutral or line leads (or the positive and negative DC power leads), and ½”...

  • Page 17: Wiring The Transducers

    Chapter 1. Installation 1.7.2 Wiring the Transducers !ATTENTION EUROPEAN CUSTOMERS! To meet CE Mark requirements, all cables must be installed as described in Appendix A, CE Mark Compliance. Wiring a typical Model DF868 ultrasonic liquid flowmeter system requires interconnection of the following components: •...
  • Page 18 Note: Signal names that imply direction (e.g., transmit and receive) are named from the point of view of the DTE device (the GE meter is usually considered the DTE device). When the RS232 standard is strictly followed, these signals are labeled with the same name and pin # on the DCE device side as well. Unfortunately, the convention is not followed because the DTE and DCE side get confused.
  • Page 19 Chapter 1. Installation 1.7.4b Wiring the RS485 Interface (cont.) 3. Feed one end of the cable through the conduit hole, wire it to terminal block J1 and secure the cable clamp. Connect the other end of the cable to the converter, as shown in Figure 4. Figure 4: Typical RS485 Connections 1.7.4c Wiring the Ethernet Interface...
  • Page 20 Chapter 1. Installation 1.7.4d Wiring the MODBUS/TCP Interface Customers can also use a modified DF868 that provides a MODBUS/TCP interface to communicate to an internal network. An optional MODBUS/TCP card with a unique MAC (IP) address (installed only in slots 5 or 6) includes an RJ45 connector.

  • Page 21: Wiring An Alarms Option Card

    Chapter 1. Installation 1.7.5 Wiring an Alarms Option Card The Model DF868 flowmeter can accommodate up to 4 alarm option cards. Each alarms option card includes three Form C relays (designated as A, B and C). The alarm relays on the option card are available in two types: •...

  • Page 22: Wiring A 0/4-20 Ma Analog Inputs Option Card

    Chapter 1. Installation 1.7.6 Wiring a 0/4-20 mA Analog Inputs Option Card To calculate energy measurement, the Model DF868 requires accurate temperature data from the measurement site. Transmitters installed in the flowcell can provide this information via an optional 0/4-20 mA analog inputs card. This option card includes two isolated 0/4-20 mA analog inputs (designated as A and B), each of which includes a 24 VDC power supply for loop-powered transmitters.

  • Page 23: Wiring A Totalizer/Frequency Outputs Option Card

    Chapter 1. Installation 1.7.6 Wiring a 0/4-20 mA Analog Inputs Option Card (cont.) Wire the analog input terminal block in accordance with the pin number assignments shown in Figure 10 on page 16. If the flowmeter system includes additional transmitters, the Model DF868 can accommodate up to three more analog inputs option cards.

  • Page 24: Wiring An Rtd Inputs Option Card

    Chapter 1. Installation 1.7.8 Wiring an RTD Inputs Option Card The Model DF868 can accommodate up to four RTD (Resistance Temperature Device) inputs option cards. Each RTD inputs option card provides two direct RTD inputs (designated as A and B). Each RTD input requires three wires, which should be fed through one of the conduit holes on the bottom of the electronic console.
  • Page 25 Chapter 1. Installation DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 26 Chapter 1. Installation DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)

  • Page 27: Chapter 2. Initial Setup

    Chapter 2. Initial Setup Chapter 2. Initial Setup 2.1 Introduction This chapter provides instructions for entering the minimum amount of programming data required to place the Model DF868 flowmeter into operation. Before the Model DF868 can begin taking measurements and displaying valid data, the system and pipe parameters must be entered.

  • Page 28: Accessing The User Program

    Chapter 2. Initial Setup 2.3 Accessing the User Program [PROG] To access the User Program, press the key on the keypad. Note: If the security feature is active, enter the password and press [ENT] to enter the User Program. See the SECUR submenu section in Chapter 1 of the Programming Manual for more information on the security feature.

  • Page 29: Activating A Channel

    Chapter 2. Initial Setup 2.4 Activating a Channel ACTIV submenu permits selection of the desired measurement method. In addition, it is used to activate/deactivate one or both of the channels in a 2-Channel Model DF868. 2.4.1 1-Channel Meter ACTIV [F1] 1.

  • Page 30: 2-Channel Meter

    Chapter 2. Initial Setup 2.5.2 2-Channel Meter SYSTM For the 2-Channel Model DF868, the information entered in the submenu pertains only to the currently selected channel. [F2] SYSTM 1. At the User Program screen shown, press to program the submenu. 2.

  • Page 31: 1- And 2-Channel Meters

    Chapter 2. Initial Setup 2.5.3 1- and 2-Channel Meters [F1]-[F4] 1. Use the and [ keys to select the desired Volumetric Units for the flow rate display. The abbreviations and definitions of all the available volumetric units are shown in Table 3. The choices shown on the SYSTEM UNITS option bar are determined by the selections made at the previous prompt screen.
  • Page 32 Chapter 2. Initial Setup 2.5.3 1- and 2-Channel Meters (cont.) Table 4: Totalizer Unit Options English Totalizer Units Metric Totalizer Units Gal - U.S. Gallons L - Liters MGAL - Mega U.S. gallons ML - Megaliters - Cubic Feet - Cubic Meters - Mega Cubic Feet - Mega Cubic Meters BBL - Barrels...
  • Page 33 Chapter 2. Initial Setup 2.5.3b Energy Option If you did not select the Energy Option earlier, the meter now returns to the initial User (or Channel) Program screen. But if you selected the Energy Option, several more prompts appear. [F1]-[F4] 1.

  • Page 34: Entering Pipe Data

    Chapter 2. Initial Setup 2.6 Entering Pipe Data PIPE submenu permits entry of the transducer and pipe specifications. To program this menu, complete the following steps: User (or Channel) Program [F3] PIPE 1. At the screen, press to program the submenu.

  • Page 35: Pipe Material

    Chapter 2. Initial Setup 2.6.2 Pipe Material [F1]-[F4] 3. Use the and [ keys to select the Pipe Material, as listed in Table 8. Table 8: Pipe Materials Pipe Material Category Specific Material Steel Carbon Steel or Stainless Steel Iron Ductile Iron or Cast Iron Cu - Copper None...

  • Page 36: Pipe Wall

    OD. If the pipe wall thickness is not available, look up the value in a table of standard pipe size data (such as the GE brochure Sound Speeds and Pipe Size Data, 914-004), or use the Model DF868’s on-line Help Menu (see the Programming Manual for details).

  • Page 37: Fluid Type

    Chapter 2. Initial Setup 2.6.8 Fluid Type [F1]-[F4] 10. Use the and [ keys to select the Fluid Type. The selections for fluid type vary, depending on whether: • ENERGY OPTION ; and • TRACKING WINDOW is enabled or disabled. ENERGY OPTION ENERGY OPTION Refer to Table 10 if...

  • Page 38: Reynolds Correction

    [ENT]. value, and press Note: GE recommends activating the Reynolds Correction Factor when the Depth of Reflector is set at 50%. You can disable the Reynolds Correction Factor when the Depth of Reflector is set at any other value. •...

  • Page 39: Exiting The User Program

    Chapter 2. Initial Setup 2.7 Exiting the User Program submenu and return to the initial User PIPE After the calibration factor entry has been made, the meter will exit the Program screen. PROGRAM Start ‰ To leave the User Program begin taking measurements, [EXIT] press...
  • Page 40 Chapter 2. Initial Setup [no content intended for this page] DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 41 Chapter 2: Initial Setup DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 42 Chapter 2: Initial Setup DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)

  • Page 43: Chapter 3. Operation

    1.8 m (6 ft) of the Model DF868. Immediately upon power up, the Model DF868 displays the GE logo and the software version (2AA) in the left pane of the display window. The Model DF868 performs a series of internal checks and display the results in the right pane of the display window.

  • Page 44: Using The Display

    Chapter 3. Operation 3.3 Using the Display The Model DF868 display is divided into a left pane and a right pane. The two screen panes can be set independently to display any of the available measurement or diagnostic parameters. The components of a typical measurement mode screen are shown in Figure 14.

  • Page 45: Taking Measurements

    Chapter 3. Operation 3.3 Using the Display (cont.) The middle portion of the screen pane is the prompt area. This area displays data, graphs, and logs in measurement mode and menu prompts in programming mode. In addition, error code messages, which are described in the Service Manual, are displayed in the prompt area.
  • Page 46 Chapter 3. Operation 3.4 Taking Measurements (cont.) The following screen appears after selection of the channel mode display option for a 2-channel Model DF868 or immediately after the internal checks for a 1-channel Model DF868.  and [ keys to select the desired display parameter option. [F1]-[F4], [ (Ch1) label...

  • Page 47: Foundation Fieldbus Communications

    Chapter 3. Operation 3.4.1 Foundation Fieldbus Communications Foundation Fieldbus provides a means of communicating with the flowmeter. The patent numbers which apply are 5,909,363 and 6,424,872. This Foundation Fieldbus device supports two Analog Input (AI) blocks, which can be configured to supply the following measurements on the network (see Table 15 on page 37).
  • Page 48 Chapter 3. Operation [no content intended for this page] DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)

  • Page 49: Chapter 4. Specifications

    Chapter 4. Specifications Chapter 4. Specifications 4.1 General Specifications The general specifications for the Model DF868 flowmeter are divided into the following categories: 4.1.1 Hardware Configuration 4.1.1a Package Options: Epoxy-coated aluminum (standard), Stainless steel, Fiberglass, Explosion-proof 4.1.1b Physical: Size: 14.24  11.4  5.12 in. (36.2  29  13 cm) Weight: 11 lb (5 kg) 4.1.2 Environmental 4.1.2a...

  • Page 50: Range

    Chapter 4. Specifications 4.1.4 Range 4.1.4a Transit-Time Mode: –40 to 40 ft/s (–12.2 to 12.2 m/s) 4.1.4b TransFlection Mode: –1 to –30 ft/s (–0.3 to –9.1 m/s) 1 to 30 ft/s (0.3 to 9.1 m/s) ±1 to 15 ft/s (0.3 to 4.6 m/s) 4.1.5 Rangeability 4.1.5a Transit-Time Mode:...

  • Page 51: Fluid Types

    Chapter 4. Specifications 4.1.8 Fluid Types 4.1.8a Transit-Time Mode: Acoustically conductive fluids, including most clean liquids and many with entrained solids or gas bubbles. Maximum void fraction depends on transducer interrogation carrier frequency, path length and pipe configuration. 4.1.8b TransFlection Mode: Multiphase fluids, including raw sewage, sludge, slurries, tar sands, acoustically attenuating liquids and other demanding applications.

  • Page 52: Hazardous (Classified) Location Compliance

    Chapter 4. Specifications 4.2.5 Hazardous (Classified) Location Compliance 4.2.5a CENELEC: ISSeP Ex 96D1031261, EEx d IIC T6 when housed GUB 6 enclosure. 4.2.5b NEC: Factory Mutual Research Corporation, J.K. 3Z9A1.AX, Class I, Division 2, Group A, B, C, D; Class II, division 2, Group F, G;...

  • Page 53: Operational Specifications

    Chapter 4. Specifications 4.2.6f Totalizer/Frequency Output Options: Select up to 3 Totalizer/Frequency Output Boards, each with four outputs per board, 10 kHz max. All boards allow software-selectable functioning in two modes: Totalizer Mode: one pulse per defined unit of parameter (e.g., 1 pulse/gal). Frequency Mode: pulse frequency proportional to magnitude of parameter (e.g., 10 Hz = 1 gpm).

  • Page 54: Transducer Specifications

    Chapter 4. Specifications 4.4 Transducer Specifications The transducer specifications for the Model DF868 flowmeter are divided into the following categories: 4.4.1 Wetted Ultrasonic Flow Transducers 4.4.1a Temperature Range Standard: –40° to 212°F (–40° to 100°C) Optional: –310° to 1112°F (–190° to 600°C) 4.4.1b Pressure Range Standard: 0 to 3,000 psig (0.1013 to 20 MPa)

  • Page 55: Temperature Transducers

    Chapter 4. Specifications 4.4.2 Clamp-On Ultrasonic Flow Transducers 4.4.2a Temperature Range Standard: –40° to 300°F (–40° to 150°C) Optional: –310° to 572°F (–190° to 300°C) 4.4.2b Mounting Stainless steel chain or strap, welded or magnetic clamping fixtures 4.4.2c Area Classifications Standard: General-purpose Optional: Explosion proof: Class I, Div.

  • Page 56: Pipe Size & Materials

    Chapter 4. Specifications 4.5 Pipe Size & Materials 4.5.1 Wetted Transducers 4.5.1a Materials All metals and most plastics. (Consult the factory for concrete, glass and cement.) 4.5.1b Pipe Sizes Transit-Time Mode: (ID) 1 to 200 in. (25.4 mm to 5 m) and larger. 4.5.2 Clamp-On Transducers 4.5.2a Materials...

  • Page 57: Appendix A. Ce Mark Compliance

    Appendix A. CE Mark Compliance Appendix A. CE Mark Compliance A.1 Introduction For CE Mark compliance, the Model DF868 flowmeter must be wired in accordance with the instructions in this appendix. IMPORTANT: CE Mark compliance is required only for units intended for use in EEC countries. A.2 Wiring The Model DF868 must be wired with the recommended cable, and all connections must be properly shielded and grounded.
  • Page 58 Appendix A. [no content intended for this page] DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)

  • Page 59: Appendix B. Data Records

    Appendix B. Data Records Appendix B. Data Records B.1 Option Cards Installed Whenever an option card is installed in one of the Model DF868’s expansion slots, record the type of card and any additional setup information in the appropriate row of Table 17. Table 17: Option Cards Installed Slot # Type of Option Card...

  • Page 60: Initial Setup Data

    Appendix B. Data Records B.2 Initial Setup Data After the Model DF868 flowmeter has been installed, some initial setup data must be entered via the User Program, prior to operation. Record that information in Table 18. Table 18: Initial Setup Data General Information Model # Serial #...
  • Page 61 Appendix B. Data Records Table 18: Initial Setup Data (cont.) CHx-I/O Zero Cutoff Temp. Input Fixed ( Live Pipe/Transducer Parameters - PIPE Channel 1 Channel 2 (if applicable) Trans. Type SPEC Trans. Type SPEC Transducer # Transducer # Special Transducers Special Transducers Wedge Type Rayl Shear Wettd...
  • Page 62 Appendix B. Data Records Table 18: Initial Setup Data (cont.) CHx-SETUP-ADVAN-KV/SS KV/SS Pairs KV/SS Pairs Sig. Stren. Kin. Visc. Sig. Stren. Kin. Visc. CHx-SETUP-ADVAN-MULTIK Custom Type CstV CstR Custom Type CstV CstR K-Factor Table K-Factor Table K-Factor # Vel./Reyn. K Factor K-Factor # Vel./Reyn.
  • Page 63 Appendix B. Data Records Table 18: Initial Setup Data (cont.) CHx-SETUP-ADVAN-MULTIK (cont.) K-Factor Table K-Factor Table K-Factor # Vel./Reyn. K Factor K-Factor # Vel./Reyn. K Factor CHx-SETUP-ADVAN-MASS Channel 1 Channel 2 (if applicable) Mass Flow Mass Flow Static Density Static Density CHx-SETUP-ADVAN-CODEL Code Length Auto 1bit 2bit 4bit 11bit...
  • Page 64 Appendix B. [no content intended for this page] DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)

  • Page 65: Appendix C. Optional Enclosures

    Appendix C. Optional Enclosures Appendix C. Optional Enclosures C.1 Introduction Upon request the Model DF868 flowmeter may be supplied in an enclosure other than the standard Type-4X enclosure described in Chapter 1, Installation, of this manual. Although the standard installation and wiring instructions still apply in general terms, some of the details may vary for different enclosure types.

  • Page 66: Rack Mount Front Panel

    Appendix C. Optional Enclosures C.3 Rack Mount Wiring (cont.) 3. Wire the 0/4-20 mA analog outputs at the left side of the rear panel in accordance with the instructions in Chapter 1, Installation, of this manual. 4. Wire the RS232 serial port by completing the following steps: a.
  • Page 67 Appendix C. Optional Enclosures DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 68 Appendix C. Optional Enclosures REAR-VIEW DC OPTION DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 69 Appendix C. Optional Enclosures DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 70 Appendix C. Optional Enclosures DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)

  • Page 71: Appendix D. Measuring P And L Dimensions

    Appendix D. Measuring P and L Dimensions Appendix D. Measuring P and L Dimensions D.1 Measuring P and L If you are using wetted transducers, the DF868 requires you to enter the path length (P) and the axial dimension (L). P is the transducer face-to-face distance, and L is the axial projection of P in the flow stream.
  • Page 72 Appendix D. Measuring P and L Dimensions D.1 Measuring P and L (cont.) Use Figure 19 to properly measure the coupling length. Typically, the transducer face is positioned just outside the inside diameter (ID) of the pipe, or slightly retracted inside the coupling. Figure 19: Determining the Pipe Coupling Length Use the following formula to determine the P dimension: [ID + 2(WT)]/(cos MA) = 2 (CL–FD) = P dimension...
  • Page 73 Index ....21 Dimensions Abbreviations, Volumetric Units ......16 .
  • Page 74 Index ....7 ......36 Lightning Protector, Connecting Parameter Options .
  • Page 75 Index T (cont.) Safety Transducers ..... . vii ......61 Auxiliary Equipment Axial Dimension .
  • Page 76 Index [no content intended for this page] DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 77 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.
  • Page 78 Warranty [no content intended for this page] DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
  • Page 79 EC DECLARATION Sensing CONFORMITY DOC-0013, Rev. C GE Sensing 1100 Technology Park Drive Billerica, MA 01821 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™...
  • Page 82 Customer Support Centers U.S.A. The Boston Center 1100 Technology Park Drive Billerica, MA 01821 U.S.A. Tel: 800 833 9438 (toll-free) 978 437 1000 E-mail: sensing@ge.com Ireland Sensing House Shannon Free Zone East Shannon, County Clare Ireland Tel: +353 61 61470200 E-mail: gesensingsnnservices@ge.com An ISO 9001:2008 Certified Company www.gemeasurement.com/en/about-us/quality.html...

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