GE DigitalFlow DF968 Service Manual

GE

Sensing & Inspection Technologies

DigitalFlow™ DF868

Panametrics Multipurpose Ultrasonic Liquid Flowmeter

Service Manual

GE

Sensing & Inspection Technologies

DigitalFlow™ DF868

Panametrics Multipurpose Ultrasonic Liquid Flowmeter

Service Manual

910-176SD1
March 2008

The DigitalFlow DF868 is a GE Panametrics product. GE Panametrics has joined other GE high-technology
businesses under a new name—GE Sensing & Inspection Technologies.

March 2008

Warranty Each instrument manufactured by GE Sensing, Inc. 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. Fuses and
batteries are specifically excluded from any liability. This warranty is
effective from the date of delivery to the original purchaser. If GE
determines that the equipment was defective, the warranty period is:

• one year for general electronic failures of the instrument

• one year for mechanical failures of the sensor

If GE 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, 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
(including warranties of merchantability and fitness for a
particular purpose, and warranties arising from course of
dealing or usage or trade).

Return Policy If a GE Sensing, Inc. instrument malfunctions within the warranty

period, the following procedure must be completed:

1. Notify GE, 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 will issue a
RETURN AUTHORIZATION number (RA), and shipping instructions
for the return of the instrument to a service center will be
provided.

2. If GE 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 will evaluate the instrument to determine the
cause of the malfunction.

Then, one of the following courses of action will then be taken:

• If the damage is covered under the terms of the warranty, the

instrument will be repaired at no cost to the owner and returned.

• If GE 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.

iii

March 2008

Table of Contents

Chapter 1: Calibration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Calibrating the Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Accessing the Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Calibrating the Low End of the Output Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Calibrating the High End of the Output Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Testing the Analog Output Linearity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Calibrating the Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Accessing the Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

aLOW Option = [F1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

aHIGH Option = [F2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4 mA Option = [F3]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

20 mA Option = [F4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Calibrating the RTD Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Accessing the Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

LOW Option = [F1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

HIGH Option = [F2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Alarms Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Accessing the Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

Totalizer/Frequency Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Accessing the Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Entering Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Entering Pulse Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Chapter 2: Error Codes and Screen Messages

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

E0: No Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E1: Low Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E2: Sound Speed Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E3: Velocity Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E4: Signal Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E5: Amplitude Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E6: Cycle Skip, Accel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E7: Special Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E8: Temp In Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E9: Temp In Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E10: Weak Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E11: Poor Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E12: Incoherent Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E13: Over Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

E14: Totals Overflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Screen Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

v

March 2008

Table of Contents (cont.)

Chapter 3: Diagnostics

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Displaying Diagnostic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostic Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Flowcell Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Fluid Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Pipe Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Transducer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Wetted Transducer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Clamp-on Transducer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Chapter 4: Parts Replacement

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removing the Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Replacing the EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Installing an Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Replacing the LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Installing the Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Appendix A: Service Record

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Diagnostic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Appendix B: Optional Enclosures

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Rack Mount Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Rack Mount Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Rack Mount Option Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Rack Mount EPROM Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Rack Mount LCD Display Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Rack Mount Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Circuit Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Circuit Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

vi

Chapter 1

Calibration

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Calibrating the Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Calibrating the Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Alarms Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Totalizer/Frequency Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

March 2008

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

• testing optional Slot 1 through Slot 6 alarm relays

• 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
which is designated as

Slot 0.

I/O,

Note: Convention in this manual identifies any expansion slot as

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.

Menu Map The Calibration Menu is accessed by pressing the [CAL] key on the

keypad. Use this menu to calibrate and test the
as well as to calibrate and test any option cards that are installed in the
expansion slots. Refer to the menu map in Figure 1-6 on page 1-15 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 DF868 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
appropriate sections of this chapter to calibrate and test all of the
installed inputs and/or outputs.

[F1]-[F4] with [F5]-[F8]. Proceed to the

Slot 0 analog outputs,

Slot

Note: While in the Calibration Menu, if there is no keypad activity

for two minutes, the Model DF868 will automatically reboot
and return to measurement mode.

Calibration 1-1

March 2008

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 μA
(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 procedur e 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 1-1 below. Refer to the

menu map in Figure 1-6 on page 1-15.

Terminal Block I/O (Slot 0)

41

B

RTN

B

SIG

A

RTN

A

SIG

Figure 1-1: Ammeter Connection (Output A)

Press the

CALIBRATION ‰

Cal
last slot selected

SLOT0 SLOT1 SLOT2 SLOT3

[CAL] key to enter the Calibration Program:

-

+

Ammeter

Press [F1] to calibrate Slot 0. (The
option bar will include a slot
listing for each installed option
card.)

1-2 Calibration

Accessing the Calibration Menu

March 2008

8

D

SIG

D

RTN

C

SIG

C

RTN

B

SIG

B

RTN

A

SIG

A

RTN

1

Terminal Block (Option Card)

+

Ammeter

–

Calibrating the Low End of the Output Range

Figure 1-2: Ammeter Connection (Output A)

1. Press the

2. Press

[CAL] key to enter the Calibration Program.

[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 differ ent output, be sur e
to reconnect the ammeter to the appropriate pins on
terminal block

I/O. See Figure 1-1 on page 1-2 or

Figure 1-2 above for the correct pin numbers.

1. Press [F1] to calibrate the low end of the output range.

2. Press

3. Press

[F1] or [F2] to adjust the ammeter reading UP or DOWN, until

a 4 mA reading is achieved. If you press
numeric value and press

[F4] to STORE the setting or press [→] and [F1] to ABORT the

[ENT].

[F3], Numer, enter the

calibration.

Note: If the ammeter reading cannot be adjusted within 5.0 μA of the

4 mA setting, contact the factory for assistance.

Calibration 1-3

March 2008

Calibrating the High End of the Output Range

Testing the Analog Output Linearity

1. Press [F2] to calibrate the high end of the output range.

2. Press

3. Press

[F1] or [F2] to adjust the ammeter reading UP or DOWN, until

a 20 mA reading is achieved. If you press
numeric value and press

[F4] to STORE the setting or press [→] and [F1] to ABORT the

[ENT].

[F3], Numer, enter the

calibration.

Note: If the ammeter reading cannot be adjusted within 5.0 μA of the

20 mA setting, contact the factory for assistance.

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 (0-100%) and press

4. Check the ammeter reading at this setting. Press

[ENT] when done.

[ENT].

Table 1-1 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 1-1: Expected Ammeter Readings

% Full Scale 4-20 mA Scale* 0-20 mA Scale*

0% 4.000 0.000
10% 5.600 2.000
20% 7.200 4.000
30% 8.800 6.000
40% 10.400 8.000
50% 12.000 10.000
60% 13.600 12.000
70% 15.200 14.000
80% 16.800 16.000
90% 18.400 18.000

100% 20.000 20.000

* All ammeter readings should be ±0.005 mA

If the linearity test readings are not within 5 μA of the values listed in
Table 1-1 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.

1-4 Calibration

March 2008

Procedure Options You have completed calibration of the analog output. Do one of the

following:

• T o calibrate or test another output, press [F4] (EXIT) and return to

Step 3 in Accessing the Calibration Menu on page 1-3.

• To calibrate/test additional slots, press [F4] (EXIT) twice and

proceed to the appropriate section.

• To leave the Calibration Menu, press [F4] (EXIT) three times.

Calibration 1-5

March 2008

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
calibration. During the analog input calibration, the

Slot 0 analog outputs may be used for the

Slot 0 analog

output will supply the low reference, high reference, 4 mA and 20
mA signals at the appropriate times.

Note: If a

Slot 0 analog output will be used to calibrate the analog

inputs, make sure that the

Slot 0 analog output calibration

procedure has already been completed.

Connect the

Slot X analog output(s) (or an independent calibrated

current source) to the analog input(s) on the option card, as shown in
Figure 1-3 below. Refer to the menu map in Figure 1-6 on page 1-15
as a guide.

8

B

RTN

B

INLO

B

INHI

+24

A

RTN

A

INLO

A

INHI

+24V

1

Analog Input Option Card

Terminal Block I/O (Slot 0)

41

B

RTNBSIGARTNASIG

B

A

Figure 1-3: Analog Input Calibration Connections

1-6 Calibration

March 2008

Calibrating the Analog
Inputs (cont.)

Accessing the Calibration Menu

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 procedur e always uses the 4
mA point, as the meter will extrapolate this value to obtain the
0 mA point.

1. Press the [CAL] key to enter the Calibration Program.

2. Press

3. Press

The procedure 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 1-3 on page 1-6 for the correct pin numbers.

4. Press

[Fx] to calibrate the desired slot. (The option bar will include

a slot listing for each installed option card.)

[F1] to select the desired input.

Input A is identical to that for calibrating

[F1]-[F4] to select the reference point to be calibrated.

Do one of the following:

• If you selected [F1] (aLOW), proceed to aLOW Option on the next

page.

• If you selected [F2] (aHIGH), proceed to aHIGH Option on the next

page.

• If you selected [F3] (4 mA), proceed to 4 mA Option on the next

page.

• If you selected [F4] (20 mA), proceed to 20 mA Option on the next

page.

Calibration 1-7

March 2008

aLOW Option = [F1] 1. Enter the low reference value and press the [ENT] key.

2. Press

3. Press

[F1] to store the current low reference value or press [F2] to

cancel the entry. In either case, the
reappear.

[F2] to proceed to the next section.

ANALOG INPUT prompt will

aHIGH Option = [F2] 1. Enter the high reference value and press the [ENT] key.

2. Press

3. Proceed to Procedure Options below.

[F1] to store the current high reference value or press [F2] to

cancel the entry. In either case, the
reappear.

ANALOG INPUT prompt will

4 mA Option = [F3] 1. Connect the 4 mA current source to the currently selected analog

input, as shown in Figure 1-3 on page 1-6.

2. Press

3. Press

[F1] to store the current 4 mA value or press [F2] to cancel the

entry. In either case, the

[F4] to proceed to the next section.

ANALOG INPUT prompt reappears.

20 mA Option = [F4] 1. Connect the 20 mA current source to the currently selected analog

input, as shown in Figure 1-3 on page 1-6.

2. Press

3. Proceed to Procedure Options below.

[F1] to store the current 20 mA value or press [F2] to cancel

the entry . In either case, the

ANALOG INPUT prompt reappears.

Procedure Options You have completed calibration of the analog input. Do one of the

following:

• To calibrate another input, return to Step 3 in Accessing the

Calibration Menu on the previous page.

• T o calibrate/test additional slots, press [F4] (EXIT) and proceed to

the appropriate section.

• To leave the Calibration Menu, press [F4] (EXIT) twice.

1-8 Calibration

March 2008

Calibrating the RTD Inputs

Accessing the Calibration

Calibrating an RTD option card involves a slightly different
procedure than for other analog input cards. However, yo u access the
card in the same manner.

1. Press the [CAL] key to enter the Calibration Program.

Menu

2. Press

3. Press

4. Press

Do one of the following:

[Fx] to calibrate the desired slot. (The option bar will include

a slot listing for each installed option card.)

[F1] to select Input A, or [F2] to select Input B.

[F1]-[F2] to select the reference point to be calibrated.

• If you selected [F1] (LOW), proceed to step 5.

• If you selected [F2] (HIGH), proceed to step 8.

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
prompt.

ANALOG INPUT

7. Press

[F2] to proceed to the next section.

HIGH Option = [F2] 8. Enter the high reference value and press the [ENT] key.

9. Press

10.Proceed to Procedure Options below.

[F1] to STORE the current high reference value or press [F2] to

ABORT the entry. In either case, the ANALOG INPUT prompt will

reappear.

Procedure Options You have completed calibration of the RTD input. Do one of the

following:

• To calibrate another input, press [EXIT].

• T o calibrate additional slots, press [EXIT] an d then [F4] (EXIT) and

proceed to the appropriate section.

• To leave the Calibration Menu, press [F4] (EXIT) twice.

Calibration 1-9

March 2008

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 1-4 below. Refer to the menu map in Figure 1-6 on page 1-15 as a guide.

9

1

C

NC

C

COM

C

NO

B

NC

B

COM

B

NO

A

NC

A

COM

A

NO

Terminal Block (Option Card)

–

Ohmmeter

+

Figure 1-4: Typical Ohmmeter Connections

For this discussion, assume that the option card has been installed in

Slot x.

Accessing the Calibration

1. Press the [CAL] key to enter the Calibration Program.

Menu

2. Press

3. Press

1-10 Calibration

[Fx] to select Slot x. (The option bar will include a slot listing

for each installed option card.)

[F1]-[F3] to select alarm relay A, B or C, respectively.

March 2008

Testing the Alarm Relays
(cont.)

Note: The procedure for testing Alarm Relay A is identical to that for

testing
ohmmeter is connected to the desired normally-open or
normally-closed contact of the currently selected relay . See
Figure 1-4 on page 1-10 for the correct pin numbers on the
option card terminal block.

4. Pressing

zero. Pressing
reading.

5. Press

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.

Alarm Relays B and C. However, make sure that the

[F1] (CLOSE) should yield an ohmmeter reading of about

[F2] (OPEN) should yield an infinite ohmmeter

[F3] to EXIT.

Procedure Options You have completed testing the alarm relays. Do one of the following:

• T o calibrate/test additional slots, press [F4] (EXIT) and proceed to

the appropriate section.

• To leave the Calibration Menu, press [EXIT] twice.

Calibration 1-11

March 2008

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 1-5 below.
Refer to the menu map in Figure 1-6 on page 1-15 as a guide.

8

D

NO

D

COM

C

NO

C

COM

B

NO

Terminal Block (Option Card)

B

1

COM

A

NO

A

COM

IN

COM

Frequency

Counter

Figure 1-5: Frequency Counter Connections

For this discussion, assume that the option card has been installed in

Slot x.

Accessing the Calibration

1. Press the [CAL] key to enter the Calibration Program.

Menu

2. Press

3. Press

[Fx] to select Slot x. (The option bar will include a slot listing

for each installed option card.)

[F1]-[F4] to select output A, B, C or D, respectively.

Entering Frequency 4. Enter a new frequency in the range of 1-10,000 Hz and press the

[ENT] key. Verify that the frequency counter reads the correct

value.

1-12 Calibration

March 2008

Entering Pulse Number 5. Enter the number of pulses desired (between 1 and 10,000) and

press the
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.

[ENT] key. That number of pulses will then be output at

Procedure Options Y ou have completed testing the totalizer/ frequency outputs. Do one of

the following:

• T o calibrate/test additional slots, press [F4] (EXIT) and proceed to

the appropriate section.

• To leave the Calibration Menu, press [EXIT] twice.

Calibration 1-13

Slot 0 Outputs

F1 F2

AB

ANALOG OUTPUT

F2

F1

20 mA

4 mA

CALIBRATING

F1

UPF2DOWNF3STOREF4ABORT

TEST

(TB I/O)

F3

% Full Scale

EXIT

March 2008

CAL

Cal

F3

F2

F1

SLOT1

SLOT0

F4

LOW REFERENCE

SLOT3

SLOT2

F1

aLOWF2aHIGHF34 mA

LOW REF

F1

STOREF2ABORTF3STOREF4ABORT

F1

F4

SLOT4

Slot x

(Option Card)

Slot x Inputs

F1 F2

AB

ANALOG INPUT

HIGH REFERENCE
HIGH REF

SLOT5

(Analog Inputs)

F3

F2

SLOT6

F4

20 mAF1EXIT

CALIBRATING

Slot x Outputs

CLOSEF2OPENF3EXIT

(Alarms)

F1 F2

AB

ALARMS

F1

F3

C

Slot x Outputs

F1 F2

AB

ANALOG OUTPUT

F1

4 mA

CALIBRATING

F1

UPF2DOWNF3STOREF4ABORT

20 mA

F2

(Analog Outputs)

CD

TEST

F3 F4

F3

% Full Scale

EXIT

Slot x Inputs

(RTD Inputs)

F1 F2

AB

ANALOG INPUT

F4

LOW REFERENCE

F1

aLOWF2aHIGH

HIGH REFERENCE

LOW REF

HIGH REF

F1

STOREF2ABORT

F1

EXIT

NOTE: Plain text represents prompt area mess ages and
boxed text represents option bar choices.
Fx represent function keys to select option bar choices.

Slot x Outputs

F1 F2

AB

FREQUENCY

(Freq./Total.)

PULSES

F3CF4

D

Calibration 1-15

Figure 1-6: Calibration Menu Map

Chapter 2

Error Codes and Screen Messages

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

E0: No Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E1: Low Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E2: Sound Speed Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E3: Velocity Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

E4: Signal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E5: Amplitude Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E6: Cycle Skip, Accel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E7: Special Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

E8: Temp In Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E9: Temp In Return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E10: Weak Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E11: Not Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E12: Incoherent Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

E13: Over Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

E14: Totals Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Screen Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

March 2008

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 2-1 below.

Prompt Area

Locator Bar

Pointer

Velocity Ft/s

6.95

Ch1 E1: Low Signal

Option Bar

Error Message

Figure 2-1: A Typical Display Screen

Note: For a 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 DF868.

If an error message appears on the display screen during oper ation of
the Model DF868, refer to the appropriate section of this chapter for
instructions on how to proceed.

Error Codes and Screen Messages 2-1

March 2008

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
Program.

Action: Using the procedures in Chapter 3, Diagnostics, check

the components listed above. Also, check the value
programmed into the
in the Programming Manual (page 1-31 for the 1-channel
DF868, or page 1-25 for the 2-channel DF868).

SETUP SIGNL submenu of the User

SETUP SIGNL submenu, as described

E2: Sound Speed Error Problem: The sound speed exceeds the limits programm ed 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 sound speed to tabulated nominal

values for the fluid being used and correct any
programming errors. Refer to Chapter 3, Diagnostics, to
correct any flowcell and/or transducer problems (pages
3-5 to 3-8).

E3: Velocity Range Problem: The velocity exceeds the limits programmed in the 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).

2-2 Error Codes and Screen Messages

March 2008

E4: Signal Quality Problem: The signal quality is outside the limits programmed in the

SETUP submenu of the User Program.

Cause: T oo high a signal strength may be caused by th e 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.

E5: Amplitude Error Problem: The signal amplitude exceeds the limits programmed in

SETUP submenu of the User Program.

the

Cause: Excessive levels of an attenuating gas, such as CO

, are

2

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.

Error Codes and Screen Messages 2-3

March 2008

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 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 two­phase content — switch to transit-time mode.

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 two­phase 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 two­phase content — switch to transit-time mode.

2-4 Error Codes and Screen Messages

March 2008

E13: Over Range Problem: This error code message indicates that the present

measurement exceeds the capacity of the meter.

Cause: A internal mathematical overflow has occurred in either

the volumetric or mass flow calculations.

Action: 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 Gu ide

for instructions.

E14: Totals Overflow Problem: The totalizers are unable to keep up with the total flow

signals.

Cause: The programmed units/pulse value is too small.

Action: Select a larger number of units/pulse value.

Error Codes and Screen Messages 2-5

March 2008

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 2-1 below.

Table 2-1: Screen Messages

Message Meaning

Power Up Messages

Backup Battery FAIL The 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 The DSP (digital signal processor) has passed.

DSP RAM Failed The DSP (digital signal processor) RAM has failed. Contact the factory.

DSP RAM OK The DSP (digital signal processor) RAM has passed.

EPROM sum = XXXX Record the EPROM sum at initial power up and periodically thereafter.

FRIGID_INIT Executed The NVR (non-volatile RAM) was automatically initialized due to a memory

fault. Contact the factory.

NVR FAIL The non-volatile RAM has failed. Contact the factory.

NVR OK The non-volatile RAM has passed.

Measurement Mode Messages

All Logs Cleared! hit key 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 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

2. recalling a site - there are no site files to recall

3. clearing a site - there are no sites to delete

4. printing a site - there are no sites to print

5. displaying a site - there are no sites to display

Hit any key to resume taking measurements.

Do you want to SAVE? 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.

End Time must exceed

Start Time by 5 min.

Header invalid An option card error indicating a programming failure or a loss of memory.

The site file or log name is already in use. Enter a different name.

This message appears when in the LOG menu. Enter an end time that is at
least five minutes later than the start time.

Contact the factory.

2-6 Error Codes and Screen Messages

March 2008

Table 2-1: Screen Messages

Message Meaning

Log Active, END only

hit any key
Log DONE,

to inspect hit any key

Log hasn’t started! hit key When in the LOG menu, this message indicates that the log has not yet

OK, settling The measurement has not stabilized. Wait before taking a reading.

Outside limits,

value rejected.

Overflow The display value overflowed. Reduce the number of decimal digits or

??P<L Enter L again. The entered path length (P) is less than the axial dimension (L). Enter a new

range is X.XX to X.XX When in the User Program, this message indicates that the entered number

Review calibration An option card error indicating a programming failure or a loss of memory.

Review parameters An option card error indicating a programming failure or a loss of memory.

Staring time must exceed

current time

Write error. An option card error indicating a programming failure or a loss of memory.

When in the LOG menu, this message indicates that the log is still compiling
data. Only the End Time may be edited.

When in the LOG menu, this message indicates that the log is complete. Hit
any key to display the log.

started.

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.

change the units.

value for L.

is unacceptable. Hit any key and enter a number within the allowable range.

Contact the factory.

Contact the factory.
This message appears when in the LOG menu STD option. Enter a start time

that is later than the current time.

Contact the factory.

Error Codes and Screen Messages 2-7

Chapter 3

Diagnostics

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Displaying Diagnostic Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostic Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Flowcell Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Transducer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

March 2008

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

• 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.

Displaying Diagnostic Parameters

The Model DF868 has a built-in Diagnostics Menu to aid in the
troubleshooting of flowcell, transducer and/or electrical problems.
The Diagnostics Menu may only be entered from the Big or Dual
measurement mode display. See Chapter 2, Displaying Data, in the
Programming Ma nual for instructions on setting the display screen to
the desired format, and enter the Diagnostics Menu as shown below.

(Ch1) label gSITE ‰

Velocity Ft/s

6.95

(error codes appear here)

CH1 CH2 SUM DIF

Note: For a 1-Channel Model DF868, the above prompt does not

appear, and the following prompt is the initial screen.

(Ch1) label gSITE ‰

Velocity Ft/s

6.95

Press the [←] or [→] keys until
the desired channel option
appears on the option bar. Press
the appropriate
this option.

Press the [←] or [→] keys until

DIAG appears on the option bar.

Press the appropriate
select this option.

[Fx] key to select

[Fx] key to

(error codes appear here)

TIME DIAG

Note: Ch1 (or Ch2), which is shown in parentheses above, appears

in the locator bar only with a 2-Channel Model DF868.

Diagnostics 3-1

March 2008

Displaying Diagnostic
Parameters (cont.)

For example, pressing [F1] displays the Tdown parameter, as shown in
the following prompt.

(Ch1) label gSITE ‰

Ch1 DN Transit usec

Press the [←] and [→] keys and
the appropriate

[Fx] key to

display a different diagnostic

519.7

parameter or to

EXIT the

Diagnostics Menu.

(error codes appear here)

Tdown DEL TA PEAK% Qup

Table 3-1 below lists 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 3-1: Available Diagnostic Parameters

Option Bar Screen Display Description Good Bad

SS up UP Sig Strength Displays the signal strength for the

upstream transducer.

SS do DN Sig Strength Displays the signal strength for the

downstream transducer.

SNDSP Soundspeed Ft/s Displays the measured sound speed of

the fluid.

Tup UP Transit S usec Displays the upstream transit time of

the ultrasonic signal in microseconds.

Tdown DN Transit usec Displays downstream transit time of

the ultrasonic signal in microseconds.

DELTA DeltaT usec Displays the difference in µsec

between upstream and downstream
transit times.

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 N.A. N.A.

PEAK% PEAK% Displays the percentage of peak

(set to +50 by default).

THETA 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).

Qup UP Signal Q Displays the signal quality for the

upstream transducer.

Qdown DN Signal Q Displays the signal quality for the

downstream transducer.

50–75 <50 or >75

50–75 <50 or >75

N.A. N.A.

N.A. N.A.

N.A. N.A.

N.A. >10,000

nsec

N.A. N.A.

N.A. N.A.

N.A. N.A.

Š 1200 –400 to +400

Š 1200 –400 to +400

3-2 Diagnostics

March 2008

Table 3-1: Available Diagnostic Parameters (Continued)

Option Bar Screen Display Description Good Bad

AMPup UP Amp Discrim Displays the value for the amplitude

discriminator of upstream transducer.

AMPdn DN Amp Discrim Displays the value for the amplitude

discriminator of the downstream
transducer.

CNTup Counts up Displays automatic gain control

setting for the upstream signal.

CNTdn Counts down Displays automatic gain control

setting for the downstream signal.

P#up UP +- Peak Displays signal peaks for the upstream

transducer.

P#dn DN +- Peak Displays signal peaks for the

downstream transducer.

NFup UP Norm Factor Displays the normalization factor for

the upstream transducer.

NFdn DN Norm Factor Displays the normalization factor for

the downstream transducer.

Cxdcr CEE1 Displays the speed of sound in the

transducer (clamp-on only).

TEMPs Supply Temp deg F Displays the temperature for the

supply input (energy measurement).

TEMPr Return Temp deg F Displays the temperature for the

return input (energy measurement).

Ts-Tr Supply-Rtn Difference between supply input and

return input measurement (energy
measurement).

DENSs Supply Dens Displays the density for the supply

input (energy management)

DENSr Return Dens Displays the density for the return

input (energy management)

DELTh Delta h Displays the delta enthalpy, which is

the difference between the supply and
return. Enthalpy is a measure of
energy contained in the fluid (energy
measurement).

TW Transmit Wedge Displays the current adjustment in

transit time measurements due to the
signal delay in the transducers.

24 ± 5 <19 or >29

24 ± 5 <19 or >29

N.A. N.A.

N.A. N.A.

100-2300 <100 or

>2300

100-2300 <100 or

>2300

0.85-1.0 <0.85

0.85-1.0 <0.85

N.A. N.A.

N.A. N.A.

N.A. N.A.

N.A. N.A.

N.A. N.A.

N.A. N.A.

N.A. N.A.

N.A. N.A.

Diagnostics 3-3

March 2008

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 A-2 on page A-3. These values can then be
compared to future values to help diagnose any future malfunction of
the system.

3-4 Diagnostics

March 2008

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:

• liquid problems

• pipe problems.

Read the following sections carefully to determine if the problem is
indeed related to the flowcell. If the instructions in this section fail to
resolve the problem, contact the factory for assistance.

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 des ign.

3. The fluid must not excessively attenuate ultrasound signals.

Some fluids, particularly those that are very viscous, readily
absorb ultrasound energy . In such a case, an
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.

E1 error code message

Diagnostics 3-5

March 2008

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 cures 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 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.

3-6 Diagnostics

March 2008

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.

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
must be replaced. Contact the factory for information on
transducers in materials suitable for the application.

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.

Diagnostics 3-7

March 2008

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
between 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 als o 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: 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.

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.

3-8 Diagnostics

Chapter 4

Parts Replacement

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removing the Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Replacing the EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Installing an Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Replacing the LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Installing the Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

March 2008

Introduction The electronics console of the Model DF868 has been designed to

permit easy on-site upgrades and parts replacement. See Figure 4-1
on page 4-10 and Figure 4-2 on page 4-11 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:

• fuse replacement

• printed circuit board (PCB) removal and installation

• EPROM replacement

• 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 unit.

Note: For compliance with the European Union’s Low Voltage

Directive (73/23/EEC), this unit requires an external power
disconnect device such as a switch or circuit breaker. The
disconnect device must be marked as such, clearly visible,
directly accessible, and located within 1.8 m (6 ft) 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.

Parts Replacement 4-1

March 2008

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 before 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 (

RS232 terminal block. As shown in Figure 4-1 on page 4-10, 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.

TB1) and the

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 4-1 below and on the wiring diagram label.

Table 4-1: Line Voltages & 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. For LVD 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 into service.
Reconnect the main power and resume taking measurements.

Note: Be sure to recor d the fuse replacement in Appendix A, Service

Record.

4-2 Parts Replacement

March 2008

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 4-1 on page 4-10 and Figure 4-2 on page 4-11 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 standoffs along the bottom edge of the printed circuit board.

Note: For an LVD compliant meter with the clear plastic shroud

over the electrical connectors, there will be standoffs in these
two locations. For meters not equipped with this shroud, there
will be Phillips head screws in 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 4-2 on page 4-11). 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.

Parts Replacement 4-3

March 2008

Removing the Printed
Circuit Board (cont.)

If the printed circuit board is being replaced, proceed to the section on
Installing the Printed Circuit Board (page 4-7) now. Otherwise, refer
to the appropriate section for instructions on Installing an Option

Card (page 4-5), Replacing the EPROM (below), or Replacing the
LCD Display (page 4-6).

Replacing the EPROM The Model DF868’s User Program is stored on an erasable

programmable read only memory (EPROM) chip. The EPROM,
which is designated as component
of the rear of the printed circuit board. See Figure 4-2 on page 4-11
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.

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.

U4, is located in the top left corner

Caution!

3. Using a chip puller, remove the EPROM from its socket. If a chip

puller is unavailable, a straightened paper clip may be used in the
notches at 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. By applying equal pressure on all four corners, gently press the

EPROM into the socket until it is fully seated. Do not strike the
EPROM or apply excessive force during this procedure.

Complete the EPROM replacement by proceeding to the Installing
the Printed Circuit Board (page 4-7) 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).

4-4 Parts Replacement

March 2008

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 4-2 on page 4-11 and
complete the following steps:

1. Remove the printed circuit board, as described in a previous

section of this chapter.

2. If one 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.

3. There are six 32-pin option card sockets (

J41–J46) on the rear of

the printed circuit board. T o 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 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.

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 4-1 on
page 4-10.

Complete the option card installation by proceeding to the Installing
the Printed Circuit Board (page 4-7) section of this chapter.

Parts Replacement 4-5

March 2008

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 4-1 on page 4-10
for the component locations, and complete the following steps:

1. Remove the printed circuit board, as described in a previous

section of this chapter.

2. Using a 3/16 in. nutdriver, remove the four nut/washer sets that

secure the display shroud to the inside of the console cover. Lift
the display shroud off its mounting studs.

3. Using a 1/4” nutdriver, remove the 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 4-2 on page 4-11.

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.

4-6 Parts Replacement

March 2008

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 4-1 on page 4-10 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 4-2 on page 4-11). 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 4-1 on page 4-10 and
Figure 4-2 on page 4-11 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 towar d 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

printed 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

install the three long standoffs on the right side of the

some patience, but resist the temptation to place the
grounding strap on top of the printed circuit board.

Parts Replacement 4-7

March 2008

Installing the Printed
Circuit Board (cont.)

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 circuit 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: For an 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 scre ws in these two locations.

9. For LVD 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, refer to Chapter
2, Initial Setup, of the Startup Guide and Chapter 1, Calibration, of
the Service Manual for instructions on properly 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 Parts Replacement

March 2008

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 4-2.

Table 4-2: Spare Parts List

Part Number Description

703-1127-02 Option Card - Alarms, Hermetically Sealed
703-1127-03 Option Card - Alarms, General Purpose
703-1145-02 Option Card - Analog Inputs
703-1126-02 Option Card - Analog Outputs
703-1145-03 Option Card - RTD Inputs
703-1144-02 Option Card - Totalizer/Frequency Outputs

703-1358 Option Card - MODBUS

421-703 Card Cage (Metal Bracket)
417-027 Card Guide, Nylon

703-1247 Printed Circuit Board

705-671 LCD Display Assembly
147-744 EPROM
421-700 Conduit Plate, 1/2”
421-701 Conduit Plate, 3/4”
421-702 Conduit Plate, Blank
421-946 LVD Plastic Shroud
421-686 Main Aluminum Shroud
442-484 Label, Wiring Diagram

T o purchase the parts listed in Table 4-2 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 purchase.

Parts Replacement 4-9

FRONT VIEW

G – + DC
G N/L2 L1 AC

March 2008

SIDE VIEW

BOTTOM VIEW

Parts Replacement 4-10

Figure 4-1: Standard Model DF868 - Electronics Console Assembly

G – + DC

G N/L2 L1 AC

March 2008

Figure 4-2: Standard Model DF868 - Printed Circuit Board Assembly

Parts Replacement 4-11

Appendix A

Service Record

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

March 2008

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.

Data Entry Record complete and detailed service data for the Model DF868 in

Table A-1 below. Make additional copies of the table as needed.

Table A-1: Service Record

Date Description of Service Performed By

Service Record A-1

March 2008

Table A-1: Service Record (Continued)

Date Description of Service Performed By

A-2 Service Record

March 2008

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 A-2 below.

Table A-2: Diagnostic Parameters

Parameter Initial Current Parameter Initial Current

SS up CNTup
SS do CNTdn

SNDSP P#up

Tup P#dn

Tdown NFup

DELTA NFdn

Reynolds #

K (RE)

PEAK%

1

THETA

Qup

Qdown

AMPup

AMPdn TW

1

available only for Clamp-on transducers

2

available only if Energy = ON

Cxdr

TEMPs

TEMPr

Ts-Tr

DENSs

DENSr

DELTh

1

2

2

2

2

2

2

Service Record A-3

Appendix B

Optional Enclosures

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Rack Mount Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Rack Mount Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Rack Mount Option Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Rack Mount EPROM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Rack Mount LCD Display Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Rack Mount Printed Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . B-7

March 2008

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

• EPROM replacement

• LCD display replacement

• 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 device must be marked as such, clearly visible,
directly accessible, and located within 1.8 m (6 ft) of the
Model DF868.

Rack Mount Enclosure Refer to Figure B-1 on page B-10 and Figure B-2 on page B-11 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.

Optional Enclosures B-1

March 2008

Rack Mount Fuse Replacement

If it has been determined that the fuse in the Model DF868 requires
replacement, refer to Figure B-1 on page B-10 and Figure B-2 on
page B-11, and complete the following steps:

1. On the 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 Table B-1 below and on the rear panel label.

Table B-1: Line Voltages & 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 recor d the fuse replacement in Appendix A, Service

Record.

B-2 Optional Enclosures

March 2008

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: If 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 B-2 on page B-11 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 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.

Optional Enclosures B-3

March 2008

Rack Mount Option Card
Installation (cont.)

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 rotated 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.

B-4 Optional Enclosures

March 2008

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. T o replace the EPROM, refer
to Figure B-2 on page B-11 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. 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.

2. Using a chip puller, remove the EPROM from its socket. If a chip

puller is unavailable, a straightened paper clip may be used in the
notches at opposite corners of the socket. Gently pry the EPROM
up, a little at a time, at each notch until it comes free.

3. Make sure that the beveled 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.

Optional Enclosures B-5

March 2008

Rack Mount LCD Display Replacement

The Model DF868 measurements are displayed on a two-pane LCD
graphic display panel. The LCD display normally provides year s of
dependable service, but it is field-replaceable when necessary.

To replace the LCD display, refer to Figure B-2 on page B-11 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 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 over
the cables to protect them against abrasion.

B-6 Optional Enclosures

March 2008

Rack Mount LCD Display
Replacement (cont.)

Rack Mount Printed Circuit Board Replacement

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.

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.

Circuit Board Removal Refer to Figure B-2 on page B-11 and complete the followi ng 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. 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

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

from the printed circuit board. Use a marker to identify pin #1 on
the right side (keypad side) of these connectors.

RS232, ANALOG OUT and TRANSDUCER connectors

POWER LEADS from the screw terminals at the

Optional Enclosures B-7

March 2008

Circuit Board Removal
(cont.)

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

connector

J2 beneath the left side of the printed circuit board.

DISPLAY BACKLIGHT cab le from

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 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.

Circuit Board Installation Refer to Figure B-2 on page B-11 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

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

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

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.

LCD DISPLAY CABLE connector to terminal J52 near

DISPLAY BACKLIGHT cable to connector J2

KEYPAD CABLE connector to terminal J50 near the

B-8 Optional Enclosures

March 2008

Circuit Board Installation
(cont.)

5. Install the RS232, ANALOG OUT and TRANSDUCER connectors onto

the printed circuit board at the locations indicated in Figure B-2 on
page B-11. Make sure the marked pin #1 sides of the connectors
face the right side (keypad side) of the enclosure.

Note: If any leads have come loose from the screw terminals on

these connectors, refer to Appendix C, Optional Enclosures, of
the Startup Guide for wiring instructions.

6. Reconnect 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.

Optional Enclosures B-9

March 2008

4.19 (106)

3.31 (84)

Fuse

11.37
(289)

USE ONLY WITH A 250V FUSE

14.83 (377)

16.99 (432)

15.70 (399)

A / OUT ALARMS A / IN RTD IN

11.82
(300)

13.13
(333)

Figure B-1: Model DF868 Rack Mount Enclosure Dimensions (ref. dwg #712-1076)

2.25

5.22

(57)

(133)

DF868

18.25 (464)

19.00 (483)

Optional Enclosures B-10

March 2008

Figure B-2: Model DF868 Rack Mount Console Assembly (ref. dwg #705-849)

Optional Enclosures B-11

Index

March 2008

A

Acceleration Error - E6 . . . . . . . . . . . . . . . . . 2-3

Alarms Option Card, Testing . . . . . . . . . . . . 1-10

Amplitude Error - E5 . . . . . . . . . . . . . . . . . . . 2-3

Analog Inputs Option Card, Calibrating . . . . 1-6

Analog Outputs (Slot 0)

As Calibrated Current Source . . . . . . . . . . 1-6

Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Linearity. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Resolution . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

B

Bracket, Option Card . . . . . . . . . . . . . . . . . . . 4-5

C

Cable

Backlight . . . . . . . . . . . . . . . . . . . . . . 4-3, 4-8

Display . . . . . . . . . . . . . . . . . . . . . . . . 4-3, 4-6

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Calibrating

See Parameter Name

Calibration Menu, Entering . . . . . . . . . . . . . . 1-1

Contamination, Gas . . . . . . . . . . . . . . . . . . . . 3-5

Corrosion, Transducers . . . . . . . . . . . . . . . . . 3-7

E

EPROM

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

User Program . . . . . . . . . . . . . . . . . . . . . . .4-4

Error Codes. . . . . . . . . . . . . . . .2-2, 2-3, 2-4, 2-5

Error Message, Display Screen. . . . . . . . . . . .2-1

Expansion Slots. . . . . . . . . . . . . . . . . . . . . . . .1-1

F

Flowcell Problems

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Fluid Problems . . . . . . . . . . . . . . . . . . . . . . . .3 -5

Fuse Replacement. . . . . . . . . . . . . . . . . . . . . .4-2

G

Gas

Contamination. . . . . . . . . . . . . . . . . . . . . . .3-5

Physical Requirements . . . . . . . . . . . . . . . .3-5

Soundspeed . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Grounding Strap . . . . . . . . . . . . . . . . . . . . . . .4-7

Guides, Option Card . . . . . . . . . . . . . . . . . . . .4-5

I

D

Diagnostic Parameters

Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Record of Values . . . . . . . . . . . . . . . . . . . .A-3

Diagnostics Menu

Entering . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Exiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Display

Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Display Screen . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Incoherent Signal Error - E12. . . . . . . . . . . . .2-4

K

Keypad Cable . . . . . . . . . . . . . . . . . . . . . . . . .4-3

L

LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Leaks, Transducers . . . . . . . . . . . . . . . . . . . . .3-7

Low Signal Error - E1. . . . . . . . . . . . . . . . . . .2-2

LVD Statement . . . . . . . . . . . . . . . . . . . . . . . .4-1

N

No Error - E0 . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Numer Option for RTD Option Card . . . . . . .1-9

Index 1

March 2008

Index (cont.)

O

Option Card

Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Expansion Slots . . . . . . . . . . . . . . . . . . . . .1-1

Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Installing. . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Over Range Error - E13 . . . . . . . . . . . . . . . . .2-5

P

Pipe

Measurements. . . . . . . . . . . . . . . . . . . . . . .3-6

Problems . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Poor Signal Error - E11 . . . . . . . . . . . . . . . . .2-4

Printed Circuit Board

EPROM. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Problems

Flowcell . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Transducers. . . . . . . . . . . . . . . . . . . . . . . . .3-7

T

Temperature Input Return Error - E8 . . . . . . 2-4

Temperature Input Supply Error - E8 . . . . . . 2-4

Totalizer/Frequency Option Card, Testing . 1-12

Totals Overflow Error - E14 . . . . . . . . . . . . . 2-5

Transducers

Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Internal Damage . . . . . . . . . . . . . . . . . . . . 3-7

Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Physical Damage . . . . . . . . . . . . . . . . . . . . 3-7

Placement . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

U

User Program

ERPOM . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Upgrading . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

V

Velocity Range Error - E3 . . . . . . . . . . . . . . . 2-2

R

Reboot, Automatic . . . . . . . . . . . . . . . . . . . . .1-1

Replacing

See Part Name

RTD Option Card, Calibrating . . . . . . . . . . . .1-9

S

Screen Messages, Table . . . . . . . . . . . . . . . . .2-6

Service Record . . . . . . . . . . . . . . . . . . . . . . . A-1

Shroud

Aluminum. . . . . . . . . . . . . . . . . . . . . . 4-1, 4-8

LCD Display. . . . . . . . . . . . . . . . . . . . . . . .4-6

LVD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Signal Quality Error - E4 . . . . . . . . . . . . . . . .2-3

Sockets, Option Card . . . . . . . . . . . . . . . . . . .4-5

Soundspeed

Error - E2 . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . .4-9

Special Input - E7 . . . . . . . . . . . . . . . . . . . . . .2-3

W

Weak Signal Error - E10 . . . . . . . . . . . . . . . . 2-4

2 Index

GE

Sensing

We, Panametrics Limited

Shannon Industrial Estate

Shannon, County Clare

Ireland

declare under our sole responsibility that the

DF868 Liquid Ultrasonic Flowmeter

GF868 Flare Gas Ultrasonic Flowmeter

GM868 Multi-Purpose Gas Ultrasonic Flowmeter

GN868 Natural Gas Ultrasonic Flowmeter
GS868 Steam Mass Ultrasonic Flowmeter

to which this declaration relates, are in conformity with the following standards:

• EN 61326:1998, Class A, Annex A, Continuous Unmonitored Operation

• EN 61010-1:1993 + A2:1995, Overvoltage Category II, Pollution Degree 2

DECLARATION

OF

CONFORMITY

following the provisions of the 89/336/EEC EMC Directive and the 73/23/EEC Low Voltage Directive.

The units listed above and any transducers supplied with them (spoolpieces are addressed under a separate
declaration of conformity) 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.

Shannon - June 1, 2002

Mr. James Gibson

GENERAL MANAGER

TÜV

TÜV ESSEN

ISO 9001

U.S.

CERT-DOC-H4 August 2004

GE

Sensing

Nous, Panametrics Limited

Shannon Industrial Estate

Shannon, County Clare

Ireland

déclarons sous notre propre responsabilité que les

DF868 Liquid Ultrasonic Flowmeter

GF868 Flare Gas Ultrasonic Flowmeter

GM868 Multi-Purpose Gas Ultrasonic Flowmeter

GN868 Natural Gas Ultrasonic Flowmeter
GS868 Steam Mass Ultrasonic Flowmeter

rélatif á cette déclaration, sont en conformité avec les documents suivants:

• EN 61326:1998, Class A, Annex A, Continuous Unmonitored Operation

• EN 61010-1:1993 + A2:1995, Overvoltage Category II, Pollution Degree 2

DECLARATION

DE

CONFORMITE

suivant les régles de la Directive de Compatibilité Electromagnétique 89/336/EEC et de la Directive Basse Tension 73/
23/EEC.

Les matériels listés ci-dessus ainsi que les transducteurs pouvant être livrés avec (les manchettes faisant l'objet d'une
déclaration de conformité séparée) ne portent pas le marquage CE de la directive des équipements sous pression,
car ils sont fournis en accord avec la directive 97/23/EC des équipements sous pression pour les DN<25, Article 3,
section 3 qui concerne les pratiques et les codes de bonne fabrication pour l'ingénierie du son.

Shannon - June 1, 2002

Mr. James Gibson

DIRECTEUR GÉNÉRAL

TÜV

TÜV ESSEN

ISO 9001

U.S.

CERT-DOC-H4 August 2004

GE

Sensing

Wir, Panametrics Limited

Shannon Industrial Estate

Shannon, County Clare

Ireland

erklären, in alleiniger Verantwortung, daß die Produkte

DF868 Liquid Ultrasonic Flowmeter

GF868 Flare Gas Ultrasonic Flowmeter

GM868 Multi-Purpose Gas Ultrasonic Flowmeter

GN868 Natural Gas Ultrasonic Flowmeter
GS868 Steam Mass Ultrasonic Flowmeter

folgende Normen erfüllen:

• EN 61326:1998, Class A, Annex A, Continuous Unmonitored Operation

• EN 61010-1:1993 + A2:1995, Overvoltage Category II, Pollution Degree 2

KONFORMITÄTS-

ERKLÄRUNG

gemäß den Europäischen Richtlinien, Niederspannungsrichtlinie Nr.: 73/23/EG und EMV-Richtlinie
Nr.: 89/336/EG.

Die oben aufgeführten Geräte und zugehörige, mitgelieferte Schallwandler (Messrohre werden in einer separaten
Konformitätserklärung behandelt) tragen keine CE-Kennzeichnung gemäß der Druckgeräte-Richtlinie, da sie in
Übereinstimmung mit Artikel 3, Absatz 3 (gute Ingenieurpraxis) der Druckgeräte-Richtlinie 97/23/EG für DN<25
geliefert werden.

Shannon - June 1, 2002

Mr. James Gibson

GENERALDIREKTOR

TÜV

TÜV ESSEN

ISO 9001

U.S.

CERT-DOC-H4 August 2004

USA

1100 Technology Park Drive
Billerica, MA 01821-4111
Web: www.gesensing.com

Ireland

Sensing House
Shannon Free Zone East
Shannon, County Clare
Ireland