GE Sensing DF868 Start up Guide
GE
Measurement & Control Flow
DigitalFlow™ DF868
Multipurpose Ultrasonic Liquid Flowmeter
Startup Guide (1- and 2-Channel)
910-176U Rev.E1
February 2016
GE
Measurement & Control
DigitalFlow™ DF868
Multipurpose Ultrasonic Liquid Flowmeter
Startup Guide (1- and 2-Channel)
910-176U Rev. E1
February 2016
www.gemeasurement.com
©2016 General Electric Company. All rights reserved.
Technical content subject to change without notice.
[no content intended for this page]
ii
Preface
Information Paragraphs
Note: These paragraphs provide information that provides a deeper understanding of the situation, but is not
essential to the proper completion of the instructions.
IMPORTANT: These paragraphs provide information that emphasizes instructions that are essential to proper
setup of the equipment. Failure to follow these instructions carefully may cause unreliable
performance.
CAUTION! This symbol indicates a risk of potential minor personal injury and/or severe damage
to the equipment, unless these instructions are followed carefully.
WARNING! This symbol indicates a risk of potential serious personal injury, unless these
instructions are followed carefully.
Safety Issues
WARNING! It is the responsibility of the user to make sure all local, county, state and national
codes, regulations, rules and laws related to safety and safe operating conditions are met for each
installation. The safety of any system incorporating the equipment is the responsibility of the
assembler of the system.
Auxiliary Equipment
Local Safety Standards
The user must make sure that he operates all auxiliary equipment in accordance with local codes, standards,
regulations, or laws applicable to safety.
Working Area
WARNING! Auxiliary equipment may have both manual and automatic modes of operation. As
equipment can move suddenly and without warning, do not enter the work cell of this equipment
during automatic operation, and do not enter the work envelope of this equipment during manual
operation. If you do, serious injury can result.
WARNING! Make sure that power to the auxiliary equipment is turned OFF and locked out before
you perform maintenance procedures on the equipment.
DigitalFlow™ DF868 Startup Guide (1- and 2-Channel) iii
Preface
Qualification of Personnel
Make sure that all personnel have manufacturer-approved training applicable to the auxiliary equipment.
Personal Safety Equipment
Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary
equipment. Examples include safety glasses, protective headgear, safety shoes, etc.
Unauthorized Operation
Make sure that unauthorized personnel cannot gain access to the operation of the equipment.
Environmental Compliance
Waste Electrical and Electronic Equipment (WEEE) Directive
GE Measurement & Control is an active participant in Europe’s Waste Electrical and Electronic Equipment
(WEEE) take-back initiative, directive 2012/19/EU.
The equipment that you bought has required the extraction and use of natural resources for its production. It
may contain hazardous substances that could impact health and the environment.
In order to avoid the dissemination of those substances in our environment and to diminish the pressure on
the natural resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or
recycle most of the materials of your end life equipment in a sound way.
The crossed-out wheeled bin symbol invites you to use those systems.
If you need more information on the collection, reuse and recycling systems, please contact your local or
regional waste administration.
Visit
www.gemeasurement.com/environmental-health-safety-ehs for take-back instructions and more
information about this initiative.
iv DigitalFlow™ DF868 Startup Guide (1- and 2-Channel)
Contents
Chapter 1. Installation
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3.1 Electronics Console Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3.2 Flowcell Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3.3 Transducer Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3.4 Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3.5 Temperature Transmitters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3.6 Transducer Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4 Installing a Flowcell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.5 Installing Temperature Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.6 Mounting the DF868 Electronic Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.7 Making Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.7.1 Wiring the Line Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.7.2 Wiring the Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.7.3 Wiring the 0/4-20 mA Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.7.4 Wiring the Serial Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.7.5 Wiring an Alarms Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7.6 Wiring a 0/4-20 mA Analog Inputs Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7.7 Wiring a Totalizer/Frequency Outputs Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7.8 Wiring an RTD Inputs Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.9 Wiring a 0/4-20 mA Analog Outputs Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.10 Wiring a MODBUS Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DigitalFlow™ DF868 Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) v
Contents
Chapter 2. Initial Setup
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.2 Navigating Through the User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.3 Accessing the User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.3.1 1-Channel Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.3.2 2-Channel Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.4 Activating a Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.4.1 1-Channel Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.4.2 2-Channel Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.5 Entering System Data for a Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.5.1 1-Channel Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.5.2 2-Channel Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.5.3 1- and 2-Channel Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.6 Entering Pipe Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.6.1 Transducer Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.6.2 Pipe Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.6.3 Pipe OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.6.4 Pipe Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.6.5 Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.6.6 Path and Axial Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.6.7 Tracking Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.6.8 Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2.6.9 Reynolds Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.6.10 Calibration Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.7 Exiting the User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Chapter 3. Operation
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.2 Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.3 Using the Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.4 Taking Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.5.1 Foundation Fieldbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
vi DigitalFlow™ DF868 Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Contents
Chapter 4. Specifications
4.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.1 Hardware Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.2 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.3 Flow Accuracy (Velocity). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.4 Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.5 Rangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1.6 Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1.7 Energy Accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1.8 Fluid Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.1 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.2 Power Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.3 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.4 European Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.5 Hazardous (Classified) Location Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.6 Input/Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Operational Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.1 Site Parameter Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.2 Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.3 Display Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.4 Printer Signal Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4 Transducer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.1 Wetted Ultrasonic Flow Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.2 Clamp-On Ultrasonic Flow Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.4.3 Temperature Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.5 Pipe Size & Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.5.1 Wetted Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.5.2 Clamp-On Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.6 PC Interface Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix A. CE Mark Compliance
A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A.3 External Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Appendix B. Data Records
B.1 Option Cards Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
B.2 Initial Setup Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DigitalFlow™ DF868 Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) vii
Contents
Appendix C. Optional Enclosures
C.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
C.2 Rack Mount Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
C.3 Rack Mount Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
C.4 Rack Mount Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Appendix D. Measuring P and L Dimensions
D.1 Measuring P and L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
viii DigitalFlow™ DF868 Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
Chapter 1. Installation
1.1 Introduction
To ensure safe and reliable operation of the Model DF868 Ultrasonic Liquid Flowmeter, the system must be installed in
accordance with the guidelines established by GE engineers. Those guidelines, which are explained in detail in this
chapter, include the following specific topics:
• Unpacking the Model DF868 system
• Selecting a suitable site for the electronics console and the flowcell/transducers
• Installing a flowcell
• Installing temperature transmitters
• Installing the Electronics Console
• Wiring the Electronics Console.
WARNING! The Model DF868 flowmeter can measure the flow rate of many liquids, some of which are
potentially hazardous. In such cases, proper safety practices must be observed.
WARNING! Be sure to follow all applicable local safety codes and regulations for installing electrical
equipment and working with hazardous liquids or flow conditions. Consult company safety
personnel or local safety authorities to verify the safety of any procedure or practice.
ATTENTION EUROPEAN CUSTOMERS!
In order to meet CE Mark requirements, all wiring connections must be made in accordance with the
instructions in Appendix A, CE Mark Compliance.
1.2 Unpacking
Carefully remove the electronics console, the transducers, and the cables from the shipping containers. Before
discarding any of the packing materials, account for all components and documentation listed on the packing slip. The
discarding of an important item along with the packing materials is all too common. If anything is missing or damaged,
contact the factory immediately for assistance.
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 1
Chapter 1. Installation
1.3 Site Considerations
Because the relative physical locations of the flowcell and the Model DF868 electronics console are important, use the
guidelines given in this section to plan the Model DF868 system installation.
1.3.1 Electronics Console Location
The standard Model DF868 electronics enclosure is a Type-4X weather-resistant, dust-tight, indoor/outdoor type.
Typically, the electronics console is mounted in a meter shed. When choosing a mounting site, make sure that the
location permits easy access to the console for programming, testing, and servicing.
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.
1.3.2 Flowcell Location
The pipeline flowcell consists of the flow transducers and any temperature transducers employed as part of the
flowmeter system. Ideally, choose a section of pipe with unlimited access as the flowcell, such as a long stretch of pipe
that is above ground. However, if the flowcell is mounted on an underground pipe, dig a pit around the pipe to facilitate
installation of the transducers.
1.3.3 Transducer Location
For a given fluid and pipe, the Model DF868’s accuracy depends primarily on the location and alignment of the
transducers. In addition to accessibility, when planning for transducer location, adhere to the following guidelines:
1. Locate the transducers so that there are at least 10 pipe diameters of straight, undisturbed flow upstream and 5 pipe
diameters of straight, undisturbed flow downstream from the measurement point. To ensure undisturbed flow,
avoid sources of turbulence in the fluid such as valves, flanges, expansions and elbows.
2. Because sediment at the bottom of the pipe and gas at the top of the pipe may cause attenuation of the ultrasonic
signal, locate the transducers on the side of a horizontal pipe, when possible. If limited pipe access necessitates
top-mounted transducers and the sound beam path includes a reflection, shift the transducers to at least 10° off top
center. This will minimize the influence of any sediment or gas on the reflected ultrasonic signals.
1.3.4 Cable Lengths
Locate the flowcell/transducers as close as possible to the electronics console. The factory supplies transducer cables
up to 1,000 ft (306 m) in length. If longer cables are required, consult the factory for assistance.
1.3.5 Temperature Transmitters
When installing temperature transmitters in the flowcell, locate them downstream of the flow transducers. These
transmitters should be positioned no closer to the flow transducers than 2 pipe diameters and no further away from the
flow transducers than 20 pipe diameters.
2 DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
1.3.6 Transducer Cables
When installing the transducer cables, always observe established standard practices for the installation of electrical
cables. Specifically, do not route transducer cables alongside high amperage AC power lines or any other cables that
could cause electrical interference. Also, protect the transducer cables and connections from the weather and corrosive
atmospheres.
Note: When using non-GE cables to connect the flow transducers to the Model DF868 electronics console, the cables
must have electrical characteristics identical to the GE cables. Type RG 62 a/u coaxial cable should be used,
and each cable must be the same length (within ±4 in.).
1.4 Installing a Flowcell
A flowcell is the section of pipe where the transducers are mounted. It can be created either by mounting the
transducers on the existing pipeline or by mounting them on a spoolpiece. A spoolpiece is a separately manufactured
pipe section, matched to the existing pipe, which contains ports for mounting the transducers. This approach allows the
transducers to be aligned and calibrated before inserting the spoolpiece into the pipeline.
Figure 1 shows a diagram of a typical Model DF868 system. For detailed instructions on installing the transducers
and/or spoolpiece, refer to the supplied drawings and the GE Liquid Transducer Installation Guide (916-055).
Figure 1: A Typical Model DF868 System
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 3
Chapter 1. Installation
1.5 Installing Temperature Transmitters
Optional temperature transmitters may be installed as part of the flowcell, near the ultrasonic transducer ports. Be sure
to observe the siting requirements given earlier in this chapter. These transmitters must use a 0/4-20 mA signal to
transmit the temperature values to the Model DF868 electronics console. In turn, the electronics console will provide a
24 VDC signal to power the transmitters. Any desired transmitters or sensors may be used, but they must have an
accuracy equal to 0.5% of the reading or better.
Note: Resistive Thermal Devices (RTDs) are a good choice for measuring the temperature. If you use direct RTD
inputs, you do not require transmitters.
Typically, a 1/2” NPT female threaded port is used to mount the transmitters on the flowcell. If the pipeline is insulated,
the coupling may need to be extended to provide convenient access. Of course, other types of mounting ports,
including flanged ports, may be used for the transmitters.
Figure 2 shows a typical mounting arrangement for the pressure and temperature transmitters. The temperature sensor
should protrude 1/4 to 1/2 way into the pipe.
Figure 2: Typical Temperature Transmitter Mounting
1.6 Mounting the DF868 Electronic Console
The standard Model DF868 electronics package is housed in a NEMA-4X weather-resistant enclosure. Refer to
Figure 9 on page 15 for the mounting dimensions of this enclosure. For meters housed in one of the optional
enclosures, a dimensional drawing will be shipped with the unit.
IMPORTANT: For meters supplied in one of the optional enclosure styles, refer to Appendix C, Optional Enclosures,
for specific mounting dimensions and instructions.
WARNING! Proper grounding of the DF868 chassis is required to prevent the possibility of electric shock.
See Figure 10 on page 16 to locate the internal ground connection.
4 DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
1.7 Making Electrical Connections
!ATTENTION EUROPEAN CUSTOMERS!
To meet CE Mark requirements, all cables must be installed as described in Appendix A,
CE Mark Compliance.
This section contains instructions for making all the necessary electrical connections to the Model DF868 flowmeter.
Refer to Figure 10 on page 16 for a complete wiring diagram of the unit.
IMPORTANT: For meters supplied in one of the optional enclosure styles, refer to Appendix C, Optional Enclosures,
for the appropriate wiring diagram and specific wiring instructions.
Except for the power connector, all electrical connectors are stored in their terminal blocks during shipment and may be
removed from the enclosure for more convenient wiring. Feed the cables through the conduit holes on the bottom of the
enclosure, attach the wires to the appropriate connectors and plug the connectors back into their terminal blocks.
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.
Once the Model DF868 is completely wired, proceed to Chapter 2, Initial Setup, to configure the unit for operation.
1.7.1 Wiring the Line Power
!ATTENTION EUROPEAN CUSTOMERS!
To meet CE Mark requirements, all cables must be installed as described in Appendix A,
CE Mark Compliance.
The Model DF868 may be ordered for operation with power inputs of 100-120 VAC, 220-240 VAC, or 12-28 VDC.
The label on the shroud inside the electronics enclosure, just above the
line voltage and the fuse rating for the unit (the fuse rating is also listed in Chapter 4, Specifications). Be sure to
connect the meter only to the specified line voltage.
Note: For compliance with the European Union’s Low Voltage Directive (2006/95/EC), 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 D
Note: Only use Class 2 Rated Power supply for line power connection to DC instrument.
Refer to Figure 3 on page 6 or Figure 10 on page 16 to locate terminal block TB1 and connect the line power as follows:
WARNING! Improper connection of the line power leads or connecting the meter to the incorrect line
voltage will damage the unit. It will also result in hazardous voltages at the flowcell and
associated piping and within the electronics console.
TB1 line power terminal block, lists the required
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 5
Chapter 1. Installation
1.7.1 Wiring the Line Power (cont.)
1. Remove the plastic shroud that covers the terminal blocks. Be sure to reinstall the shroud after all of the wiring has
been completed.
2. Strip ¼” of insulation from the end of the power and neutral or line leads (or the positive and negative DC power
leads), and ½” from the end of the ground lead.
3. Connect the ground lead to the internal ground connection located on the side panel of the enclosure (see Figure 3).
IMPORTANT: The incoming ground lead must be connected to the internal ground connection.
4. Connect the neutral or line lead (or the negative – DC power lead) to TB1-2 and the line power lead (or the positive
+ DC power lead) to TB1-3 as shown in Figure 3.
IMPORTANT: Do not remove the existing PC board ground wire or the cover ground wire.
Figure 3: Wiring the Line Power
6 DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
1.7.2 Wiring the Transducers
!ATTENTION EUROPEAN CUSTOMERS!
To meet CE Mark requirements, all cables must be installed as described in Appendix A,
CE Mark Compliance.
Wiring a typical Model DF868 ultrasonic liquid flowmeter system requires interconnection of the following
components:
• a pair of transducers (per channel) mounted in the flowcell
• a lightning protector (optional)
• the electronics console
To wire the transducers, complete the following steps:
WARNING! Before connecting the transducers, take them to a safe area and discharge any static buildup by
shorting the center conductor of the transducer cables to the metal shield on the cable
connector.
1. If an optional lightning protector is being installed, connect it to the electronics end of the cables according to the
instructions provided.
2. Locate the CH1 transducer cables and connect them to the two CH1 transducers.
3. Refer to the wiring diagram in Figure 10 on page 16 and connect the transducer cables to the CH1 terminal block.
Then, secure the cable clamp.
4. For a 2-channel Model DF868 flowmeter, repeat steps 2-3 to wire the Channel 2 transducer system to terminal
block CH2.
Note: It is not required that Channel 2 of a 2-channel Model DF868 be used. This channel may be left inactive for
future use.
After the wiring has been completed, the transducer channel(s) must be activated before measurements can begin. See
Chapter 2, Initial Setup, for instructions.
1.7.3 Wiring the 0/4-20 mA Analog Outputs
The standard configuration of the Model DF868 flowmeter includes two isolated 0/4-20 mA analog outputs
(designated as A and B). Connections to these outputs may be made with standard twisted-pair wiring. The current loop
impedance for these circuits must not exceed 550 ohms.
Refer to Figure 10 on page 16 for the location of terminal block I/O and wire the terminal block as shown.
1.7.4 Wiring the Serial Port
The Model DF868 is equipped with a built-in serial communications port. The standard port is an RS232 interface, but
an optional RS485 interface is available upon request. Proceed to the appropriate sub-section for wiring instructions.
For more information on serial communications, refer to the EIA-RS Serial Communications Manual (916-054).
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 7
Chapter 1. Installation
1.7.4a Wiring the RS232 Interface
Use the serial port to connect the Model DF868 flowmeter to a printer, an ANSI terminal or a personal computer. The
RS232 interface is wired as Data Terminal Equipment (DTE), and the signals available at terminal block J1 are shown
in Table 1. Refer to Figure 10 on page 16 and complete the following steps:
1. Disconnect the main power to the unit.
2. Install the required cable clamp in the chosen conduit hole on the side of the electronics enclosure.
3. Use the information in Table 1 to construct a suitable cable for connecting the Model DF868 to the external device.
If desired, an appropriate cable may be purchased from the factory.
Table 1: RS232 Connection to DCE or DTE Device
DCE
Signal
J1 Pin
5 DTR (Data
6 CTS
7 COM (Ground) 7 5 7 5
8 RX (Receive) 2 3 3 2
9 TX (Transmit) 3 2 2 3
Description
Terminal Ready)
(Clear to Send)
DB25
Pin #
20 4 20 4
47 58
DCE DB9
Pin #
DTE
DB25
Pin #
DTE
DB9
Pin #
Note: Signal names that imply direction (e.g., transmit and receive) are named from the point of view of the DTE
device (the GE meter is usually considered the DTE device). When the RS232 standard is strictly followed,
these signals are labeled with the same name and pin # on the DCE device side as well. Unfortunately, the
convention is not followed because the DTE and DCE side get confused. Therefore, connections that imply
direction are changed to reflect their direction on the DCE side.
4. Feed the flying leads end of the cable through the conduit hole and wire it to terminal block
J1. Connect the other
end of the cable to the printer, ANSI terminal or personal computer, and secure the cable clamp.
After the wiring has been completed, consult the User’s Manual for the external device to configure it for use with the
Model DF868.
1.7.4b Wiring the RS485 Interface
Use the optional RS485 serial port to network multiple DF868 flowmeters to a single computer terminal. Upon request,
the standard RS232 port on the DF868 may be configured as a two-wire, half-duplex RS485 interface, through a device
such as the INMAC Model 800052 RS232-RS422/RS485 converter.
IMPORTANT: The DF868 must be configured at the factory for RS485 operation.
To wire the RS485 serial port, refer to Figure 10 on page 16 and complete the following steps:
1. Disconnect the main power to the unit.
2. Install the required cable clamp in the chosen conduit hole on the side of the electronics enclosure.
8 DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
1.7.4b Wiring the RS485 Interface (cont.)
3. Feed one end of the cable through the conduit hole, wire it to terminal block J1 and secure the cable clamp.
Connect the other end of the cable to the converter, as shown in Figure 4.
Figure 4: Typical RS485 Connections
1.7.4c Wiring the Ethernet Interface
A modified DF868 can use the Ethernet interface to communicate to an internal network. An optional Ethernet card
with a unique MAC (IP) address (installed only in slots 5 or 6) includes an RJ45 connector. To connect the
Ethernet-enabled DF868 to the network, insert the jack of an RJ45 cable into the RJ45 connector, route the cable
through the bottom of the DF868, and wire the other end of the cable to the Ethernet network according to the
manufacturer’s instructions. An external connection is required between the Ethernet option card and the DF868’s
RS232 connector, as shown in Table 2.
Note: The MAC address for a specific DF868 is included with customer documentation. For more information on
setting up the MAC address, refer to Chapter 6 of the Programming Manual.
Table 2: RS232 to Ethernet Interconnections
DF868 Type Terminal Block Terminal Block
RS232 on
Main Board
TB1 on
Ethernet Card
Wall Mount TX Pin 1
RX Pin 2
RTN Pin 3
RS232 on
Main Board
TB2 on
Ethernet Card
Rack Mount TX Pin 1
RX Pin 2
RTN Pin 3
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 9
Chapter 1. Installation
1.7.4d Wiring the MODBUS/TCP Interface
Customers can also use a modified DF868 that provides a MODBUS/TCP interface to communicate to an internal
network. An optional MODBUS/TCP card with a unique MAC (IP) address (installed only in slots 5 or 6) includes an
RJ45 connector. To connect the MODBUS/TCP-enabled DF868 to the network, insert the jack of an RJ45 cable into
the RJ45 connector, route the cable through the bottom of the DF868, and wire the other end of the cable to the Ethernet
network according to the manufacturer’s instructions.
Note: The MAC address for a specific DF868 is included with customer documentation. For more information on
setting up the MAC address, refer to Chapter 6 of the Programming Manual.
1.7.4e Wiring the Foundation Fieldbus Network
Fieldbus network connections are made at J8/J9, pins 1 and 2 (see Figure 5). Optionally, a shield can be connected to
J8/J9 pin 3, depending on the network wiring. Connector J8 or J9 will be installed depending on the option ordered by
the customer.
No connections are made to J8/J9, pins 7 and 9, under normal operation. If it is desired to reset the network board to
factory defaults:
1. Connect a jumper between J8/J9 pin 7 and pin 9.
2. Power cycle the instrument.
3. Ten seconds after the power has been restored to the unit, remove the jumper to return the network board to normal
operation.
9
J9
1
9
J8
1
Figure 5: Network Connections - Standard Option Interior
10 DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
1.7.5 Wiring an Alarms Option Card
The Model DF868 flowmeter can accommodate up to 4 alarm option cards. Each alarms option card includes three
Form C relays (designated as A, B and C).
The alarm relays on the option card are available in two types:
• general purpose
• hermetically sealed for Class I, Division 2 hazardous areas.
The maximum electrical ratings for the relays are listed in Chapter 4, Specifications. Each of the three alarm relays can
be wired either as Normally Open (NO) or Normally Closed (NC).
In setting up an alarm relay, it may be wired for either conventional or fail-safe operation. In fail-safe mode, the alarm
relay is constantly energized, except when it is triggered or a power failure or other interruption occurs. See Figure 6
for the operation of a NO alarm relay in both conventional and fail-safe mode.
Connect the two wires required for each alarm relay in accordance with the pin number assignments shown in
Figure 10 on page 16.
Figure 6: Conventional and Fail-Safe Operation
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 11
Chapter 1. Installation
1.7.6 Wiring a 0/4-20 mA Analog Inputs Option Card
To calculate energy measurement, the Model DF868 requires accurate temperature data from the measurement site.
Transmitters installed in the flowcell can provide this information via an optional 0/4-20 mA analog inputs card. This
option card includes two isolated 0/4-20 mA analog inputs (designated as A and B), each of which includes a 24 VDC
power supply for loop-powered transmitters. Either input may be used to process the temperature signal.
Note: To enter programming data during operation of the meter, it will be necessary to know which input is assigned
to which process parameter. This information should have been entered in Appendix B, Data Records.
The analog inputs, which have an impedance of 118 ohms, should be connected with standard twisted-pair wiring.
Power to the transmitters may be supplied either by the integral 24 VDC power supply on the analog input card or by
an external power supply. Figure 7 shows typical wiring diagrams, with and without an external power supply, for one
of the analog inputs.
Figure 7: Analog Input Wiring Diagram
12 DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
1.7.6 Wiring a 0/4-20 mA Analog Inputs Option Card (cont.)
Wire the analog input terminal block in accordance with the pin number assignments shown in Figure 10 on page 16.
If the flowmeter system includes additional transmitters, the Model DF868 can accommodate up to three more analog
inputs option cards. These option cards are identical to the temperature card described on page 12 and they should be
wired in the same manner (see Figure 10 on page 16).
The analog inputs on the option card(s) can be calibrated with the Model DF868’s built-in analog outputs. However, be
certain that the analog outputs have been calibrated first. See Chapter 1, Calibration, in the Service Manual for the
appropriate procedures.
1.7.7 Wiring a Totalizer/Frequency Outputs Option Card
The Model DF868 can accommodate up to four totalizer/frequency outputs option cards. Each totalizer/frequency
outputs option card provides four outputs (designated as A, B, C, and D) that can be used as either totalizer or
frequency outputs.
Each totalizer/frequency output requires two wires. Wire this terminal block in accordance with the pin number
assignments shown in Figure 10 on page 16. Figure 8 shows sample wiring diagrams of a totalizer output circuit and a
frequency output circuit.
Figure 8: Totalizer/Frequency Outputs Wiring
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 13
Chapter 1. Installation
1.7.8 Wiring an RTD Inputs Option Card
The Model DF868 can accommodate up to four RTD (Resistance Temperature Device) inputs option cards. Each RTD
inputs option card provides two direct RTD inputs (designated as A and B).
Each RTD input requires three wires, which should be fed through one of the conduit holes on the bottom of the
electronic console. (For maximum accuracy, the three wires must be of equal length.) Wire this terminal block in
accordance with the pin number assignments shown in Figure 10 on page 16.
1.7.9 Wiring a 0/4-20 mA Analog Outputs Option Card
The Model DF868 flowmeter can accommodate up to 4 analog outputs option cards. Each analog outputs option card
includes four isolated 0/4-20 mA outputs (designated as A, B, C and D).
Connections to these outputs may be made with standard twisted-pair wiring. The total current loop impedance for
these circuits must not exceed 1000 ohms. Wire this terminal block in accordance with the pin number assignments
shown in Figure 10 on page 16.
1.7.10 Wiring a MODBUS Option Card
A modified DF868 can use the RS485 standard for MODBUS communications. This standard allows up to 32 nodes
(drivers and receivers) on one multidrop network, at distances up to 4,000 ft (1,200 m). To connect the instrument(s) to
the host system, the factory recommends using a 24-gauge (24 AWG) twisted-pair cable with a characteristic
impedance of 120 ohms and a 120-ohm termination at each end of the communications line.
The MODBUS option card must be plugged into either slot 5 or slot 6 of the DF868. On the option card, pin 1 is the
[TMT-] inverting or negative connection and pin 2 is the [TMT+] non-inverting or positive connection. To link the DF868
to the control system, connect the two wires of the twisted-pair cable from these terminals to the corresponding
terminals at the control system, in accordance with the pin number assignments shown in Figure 10 on page 16.
Note: If two MODBUS option cards are installed in the DF868, only the card in slot 5 is activated.
14 DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel)
Chapter 1. Installation
DigitalFlow™ Multipurpose Ultrasonic Liquid Flowmeter Startup Guide (1- and 2-Channel) 15
Figure 9: Model DF868 Type 4X Enclosure (ref. dwg #425-208)
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