MAN_FloBoss S600_A6115_2001-08_EN by Energo System

FLOBOSSâ&#x201E;˘ S600 FLOW MANAGER Instruction Manual

Form A6115 August 2001

Flow Computer Division D301150X012 (loose leaf)

FloBoss S600 Instruction Manual

Revision Tracking Sheet August 2001 This manual is periodically to incorporate new or updated information. The date revision level of each page is indicated at the bottom of the page opposite the page number. A major change in the content of the manual also changes the date of the manual, which appears on the front cover. Listed below is the date revision level of each page. Page All Pages

Revision 8/01

Daniel and FloBoss are marks of one of the Emerson Process Management companies. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners. This product may be covered under one or more patents pending. ď&#x203A;&#x2122; Fisher Controls International, Inc. 2001. All rights reserved. While this information is presented in good faith and believed to be accurate, we do not guarantee satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness or any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. We reserve the right, without notice, to alter or improve the designs or specifications of the products described herein. Printed in the U.S.A.

8/01

FloBoss S600 Instruction Manual

TABLE OF CONTENTS SECTION 1 – OVERVIEW................................................................................................................1-1 1.1 1.2 1.3 1.4 1.5 1.6

Section Contents ........................................................................................................................1-1 Scope of Manual ........................................................................................................................1-1 FloBoss S600 Flow Computer...................................................................................................1-3 IPL 600 ......................................................................................................................................1-6 Config 600 Lite..........................................................................................................................1-6 Config 600 Professional.............................................................................................................1-6

SECTION 2 – INSTALLATION........................................................................................................2-1 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Scope..........................................................................................................................................2-1 Section Contents ........................................................................................................................2-1 Preparing for Installation ...........................................................................................................2-1 Unpacking the FloBoss S600.....................................................................................................2-2 Environmental Considerations...................................................................................................2-2 Required Tools for Installation ..................................................................................................2-3 Installing the FloBoss S600 .......................................................................................................2-3

SECTION 3 – OPERATION ..............................................................................................................3-1 3.1 Scope..........................................................................................................................................3-1 3.2 Section Contents ........................................................................................................................3-1 3.3 Description.................................................................................................................................3-2 3.4 Keypad .......................................................................................................................................3-3 Display .............................................................................................................................................3-6 3.6 Data Pages..................................................................................................................................3-7 3.7 Status/ID Line ............................................................................................................................3-7 3.8 Display Matrix ...........................................................................................................................3-7 3.9 Using the FloBoss S600.............................................................................................................3-9 3.10 Entering Data ...........................................................................................................................3-12 3.11 Alarms......................................................................................................................................3-17 3.12 Printing.....................................................................................................................................3-19 3.13 Special Pages ...........................................................................................................................3-21 3.14 Summary of Operation.............................................................................................................3-22 SECTION 4 – MAINTENANCE........................................................................................................4-1 4.1 4.2 4.3 4.4 4.5 4.6 4.7

Scope..........................................................................................................................................4-1 Section Contents ........................................................................................................................4-1 Cold Start Procedure..................................................................................................................4-1 Reflash Firmware.......................................................................................................................4-3 Network Setup ...........................................................................................................................4-5 Factory Setup .............................................................................................................................4-5 Troubleshooting .........................................................................................................................4-6

SECTION 5 – SETUP AND WIRING ...............................................................................................5-1

8/01

Table of Contents

iii

FloBoss S600 Instruction Manual 5.1 Scope ......................................................................................................................................... 5-1 5.2 5.3 5.4 5.5

Section Contents........................................................................................................................ 5-1 CPU Board ................................................................................................................................ 5-2 P144 I/O Board........................................................................................................................ 5-12 P154 Prover Board .................................................................................................................. 5-21

SECTION 6 – SOFTWARE INTERFACE ...................................................................................... 6-1 6.1 6.2 6.3 6.4 6.5 6.6 6.7

Scope ......................................................................................................................................... 6-1 Section Contents........................................................................................................................ 6-1 System Requirements................................................................................................................ 6-2 Software Installation Procedure ................................................................................................ 6-2 File Locations............................................................................................................................ 6-3 StartUp ...................................................................................................................................... 6-4 Connecting to the FloBoss S600 ............................................................................................... 6-4

APPENDIX A – TECHNICAL DATA............................................................................................. A-1 A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8 A.9

Scope ........................................................................................................................................ A-1 Section Contents....................................................................................................................... A-1 Mechanical and Environmental................................................................................................ A-2 Power Supply ........................................................................................................................... A-3 P152 CPU................................................................................................................................. A-4 P144 I/O ................................................................................................................................... A-7 P154 Prover ............................................................................................................................ A-13 Display-Keypad...................................................................................................................... A-16 Mezzanine Boards .................................................................................................................. A-17

APPENDIX B – ENGINEERING DRAWINGS ..............................................................................B-1 B.1 List of Engineering Drawings ...................................................................................................B-1 GLOSSARY........................................................................................................................................ G-1 INDEX ...................................................................................................................................................I-1

Table of Contents

8/01

FloBoss S600 Instruction Manual 1

SECTION 1 – OVERVIEW 1.1 Section Contents This section includes the following information: Information Section Contents Scope of Manual Organization of Manual FloBoss S600 Flow Computer IPL 600 Config 600 Lite Config 600 Professional

Section 1.1 1.2 1.2.1 1.3 1.4 1.5 1.6

Page Number 1-1 1-1 1-1 1-3 1-5 1-6 1-6

1.2 Scope of Manual This manual introduces the FloBoss S600 Flow Computer, IPL 600 software (used to transfer application programs to the FloBoss S600), and the CONFIG 600 software (used to develop FloBoss S600 applications). This manual describes the installation procedure and shows how to operate the system including entering and modifying data. Basic maintenance and troubleshooting information is also provided.

1.2.1 Organization of Manual The information in this manual is arranged as follows: ♦ Section 1 – Overview provides an overview of the FloBoss S600, including the IPL 600 and Config 600 user interfaces. ♦ Section 2 – Installation provides instructions on installing the FloBoss S600 and includes information on installation preparation, panel mounting procedures, and the installation and removal of the plug-in boards and the front panel. ♦ Section 3 – Operation shows how to use the FloBoss S600. This includes keypad functions, screen displays, system initialization, display navigation, data entry, and printing reports. ♦ Section 4 – Maintenance describes how to initiate a cold start and provides maintenance and troubleshooting information, including the basic board-level test procedures. ♦ Section 5 – Setup and Wiring describes the use of the plug-in connector blocks, field wiring configuration, and link and jumper setting for the plug-in board. ♦ Section 6 – Software Interface introduces the FloBoss S600 user interface and lists the system requirements, software installation instructions, and file locations on the host PC.

8/01

Overview

1-1

FloBoss S600 Instruction Manual ♦ Appendix A – Technical Data contains a complete list of physical, performance, and environmental specifications of the FloBoss S600 and add-in boards. ♦ Appendix B – Engineering Drawings includes pertinent installation and wiring drawings along with the spare parts list. ♦ Appendix C – Glossary is a glossary of terms and abbreviations used in this manual. The FloBoss S600 is a compact, microprocessor-based flow computer that has been designed and built using proven design techniques and methodologies. The FloBoss S600 can function as a stand-alone single/multi-stream flow computer, as a combined meter station and meter stream computer, or as a slave to an external supervisory computer. The FloBoss S600 is supplied with the IPL 600 program (which allows you to transfer applications to the flow computer from a host PC), a standard application, and a download cable. Refer to Figure 1-1 for an illustration of the FloBoss S600 system, including the optional PC interface cable.

Figure 1-1. The FloBoss S600 System

1-2

Overview

8/01

FloBoss S600 Instruction Manual

1.3 FloBoss S600 Flow Computer The FloBoss S600 accepts process input signals and provides process output and control signals to instruments used for fiscal metering, custody transfer, batch loading, and meter proving. The FloBoss S600 provides the following hardware features: ♦ Intel 32-bit 80486 DX2 CPU running at 50 MHz with built-in floating point math co-processor. This configuration is supported by six processors on each I/O board. ♦ Capacity, database, and processing capabilities for up to ten mixed metering runs. The CPU can communicate with up to seven plug-in expansion I/O modules. The panel-mounted case has capacity for one CPU module and up to three I/O modules.

Figure 1-2. CPU Board ♦ Front panel display and keypad for local system operation and data entry. The FloBoss S600 includes a backlit LCD display, 29-button keypad, and an alarm status LED. ♦ The panel case is fabricated from rugged, spot welded zinc coated mild steel with the power supply backplate mounted inside the case. ♦ Multiple communication interfaces include two RS232 serial ports for connection to a printer or RTU, and three RS422/RS485 serial ports (up to 57.6 kBaud) for connection to a Modbus SCADA data network or the DCS Supervisory System. ♦ Network connectivity through Ethernet 10baseT using FTP and TCP/IP protocols. ♦ Dedicated configuration port for connection to the CONFIG 600 user interface.

8/01

Overview

1-3

FloBoss S600 Instruction Manual ♦ Functions such as: ¾ stream and station totalization ¾ batch totalization and correction ¾ 3-term PID control ¾ flow balancing ¾ flow scheduling ¾ automatic proving sequence ¾ K-factor linearization ¾ valve monitor/control ¾ sampler control ♦ Prover operations can be configured to include compact, as well as bi-directional provers. ♦ Modular Intelligent Input/Output (I/O). The I/O can be configured to match most system requirements including multiple streams, multiple products, and primary meters. The I/O card can be configured for the measurement, control, and logic service functions as stated Table 1-1. Table 1-1. I/O Functions Number 12 4 1 3 16 12 3 2 5

Description Analog Inputs Analog Outputs Raw Pulse Output (Proving) 4-wire RTDs Digital Inputs Digital Outputs Frequency Inputs Dual Pulse Inputs 4 Single Pulse Inputs Programmable Pulse Outputs

For more details on the FloBoss S600 hardware, see Appendix A, Technical Data.

1-4

Overview

8/01

FloBoss S600 Instruction Manual

Figure 1-3. Intelligent I/O Board The FloBoss S600 incorporates the following software features: ♦ Batches can be programmed using a quantity method, and individual batch-end warning and end-reached alarms can be configured. ♦ Flow and time weighted averages are configurable for all input variables. These averages can be used to generate correction factors based on daily totals and running batch totals. ♦ Supports up to 16 different alarm groups; typically, the three most commonly used are Computer, System and Process Groups. The current alarm status displays via a single tri-color LED on the front panel of the FloBoss S600. The alarms in the system can also be viewed and accepted from the front panel. ♦ Up to 12 user-defined period reports can be configured. Maintenance, batch, and snapshot (current data) reports are also available. Separate report formats are used for gas, liquid, and proving. Reports can be printed locally. ♦ Each user can be allocated a password-enabled security level from a total of 10 security levels. ♦ Current limiting is provided on start-up in order to prevent large in-rush current spikes. ♦ PID flow control logic can be configured for each meter run as either flow or pressure control.

1.4 IPL 600 The IPL 600 software is the “Interactive Program Loader” (supplied with the FloBoss S600). The IPL 600 software is used to upload and download pre-developed configurations and applications. Note: The FloBoss S600 will not operate until a configuration file has been downloaded from the host PC.

8/01

Overview

1-5

FloBoss S600 Instruction Manual

1.5 Config 600 Lite The Config 600 Lite software (optional) is a subset of the Config 600 Professional software that can be used to upload and download pre-developed configurations and applications. Note: Config 600 Lite is used to custom configure a new FloBoss S600 during installation. Config 600 Lite allows you to perform the following functions from the Config 600 Professional list: ♦ Edit process configuration data, including orifice size, analog input scaling, alarm limits, and keypad values. ♦ Build and customize Modbus slave maps, Modbus master polling sequences, front panel displays, and period report formats. ♦ Customize the alarm system, including alarm groups, suppression, text, and inhibits. ♦ Configure system security by setting user names and passwords, and assigning access levels for each data object. ♦ Reflash the CPU module firmware with software upgrades.

1.6 Config 600 Professional The Config 600 Professional program (optional) allows you to configure the FloBoss S600 from a portable or desktop PC running Windows 95, 98, or NT. Note: The Config 600 Professional is used to create and develop new FloBoss S600 applications. Config 600 Professional allows you to perform the following functions: ♦ Create a new application from base templates for a gas orifice, gas turbine, gas ultrasonic, liquid turbine, or bi-directional prover system. ♦ Edit process configuration data, including orifice size, analog input scaling, alarm limits, and keypad values. ♦ Upload data, such as the process configuration data. ♦ Build and customize Modbus slave maps, Modbus master polling sequences, front panel displays, and period report formats. ♦ Specify the engineering units and totalization rollover value. ♦ Customize the alarm system, including alarm groups, suppression, text, and inhibits. ♦ Configure system security by setting user names and passwords, and assigning access levels for each data object. ♦ Reflash the CPU module firmware with software upgrades. For more details on using CONFIG 600 Lite and CONFIG 600 Professional software, refer to the online help file provided with the program. 1-6

Overview

8/01

FloBoss S600 Instruction Manual The online help is content-sensitive and accessible via the F1 key.

8/01

Overview

1-7

FloBoss S600 Instruction Manual

1-8

Overview

8/01

FloBoss S600 Instruction Manual 2

SECTION 2 – INSTALLATION 2.1 Scope This section provides instructions on installing the FloBoss S600 including installation preparation, panel mounting procedures, and the installation and removal of the plug-in boards, and the front panel.

2.2 Section Contents This section includes: Information Section Scope 2.1 Section Contents 2.2 Preparing for Installation 2.3 Unpacking the FloBoss S600 2.4 Environmental Considerations 2.5 Required Tools for Installation 2.6 Installing the FloBoss S600 2.7 Removing the Front Panel 2.7.1 Installing the Panel-Mounted Unit 2.7.2 Installation and Removal of the Boards 2.7.3 Installing Plug-In Boards 2.7.4 Reinstalling the Front Panel 2.7.5

Page Number 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2

2.3 Preparing for Installation Installation of the FloBoss S600 must conform to all applicable local codes and regulations. All installation procedures should be in accordance with normal practices of good workmanship. Although the FloBoss S600 may not include all of the hardware options described in this manual, the procedure for the basic installation of the unit remains the same. Note: It is strongly recommended that you familiarize yourself with the procedures described in this section before you begin to install the FloBoss S600. The FloBoss S600 uses a modular design, providing maximum flexibility, and ease of installation. The basic panel-mounted version consists of three major components: ♦ Fabricated metal case, complete with pre-installed PSU/backplate and four card slots for the plug-in cards (comprising a dedicated CPU slot and three I/O slots). 8/01

Installation

2-1

FloBoss S600 Instruction Manual ♦ Removable front panel comprising the LCD display and keypad assembly. ♦ Plug-in boards, one CPU board and one I/O board are supplied for a basic configuration (two blanking plates are supplied to cover the unused slots). Figure 2-1 shows the FloBoss S600 system components with the appropriate user-provided tools.

Figure 2-1. All Parts of the Basic FloBoss S600 System

2.4 Unpacking the FloBoss S600 Unpack the FloBoss S600 carefully and inspect all parts for visual damage. All parts should then be checked off against the purchase order. Note: Do not discard any packaging material until all pieces of the shipment have been identified and you are confident that all parts are working correctly.

2.5 Environmental Considerations The FloBoss S600 panel mount is designed for use within the control room and should be placed in a position that provides ease of use, comfort, and safety for operators and maintenance personnel. The optimum height for viewing and using the display and keypad is at operator eye level.

2-2

Installation

8/01

FloBoss S600 Instruction Manual CAUTION Where one or more units are installed in a confined space or with other heat producing equipment, special attention should be given to the combined heating effect. This combined heat could increase the environmental temperature beyond its acceptable threshold impacting performance.

2.6 Required Tools for Installation Before attempting any installation of the FloBoss S600 hardware, ensure you have the following tools: ♦ Small flat-blade screwdriver suitable for the slot headed captive screws on the rear of the case that secure each plug-in board into the case. ♦ 5 mm hex or small adjustable crescent wrench for the front panel bosses. ♦ 2.5 mm Allen wrench suitable for the hex cap screw on the front face of the front panel to secure the front panel molding to the case.

2.7 Installing the FloBoss S600 Refer to the following procedures for installing the various FloBoss S600 components, including the front panel, panel-mounted unit, and plug-in boards.

2.7.1 Removing the Front Panel To begin the installation process, first remove the front panel from the FloBoss S600 as follows: 1. Ensure the FloBoss S600 is switched off. 2. Use a 2.5 mm Allen wrench to remove the hex cap screw from the bottom center of the

front panel. Refer to Figure 2-2.

8/01

Installation

2-3

FloBoss S600 Instruction Manual

Figure 2-2. Removing the Front Panel 3. Carefully slide the FloBoss S600 face up 4 mm (0.15") to allow it to clear the retaining

groove at the top of the case, and then allow the face to come forwards to clear the panel case completely. Refer to Figure 2-3.

Figure 2-3. Lift up Panel

2-4

Installation

8/01

FloBoss S600 Instruction Manual 4. Disconnect the ribbon cable from the back of the front panel, as it is easier to refit when

reconnecting the front panel. Refer to Figure 2-4. CAUTION Do not remove the ribbon cable from the FloBoss S600 board.

Disconnect Here

Figure 2-4. Remove Connector 5. Remove the top and bottom bosses from the unit using a 5 mm hex wrench.

2.7.2 Installing the Panel-Mounted Unit After removing the front panel, you can install the panel-mounted unit as follows: 1. Keeping the environmental considerations in mind, construct the framework of the cubicle

to support the operating panel. Â&#x2122; Note: A standard 19" rack 12.25" high will accommodate up to five FloBoss S600 flow computers. 2. Refer to drawing DE-20438 in Appendix A for position details for two 7 mm (0.276") holes

and a cutout. The panel cut out should be rectangular in shape, 150 mm (5.9") vertically by 66 mm (2.6") horizontally, for each FloBoss S600 unit. A tolerance of +/- 3 mm (0.12") is allowed on each axis. 8/01

Installation

2-5

FloBoss S600 Instruction Manual 3. Panel thickness should be at least 3 mm to prevent distortion. Thinner panels can be used,

but these require the rear of the case to be supported. Refer to Figure 2-5. CAUTION It is recommended that a rear support or anchor is always used to prevent twisting and other distortion effects during installation and maintenance.

Figure 2-5. Panel Mount 4. Place the front panel case against the rear of the prepared cutout. 5. Reinstall the top and bottom bosses, and tighten with a 5 mm hex wrench. 6. When the rear support is fitted, you should use a self-tapping screw to secure the case to the

rear support. The maximum depth of the screw inside the case should be 3 mm (0.12").

2-6

Installation

8/01

FloBoss S600 Instruction Manual

2.7.3 Installation and Removal of the Boards The CPU board is dedicated to the left-most rear slot of the case. The remaining slots can be populated with plug-in I/O boards, or they can be left blank and covered with the blank plates designed for the purpose. CAUTION Ensure suitable electrostatic discharge precautions are taken prior to removing any of the plug-in boards. CAUTION The terminals on some boards may be wired to electrical potentials sufficiently high to cause electrical shock and injury. Make sure the power sources of any connected devices are turned off and discharged before performing any installation or repairs.

Removal of the plug-in boards: 1. Ensure the FloBoss S600 is powered-down before attempting to extract a plug-in board. 2. Unscrew the retention screws before attempting to remove a board to avoid damage to the

pull tabs. Refer to Figure 2-6.

Figure 2-6. Unscrewing the Retention Screws

8/01

Installation

2-7

FloBoss S600 Instruction Manual 3. Remove the plug-in boards by using the pull-tabs for the appropriate board and pull the

board clear of the case. Some rocking of the board may be required to release the connector. Refer to Figure 2-7, Figure 2-8, and Figure 2-9.

Figure 2-7. Preparing to use the pull tabs for board release

Figure 2-8. Using the Pull Tabs

2-8

Installation

8/01

FloBoss S600 Instruction Manual

Figure 2-9. Board Ready for Removal or Final Insertion

2.7.4 Installing Plug-In Boards 1. Install the plug-in boards with care by aligning them in the guides (located at top and

bottom of the case), and gently sliding the board until it mates fully with the appropriate connector on the power supply backplate. 2. Each plug-in board has two â&#x20AC;&#x153;pull tabsâ&#x20AC;? on the backplate. These should be pressed in

securely on insertion. CAUTION The insertion and location of the plug-in boards along the guides does not require excessive force. Take care not to twist or otherwise distort the boards during installation. 3. Secure the board in the case with the retention screws (two per board).

2.7.5 Reinstalling the Front Panel The final stage of the installation process is to reinstall the front panel on the FloBoss S600 as follows: 1. Connect the ribbon cable (from the front of the case) to the socket on the front panel.

8/01

Installation

2-9

FloBoss S600 Instruction Manual CAUTION Observe the orientation of the connector with its mating keyway that will prevent incorrect insertion. Do not to use excessive force to refit the cable. 2. Place the top of the front panel over the retaining groove on the top boss and slide

downwards. 3. To secure the front panel, place the hex socket screw into its recess in the bottom center of

the front panel. 4. Use a 2.5 mm Allen wrench to tighten the screw finger-tight.

CAUTION Take care not to over-tighten the screw; otherwise, damage to the panel face may occur. 5. Turn an additional 180 degrees to complete the installation.

2-10

Installation

8/01

FloBoss S600 Instruction Manual

SECTION 3 â&#x20AC;&#x201C; OPERATION 3.1 Scope This section shows how to use the FloBoss S600, including keypad functions, screen displays, system initialization, data entry, and printing reports. Operation also shows how to navigate the display matrix.

3.2 Section Contents Information Scope Section Contents Description Keypad F Keys Vector and Menu Keys Alarm Light and Keys Numeric Keys Operation Keys Display Menus Data Pages Status/ID Line Display Matrix Using the FloBoss S600 Initialization Navigating the Display Entering Data Changing a Value Example Value Changing Mode Example Mode Exponential Format Security Code

8/01

Section 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.5 3.5.1 3.6 3.7 3.8 3.9 3.9.1 3.9.2 3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5 3.10.6

Operation

Page Number 3-1 3-1 3-2 3-3 3-3 3-4 3-4 3-5 3-5 3-6 3-6 3-7 3-7 3-7 3-9 3-9 3-11 3-12 3-12 3-13 3-14 3-15 3-16 3-16

3-1

FloBoss S600 Instruction Manual Alarms Alarm Light View Alarm Alarm Accept Printing Special Pages Summary of Operation

3.11 3.11.1 3.11.2 3.11.3 3.12 3.13 3.14

3-17 3-17 3-18 3-18 3-19 3-21 3-22

3.3 Description After the FloBoss S600 has been wired for power and external devices, it may be activated by energizing the external 24 VDC power supply. When power is first applied, the unit displays the message RESETTING. Unless LK13 (cold start jumper/link) is installed, the FloBoss S600 displays the message RESTARTING. When the unit initializes properly, a menu appears. You may proceed through the instructions in this section to gain familiarity with the unit. If the FloBoss S600 does not properly initialize, proceed to Section 4 for cold start and configuration procedures. The operation of the FloBoss S600 is through an operator interface comprising an LCD display and a keypad. The layout of the FloBoss S600 front panel is shown in Figure 3-1.

3-2

Operation

8/01

FloBoss S600 Instruction Manual

Figure 3-1. Front Panel

3.4 Keypad The layout of the front panel keypad has been designed to make it easy to use and to reduce the possibility of error. The keys on the keypad are color-coded by type: ♦ Function – yellow ♦ Alarm – dark green ♦ Vector/Menu – dark green ♦ Numeric – light green ♦ Operation – dark green

3.4.1 F Keys The top of the keypad has four function keys numbered F1 to F4. Each F key can be programmed as a shortcut to a frequently used display page. To program a function key: 1. Go to the required display page. 2. Press the Decimal Point key. 3. Press the desired F key to which the display page is to be assigned. 8/01

Operation

3-3

FloBoss S600 Instruction Manual Once programmed, an F key cannot be unassigned unless the SRAM is cleared or the FloBoss S600 is cold started. Refer to Section 3.9. However, you can reassign an F key to a different display page.

3.4.2 Vector and Menu Keys The 4-way directional arrow key is located just below the Menu key. The 4-way directional arrow key allows you to navigate the display matrix and select parameters or data items to view or change. On a data page, use the or keys to view the previous or next display, respectively. The number of the current display is indicated after the decimal point on the Status/ID line. When the display moves vertically to view another row, the data item shown is always the first display cell of that row. The

key is also used as the delete/backspace key when entering or changing data.

Press the Menu key to return up one level of the display hierarchy. On a data page, this key returns key while on any menu page, you to the parent menu. By pressing the Menu key followed by the you return directly to the Main menu.

3.4.3 Alarm Light and Keys Between the F keys and the MENU key is the Alarm light and two Alarm keys, View and Accept. During normal operation, with no alarm activated, the Alarm light is green. When an alarm is activated, the Alarm light flashes red until the cause for the alarm has been viewed and acknowledged using the View and Accept keys, respectively. Unacknowledged alarms are initially displayed with the date and time in inverse video. Once acknowledged, the alarms display in normal video. Multiple alarms display in chronological order. The Alarm light shows a solid red until the alarm has been cleared. A yellow Alarm light indicates either a fault with the display or keypad, or alternatively, a communications failure between the front panel and the CPU module.

3-4

Operation

8/01

FloBoss S600 Instruction Manual

3.4.4 Numeric Keys The lower part of the keypad houses the numeric keys. The numeric keys offer the full number set (09), decimal point (.), and a minus (-) key. ♦ Numeric 0 to 9 – Used to enter or change data and to navigate the display matrix. ♦ Minus – Used to define the default display on the FloBoss S600. To define the default display: 1. Go to the required data display page. 2. Press the Minus key. 3. Press the Minus key again to confirm.

You cannot unassign a default display for a menu page. To unassign a default display, go to a menu page and repeat steps 2 and 3. You can also use the minus key to enter negative quantities and the decimal point when entering fractional quantities. The decimal point is also used to define shortcuts to access frequently used displays; see Section 3.4.1.

3.4.5 Operation Keys The Operation keys are used in conjunction with the Numeric keys to perform a variety of tasks, including: Exponent – The Expt key is used to enter quantities in scientific notation. Where the value to be entered exceeds the space available on the display (20 characters), it is necessary to express the data in exponential terms. Clear – The Clear key is used to cancel or exit from the current operation and return to the previous data display. Clear is also used to activate the default display. Display – The Disp key is used to enter the path of a required display. The path is shown on the Status/ID line at the bottom of every page. Print – The Print key is used to display the print menu, where commands can be requested for various pre-configured reports or logs to a printer or computer terminal.

8/01

Operation

3-5

FloBoss S600 Instruction Manual Change – The Chng key is used to edit a displayed database item. Only items marked with an asterisk (*) are changeable. To enter the edit sequence: 1. Press the Chng key. If more than one asterisk is shown on a data display, the FloBoss S600

highlights the first object on the page. Use the required point.

and

keys to move the highlight to the

2. Press the Chng key again to change the data values. The system automatically determines

whether your assigned security level allows you to change the selected data. In order to prevent accidental re-configuration, certain essential data entry fields require confirmation. While in Change mode, the key can be used to delete digits or characters by backspacing over the displayed data. The Clear key can be pressed at any time to abort the current operation or task. Enter – Used in combination with the numeric and Chng keys, the key is used to confirm the data has been entered correctly and complete an operational sequence.

3.5 Display The LCD display offers eight lines of information displayed as alphanumeric characters. An example of a typical display is shown below. 1. 2. 3. 4.

OVOL FR CVOL FR MASS FR ENERGY

Figure 3-2. LCD Display

3.5.1 Menus All eight lines of the display are used to show the available menu options, which are arranged in a hierarchical parent menu and sub-menu order. Each menu and associated sub-menu is allocated a number between 1 to 8 and can be selected using the numeric keys. If the menu displays more than eight options, press NEXT to display additional items. The following characters are used after the option number to identify the type of sub-menu or data page available: ♦ An asterisk (*) signifies a further menu display. ♦ A decimal point ( . ) signifies a data display.

3-6

Operation

8/01

FloBoss S600 Instruction Manual

3.6 Data Pages Generally, each data display shows a single data item along with the associated text, units, and description. Prompts and messages also appear when you enter or edit data items. For example, if you press the Chng key, and are logged in at the required security level, the display prompts you with either Enter New Value: or displays the available menu options. Depending on the base configuration, not all data items can be modified. A changeable data item is indicated by an asterisk (*) at the end of the display line.

3.7 Status/ID Line On the bottom line of every data page is the Status/ID line. Refer to Figure 3-3.

P1.1 <of 2> Figure 3-3. Status ID Line On the left-hand side of the Status/ID line is the page reference number. For example, P12.5 followed by the number of associated data pages that can be navigated using the and keys. In addition, the Status/ID line indicates whether the flow computer is in Prove mode or Maintenance mode by displaying the characters P or M, respectively, on the right-hand side.

3.8 Display Matrix The FloBoss S600 software system is organized as a structured database of parameters, such as TOTALS, I/O, and CALCULATIONS. The database groups the parameters logically in a matrix of display cells. For example, most I/O parameters are grouped in the same area of the matrix. Within these groups, related data items are organized into rows. For example, for PRT INPUTS, the parameters for Measured, Keypad, and Alarm Limits are all kept in one horizontal row. Refer to Figure 3-4.

8/01

Operation

3-7

FloBoss S600 Instruction Manual

PRT Input 1

I/001 PRT 01

In Use Value: 30.124 Deg.C

Keypad Value: 25.000 Deg.C*

Mode Status: MEASURED *

Measured Value: 30.124 Deg.C

P55.1 <of4>

P55.2 <of4>

PRT Input 1

PRT Channel 1

I/001 PRT 01

Limits (HH/H/L/LL): 100.000 Deg.C* 95.000 Deg.C* 5.000 Deg.C* 0.000 Deg.C*

Resistance: 111.72 ohms

P55.3 <of4>

P55.4 <of4>

Figure 3-4. Database Matrix The PRT Input group is shown in Figure 3-4. The first cell in the row (page 1) displays the In Use Value parameter. You can move one cell to the right, using the key, and the associated Keypad Value and Measured Value parameters display. Press the key two further times and the display changes to the Resistance parameter. You can use the Print key and the configuration option to request a display dump of the whole display matrix. Â&#x2122; Note: The content of the display matrix is application-specific. Although details may vary between different applications, the principle described is the same. Refer to the Application Manual for details of parameters installed in your FloBoss S600.

3-8

Operation

8/01

FloBoss S600 Instruction Manual

3.9 Using the FloBoss S600 If you are already familiar with Spectra Flow Computers, you may find it useful to refer to Section 3.14, Summary of Operation, on page 3-22.

3.9.1 Initialization The FloBoss S600 automatically performs an initialization sequence, including a self-test routine, during startup. The startup screen is shown in Figure 3-5.

STARTUP COMPLETED S/W Version 0.9.0 View Angle Setting 8 LCD Back Light ON Alarm OFF

Figure 3-5. Startup Screen Depending on the setting of the cold start bit-jumper (link) (LK13), located on the P152 plug in board, and the contents of the SRAM, the FloBoss S600 starts up in one of two modes: ♦ Warm Start – If the FloBoss S600 has been previously configured and the cold start jumper is not installed, the FloBoss restarts where it left off prior to being powered down. The Main menu displays following a successful startup. ♦ Cold Start – If the FloBoss S600 is un-configured, has the cold start jumper installed or a Clear SRAM command has been previously issued, the Startup menu displays. Note: The default setting of the cold start jumper is “open” which results in a warm start. When the FloBoss S600 is restarted in warm or cold start mode, the firmware is always copied from Flash to RAM and subsequent operation uses RAM. During a warm start, the configuration memory (SRAM) is not affected. The FloBoss S600 will continue operation using the data stored in the configuration memory just before the restart occurred. Any current accumulated values and online changes that have not been saved will be preserved. A warm start is generally not required when online parameters are changed and accepted.

8/01

Operation

3-9

FloBoss S600 Instruction Manual During a cold start, the configuration files are copied from Flash and replace any currently accumulated totals, as well as any online changes made to the configuration files since the last download from CONFIG 600. Therefore, a cold start is used to reflash a new configuration or to recover from extreme situations, such as a corrupted database. Â&#x2122; Note: When setting the cold start jumper, keep in mind that this setting will also be used when

the FloBoss S600 self starts for any reason, such as a low-voltage shutdown or recovery from a malfunction. Ensure the cold start jumper setting is removed when not required; otherwise, an unplanned restart could result in lost data. The following descriptions of FloBoss S600 operations assume a warm start has been performed. For information on operations after a cold start, refer to Section 4. Following a successful warm start, the Main menu displays as in Figure 3-6.

1* 2* 3* 4* 5* 6*

FLOW RATES TOTALS OPERATOR PLANT I/O SYSTEM SETTINGS TECH/ENGINEER

8* CALCULATIONS

Figure 3-6. Main Menu The Main menu is the starting point or root of the display matrix. From the Main menu, you can navigate the sub-menus to access the required data pages.

3-10

Operation

8/01

FloBoss S600 Instruction Manual

3.9.2 Navigating the Display From the Main menu, select the option you require with the appropriate numerical key. An asterisk (*) before a menu option indicates that further sub-menus are available. A decimal point ( . ) before the menu option shows there is no further sub-menu; selecting this option type displays the first cell in a row of related parameters within the display matrix. To navigate the PLANT I/O option, for example, proceed as follows: 1. Select the PLANT I/O option by pressing 4 from the Main menu (Figure 3-6) and the

available sub- menus display. Refer to Figure 3-7.

1* 2* 3* 4* 5* 6* 7*

ANALOG INPUTS PRT/RTD INPUTS FREQUENCY INPUTS PULSE INPUTS DIGITAL I/OS ANALOG OUTPUTS PULSE OUTPUTS

Figure 3-7. Submenu 2. Select the ANALOG INPUTS option by pressing 1, and then select ADC - 06 by pressing 3.

Refer to Figure 3-8.

1. ADC 01 - ADC01 2. ADC 02 - ACD02 3. ADC 06 - ACD06

Figure 3-8. Analog Inputs

8/01

Operation

3-11

FloBoss S600 Instruction Manual The data item In Use Value for I/O01 ADC 06 displays, which is the first cell in the row of related analog input parameters. As the configuration of your FloBoss S600 may differ from this example, try selecting options from the menus offered in order to reach the parameter that you require. The Status/ID line on the bottom of the display changes as you move left or right across the row of related display pages. An alternative method of selecting the required data page is to enter the unique page address using the Disp key. If you know the location number of the parameter you wish to view, proceed as follows: 1. Press Disp followed by the location number in the format “column.row” such as 1.3. 2. Press Enter.

If you only enter a single number such as the column value, the first cell of the row displays. To return to the parent menu, press the Menu key located above the arrow key; repeated pressing of this key moves you up the display matrix to the Main menu. Note: If you are on a menu or data page, you can return directly to the Main menu at any time key. (except during a change sequence) by pressing the Menu key followed by the If you have pressed the Chng key, the Menu key will not respond until either Clear (to abort the change) or Enter (to complete the change) has been pressed.

3.10 Entering Data Changing the value or mode of any displayed parameter is straightforward with the FloBoss S600. You can modify both numeric values and calculation modes using the Chng key.

3.10.1 Changing a Value Locate the parameter to be changed using one of the methods described in section 3.9.2. If the value is changeable, the data is marked with an asterisk; if there is no asterisk, the data cannot be modified. To change the value of a parameter, proceed as follows: Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required data page. 1. Press Chng on the required data page. 2. Select the required parameter using the

3-12

Operation

keys.

8/01

FloBoss S600 Instruction Manual 3. Press Chng and the prompt ENTER CODE: displays. 4. Key in your Security Code and press Enter (the security code number does not display, but

each digit is indicated by a dot as you key it in). 5. At the prompt ENTER NEW VALUE: key in the new value in integer, numeric, or scientific

notation as appropriate (the current value and any entry limits associated with this parameter are also shown). 6. Press Enter to confirm.

The change mode is automatically exited on accepting or rejecting the mode change if only one data item is changeable on the data page. If necessary, you can edit the new data as you key it in. Enter Change mode and use the delete single figures or characters. If you wish to abort the change, press Clear.

key to

Deleting or canceling the change to the parameter should be done before pressing Enter. The Enter command confirms that you wish the revision to proceed.

3.10.2 Example Value The following example shows how to change the alarm limits for the A/D Converter analog input. 1. Locate the page displaying the alarm limits (HH/H/L/LL) for the Channel 1 I/O01 parameter.

The display shows the location number and the asterisk indicates that the values are changeable. Refer to Figure 3-9.

ADC CHANNEL 1 I/O01 ADC 01 Limits (HH/H/L/LL) 1000.000 barg* 95.000 barg* 5.000 barg* 0.0 barg* 1.0 P52.3 <of5>

Figure 3-9. Alarm Limits

8/01

Operation

3-13

FloBoss S600 Instruction Manual 2. Press Chng and highlight the HH value.

♦ Press Chng again and the display responds with the prompt ENTER CODE:. ♦ Key in your Security Code and press Enter. ♦ At the prompt ENTER NEW VALUE: key in the new value 100 and verify this on the display. 3. Once you have verified the data, press Enter to confirm. The value in the display changes to the new data and recalculates any linked parameters. 4. Repeat the above process for the H, L, and LL limits.

3.10.3 Changing Mode To select a new calculation mode, the key sequence is similar to changing a value. Locate the parameter to be changed using one of the methods described under Section 3.9.2 If the mode is changeable, the mode is marked with an asterisk; if there is no asterisk, the mode cannot be modified. Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required data page. 1. Press Chng on the required data page. 2. Select the required parameter using the

keys.

3. Press Chng and the prompt ENTER CODE: displays. 4. Key in your Security Code and press Enter (the security code number does not display but

each digit is indicated by a dot as you key it in). 5. At the prompt, select the required mode by using the appropriate numerical key (1 to 8). 6. A second mode change window displays asking for confirmation. Press 1 to accept or 2 to

reject the mode change. The change mode is automatically exited on accepting or rejecting the mode change if only one data item is changeable on the data page. The Clear key enables you to cancel the mode change to the parameter, if necessary.

3-14

Operation

8/01

FloBoss S600 Instruction Manual

3.10.4 Example Mode The following example shows how to change the standard density parameter to a calculated value from a keypad-entered value. 1. Locate the page displaying the STR01 STANDARD DENS mode status. Refer to Figure 3-10.

STR01 STANDARD DENS In Use Value: 10.000000 kg/m3

Mode Status: KEYPAD

P32.10 <of 21>

Figure 3-10. Standard DENS 2. Press Chng, key in your Security Code and press Enter. 3. Press 1 to select CALCULATED. Refer to Figure 3-11.

1. CALCULATED 2. KEYPAD

Figure 3-11. Calculated

8/01

Operation

3-15

FloBoss S600 Instruction Manual

Confirm SET TO: CALCULATED

1. YES 2. NO

Figure 3-12. Confirm 4. Press 1 to confirm. The display indicates the revised operational mode. Refer to Figure 3-12.

Note: If the change is not allowed, ‘Denied’ displays on the line you are changing and the change is not implemented.

3.10.5 Exponential Format The Expt key allows you to enter parameters in scientific notation. Where a value is smaller than 0.00000001 or greater than 10000000 (8 significant figures), you must use the Expt key to express the value in exponential terms. You can also use the exponential notation for entering numbers that are within the range of 8 significant figures; but the displayed value will be shown as a normal number. To enter an exponential value: 1. Key in the value. 2. Press the Expt key (an E appears on the display) and then enter the required power. 3. Press the Enter key.

For example, to enter the figure 0.00000009 as an exponential value: Key in 9.0, press Expt, enter -8 to represent the power and press Enter to confirm.

3.10.6 Security Code The security system allows up to 50 unique users. Each user is allocated two individual passwords; one is numeric for access to the FloBoss S600 and the other is alphanumeric for access to the CONFIG 600 Software. In addition, each user is allocated a security level between 0 (highest) and 9 (lowest). Note: Each user should have a unique FloBoss S600 security code and username. Level 0 cannot be set as a login level as it is used for totalizer values, measured values, and such. 3-16

Operation

8/01

FloBoss S600 Instruction Manual The configuration parameters are assigned in predefined groups with common minimum-security level. The security level can be modified for each user application from within CONFIG 600. Please refer to your System Administrator for further information on your password settings and security levels.

3.11 Alarms The default alarm system installed in the FloBoss S600 is a latching, manual, common-accept system. Alarms are triggered when measurements exceed the pre-set limits for a parameter or if there is a malfunction. The alarm may be relayed to a terminal or siren (klaxon) in the Control Room. On the panel of the FloBoss S600, a light indicates an alarm and the source of the alarm is shown on the display.

3.11.1 Alarm Light During normal operation, with no alarms present, the Alarm light is a constant green. When an alarm is activated, the light flashes red until the cause for the alarm has been viewed and the Accept key has been pressed. Refer to Section 3.11.3, Alarm Accept, on page 3-18. Once acknowledged, the light shows a constant red until the alarm condition has been cleared.

8/01

Operation

3-17

FloBoss S600 Instruction Manual

3.11.2 View Alarm Press the View key to display the parameters that have triggered the alarm. The first line of the alarm display indicates the date and time of the alarm. While the alarm remains unaccepted, this line is shown in inverse video. The second and third lines are used to describe where the alarm has been activated and its nature. The total number of alarms, accepted and unaccepted, is shown on the bottom line. Refer to Figure 3-13.

09/11/1999 13:05:00 STR01 CHROM MODE TELEM

Alarm

1 of 9

Figure 3-13. Alarm Display When there is more than one alarm to be viewed, the display can be cycled around all the alarms using the or keys.

3.11.3 Alarm Accept Press the Accept key to notify the FloBoss S600 that you have viewed all the alarms and are prepared to acknowledge them all together. The inverse time and date on all the alarms then returns to normal video. Once an alarm condition is cleared, its alarm prompt is automatically cleared from the display. When all the alarms in the system have cleared, the Alarm light resets to a constant green.

3-18

Operation

8/01

FloBoss S600 Instruction Manual

3.12 Printing By default the FloBoss S600 is configured to output reports to a serial printer or a terminal. The Print key is used to generate either a constant log or pre-configured reports. The Print menu is Figure 3-14.

PRINT OPTIONS 1. 2* 3* 4* 5.

HELP CONFIGURATION REPORTS COMMUNICATIONS CURRENT ALARMS

Figure 3-14. Print Options Pressing 1 or 5 performs the action; 2, 3, or 4 go to the following submenus:

PRINT OPTIONS 1. 2. 3. 4.

CONSTANTS LOG DISPLAY DUMP SECURITY DUMP ALL ALARMS

Figure 3-15. Print Options 2

8/01

Operation

3-19

FloBoss S600 Instruction Manual

PRINT OPTIONS 1. CURRENT REPORT 2. CONFIG REPORT 3. ARCHIVED REPORTS

Figure 3-16. Print Options 3 Pressing 3 in the menu displayed in Figure 3-16 takes you to a submenu listing the reports that are setup to archive reports. Choosing any of those will then display the available reports to print.

PRINT OPTIONS 1. MODBUS MAPS

Figure 3-17. Print Options 4 The following reports can be requested: Constants Log – Lists all the constant parameters and the in-use values that are available for change from the display. Display Dump – Lists the whole display matrix. Security Dump – Lists the current security levels assigned to data items. All Alarms – Lists all possible alarms that can be generated by the alarm system. Current Report – Lists the meter run totals.

3-20

Operation

8/01

FloBoss S600 Instruction Manual Config Report – Lists the configuration parameters, including the installed calculation sets. Archived Reports – Includes all archived reports listed by time and date. Current Alarms – Lists all the acknowledged and un-acknowledged alarms currently set in the flow computer in separate chronological lists. Modbus Maps – Lists the Modbus maps stored in the FloBoss S600 that are assigned to a telemetry link.

3.13 Special Pages The FloBoss S600 includes display pages to perform specific functions, which are located under the TECH-ENGINEER/DISPLAY SETUP menu. Refer to Figure 3-18.

1. 2. 3. 4. 5. 6.

DISPLAY SETUP CONTRAST DATE & TIME DISPLAY TEST SECURITY COMMUNICATIONS

Figure 3-18. Display Setup Menu Display Setup – Includes the parameters associated with the display setup. ♦ Display T/O – The display timeout is the period of non-use before the default display is shown (default 300sec). ♦ Logout T/O – The logout timeout is the period of non-use in change mode before the current user is automatically logged out (default 20sec). ♦ Ident T/O – This is the timeout period of non-use in change mode before the display mode is activated (default 120sec). ♦ Contrast – Used to set the LCD viewing angle. Note: Some models have automatic temperature correction of viewing angle with no manual adjustment provided. Date & Time – Used to set the current date and time.

8/01

Operation

3-21

FloBoss S600 Instruction Manual Display Test – Used to turn all the pixels on and off. Security – Used to enable/disable keypad access and file transfer from the host PC. Communications – Used to display the available COM ports and link status, and define the serial port settings.

3.14 Summary of Operation The following is a summary of the operational features available on the FloBoss S600. Display Matrix – Data items are arranged logically in groups and are placed in cells and rows within a display matrix. See your Application Manual for details of the parameters installed on your FloBoss S600. View Parameter – First, use the numerical keys to select the relevant menu and sub-menu option, and then use the and keys to display the required parameter in the matrix row. Alternatively, press the Disp key, enter the location number (row.column), and press Enter. Return to Main menu – Press the Menu key to view the parent menu. Repeated pressing of this key moves you to the Main menu. Alternatively, press the Menu key followed by the key while viewing a menu or data display (but not during a change sequence) to return directly to the Main menu. Change Value – Select the display cell of the parameter to be changed. An asterisk indicates that the value is changeable. Press Chng, enter Security Code, press Enter, enter new value, and press Enter to confirm. Change Mode – Select the display cell of parameter to be changed. An asterisk indicates that the value is changeable. Press Chng, enter Security Code, press Enter, select the required mode from option list, and press 1 to confirm. Clear – Press Clear to abort the change sequence. Scientific Notation – Use the Exponent key when a value exceeds 8 significant figures. Key in the new value, press Expt, enter required power, and then press Enter to convert value to exponential format. Alarm – Alarms are indicated by a flashing red light. Display alarm details by pressing the View key. Accept each alarm as it displays by pressing the Accept key. Once the fault conditions are removed, the Alarm Light shows a constant green. Print – Press the Print key to print a constant log or generate a report.

3-22

Operation

8/01

FloBoss S600 Instruction Manual Default Display â&#x20AC;&#x201C; Select data display page to be used as default, press the Minus key, and press the Minus key again to confirm. Note you cannot assign a default display for a data entry or menu page. To select a different page to be used as the default, go to the desired page, press the Minus key, and press the Minus key again to confirm. To clear the default page function, go to any menu page, press the Minus key, and press the Minus key again to confirm. Program Function Keys â&#x20AC;&#x201C; Go to the required display page, press the Decimal Point key, and then press the required F key to which the display page is to be assigned.

8/01

Operation

3-23

FloBoss S600 Instruction Manual

3-24

Operation

8/01

FloBoss S600 Instruction Manual 1

SECTION 4 – MAINTENANCE 4.1 Scope This section describes the procedure for initiating a Cold Start on the FloBoss S600. Maintenance also provides instructions for maintaining and troubleshooting the FloBoss S600.

4.2 Section Contents This section includes: Information Scope Section Contents Cold Start Procedure Run Mode Reflash Firmware Download and Reflash Config File Cold Start Network Setup Factory Setup Clear SRAM RAM Disc Start Format Flash Troubleshooting Initial Checks Removing and Replacing Plug-in Boards Changing the Fuse Startup List

Section 4.1 4.2 4.3 4.3.1 4.4 4.4.1 4.4.2 4.5 4.6 4.6.1 4.6.2 4.6.3 4.7 4.7.1 4.7.2 4.7.3 4.7.4

Page Number 4-1 4-1 4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2

4.3 Cold Start Procedure Normally, the FloBoss S600 would be requested to Warm Start. The FloBoss S600 will be unable to Warm Start if: ♦ The FloBoss S600 has not been previously configured. ♦ The Cold Start jumper (LK13) installed. ♦ A Clear SRAM command has been issued. 8/01

Maintenance

4-1

FloBoss S600 Instruction Manual CAUTION Only a suitably qualified person should perform reprogramming of the FloBoss S600.

4.3.1 Run Mode On a running FloBoss S600, prior to programming the Flash memory with the FloBoss S600 operating system firmware, you must set the run mode to Cold Start, as follows: 1. Go to the SYSTEM SETTINGS menu. 2. Select the SYSTEM STATUS sub-menu.

Note: The sequence of keys to access the SYSTEM STATUS page may vary on customized displays. This may also be true for any page in a customized system. 3. Press Chng and the prompt Enter Code: displays. 4. Key in your Security Code. 5. Press 1 to select Cold Start, and press 1 again to confirm. 6. Reboot the FloBoss S600 (power down, wait a minimum of five seconds, and then repower).

Once the FloBoss S600 has completed its start-up initialization sequence, the FloBoss S600 Startup menu displays. Refer to Figure 4-1.

1. WARM START 2. COLD START 3. NETWORK SETUP 4. REFLASH FIRMWARE 5. REFLASH CONFIG 6. 7. 8. FACTORY SETUP

Figure 4-1. Startup Menu The FloBoss S600 Startup menu options include: ♦ Warm Start – This selection restarts a previously configured FloBoss S600 where it left off prior to being powered down. ♦ Cold Start – This is used to build a new metering database on the FloBoss S600 using the configuration files stored in Flash memory. ♦ Network Setup – This is used to configure the TCP/IP, Gateway and Modbus addresses. If the Modbus address has been changed, restart the FloBoss S600 for the change to take place. 4-2

Maintenance

8/01

FloBoss S600 Instruction Manual ♦ Reflash Firmware – This is used to reprogram the FloBoss S600 operating system firmware stored in Flash memory. ♦ Reflash Config – This is used to copy the configuration files into Flash memory from the volatile RAM disk. ♦ Factory Setup – This is used to perform a RAM Disc Start, Clear SRAM, and Format Flash.

4.4 Reflash Firmware The Reflash Firmware option allows you to reprogram the Flash memory with new values for the operating system components and the application firmware. This option requires you to download a binary file from CONFIG 600 into the volatile RAM disk on the FloBoss S600 prior to erasing and reprogramming the Flash memory. Refer to Section 5, PC Setup, for PC software setup and use. CAUTION Under no circumstances should you allow the FloBoss S600 to be turned off while it is erasing or reprogramming the Flash memory; otherwise, the FloBoss S600 will be rendered unusable. Should this occur, the FloBoss S600 must be returned to the factory for system reprogramming. To reprogram the Flash memory: 1. Select the REFLASH FIRMWARE command from the FloBoss S600 Startup menu. 2. Press 1 to confirm, and the following message displays:

PERFORM CONFIG 600 FLASH COMMAND NOW 3. From CONFIG 600, enter the Transfer program, select the required vxworks.bin file and click on

Send Now to download it to the FloBoss S600. 4. The following message displays on the FloBoss S600:

RECEIVING BINARY FILE Once the file has been successfully downloaded, the FloBoss S600 displays the message: RECEIVED OK Note: Do not proceed if the message FLASH FAILED displays. Remove the power connector for 5 seconds and the FloBoss S600 will Cold Start. 5. The FloBoss S600 proceeds to erase and reprogram the Flash memory, and displays the following

message: RESETTING - PLEASE WAIT The FloBoss S600 then restarts; if the FloBoss S600 has not restarted after 30 seconds, remove the power connector for 5 seconds to initiate a Cold Start. 8/01

Maintenance

4-3

FloBoss S600 Instruction Manual

4.4.1 Download and Reflash Config File To allow the FloBoss S600 to retain the configuration data indefinitely following a download from CONFIG 600, the Reflash Config option is used to copy the configuration file into Flash memory from the volatile RAM disc. To reflash the configuration data from the RAM disc: 1. From the Config 600 software, select the Transfer Data option. 2. Choose the Com port connected to the FloBoss S600. Default parameters are 38,400 KB, 8 data

bits, 1 stop bit, and no parity. Â&#x2122; Note: Configurations can also be transferred via Ethernet, as well as by the serial communications port. 3. Select the configuration you require, then select the sections you desire to transfer to the FloBoss

S600. 4. Click on Send Now to download to the FloBoss S600. 5. Select the REFLASH CONFIG command from the FloBoss S600 Startup menu. 6. Press 1 to confirm, and the following message displays:

SAVING CONFIGURATION TO FLASH Once completed, the FloBoss S600 Startup menu displays. For further configurations, the data is automatically stored to flash memory when it has been transferred. The user is not required to manually reflash the configuration.

4.4.2 Cold Start Once the configuration file has been downloaded from the host PC, you can select the Cold Start option to build a new metering database using the configuration data stored in the Flash memory of the FloBoss S600. Prior to any network communications, the necessary network settings should also be set. These parameters can only be viewed or changed via the FloBoss S600 Startup menu. Refer to Network Setup, Section 4.5. To initiate a Cold Start of the FloBoss S600: 1. Select the COLD START command from the FloBoss S600 Startup menu. 2. Press 1 to confirm and the following message displays:

CONFIGURING - PLEASE WAIT 3. A new database is then built using the configuration files held in the Flash memory.

Once completed, the FloBoss S600 Main menu displays.

4-4

Maintenance

8/01

FloBoss S600 Instruction Manual

4.5 Network Setup The Network Setup option allows you to define the TCP/IP Ethernet, Gateway, and Modbus network addresses. When any Modbus slave configuration builder has an address of zero specified, the Modbus port will be configured with the address entered here. This is typically used when the same configuration file is loaded into multiple FloBoss S600 flow computers on the same Modbus network; thus, giving each FloBoss S600 a unique node address. These settings are kept in a separate area of the SRAM database and will be retained following a configuration download. These parameters can only be viewed or changed via the FloBoss S600 Startup menu. To define the network addresses: 1. Select NETWORK SETUP from the FloBoss S600 Startup menu. 2. Select the required address option. 3. Enter the address value (for an Enron Modbus link, a maximum value of 247 is permitted).

4.6 Factory Setup The Factory Setup options include RAM Disc Start, Clear SRAM, and Format Flash. These options, with the exception of Clear SRAM, should only be used by factory personnel in the event of a problem.

4.6.1 Clear SRAM The Clear SRAM option is used to clear out the FloBoss S600 by overwriting the SRAM area. All battery-backed configuration data will be lost, including system configuration data, process configuration data, metering totalizers, and network settings. Generally, Clear SRAM is only used prior to a new application being downloaded to the FloBoss S600. Following a Clear SRAM command, the FloBoss S600 will not be able to warm start again until a full configuration download from PC Setup has been completed. To clear the SRAM: 1. Select FACTORY SETUP from the FloBoss S600 Startup menu. 2. Select the CLEAR SRAM command. 3. Press 1 to confirm and the following message displays:

COMMUNICATIONS LINK FAILURE 8/01

Maintenance

4-5

FloBoss S600 Instruction Manual 4. Reboot the FloBoss S600 (power down, wait five seconds, and then repower). Once completed,

the FloBoss S600 Startup menu displays.

4.6.2 RAM Disc Start The RAM Disc Start option provides an alternative means of creating a new metering database on the FloBoss S600 via FTP transfer. Do not use this option. This option should only be used by factory personnel. To initiate a RAM Disc Start: 1. Select FACTORY SETUP from the FloBoss S600 Startup menu. 2. Select the RAM DISC START command. 3. Press 1 to confirm. 4. The existing SRAM database, including the totals, is deleted. A new database is then built using

the configuration files held on the SRAM disk. The following message displays: CONFIGURING - PLEASE WAIT Â&#x2122; Note: The RAM disk contents are volatile. Use the REFLASH CONFIG command to ensure the new configuration is permanently saved. Once completed, the FloBoss S600 Startup menu displays.

4.6.3 Format Flash The Format Flash option is used to reformat the Flash memory. Any data stored in Flash will be lost, including the configuration data, report formats, display setting, and Modbus addresses. This option should only be used by Flow Computer Division (Daniel) personnel. To initiate a reformat of the Flash memory: 1. Select FACTORY SETUP from the FloBoss S600 Startup menu. 2. Select the FORMAT FLASH command. 3. Press 1 to confirm.

Once completed, the FloBoss S600 Startup menu displays.

4.7 Troubleshooting The troubleshooting techniques described here allow you to determine the nature of a problem and apply the most applicable solution.

4-6

Maintenance

8/01

FloBoss S600 Instruction Manual

4.7.1 Initial Checks Before contacting your sales/support agent with a problem, first check the following: ♦ Check that all the plug-in boards are seated correctly and the retaining screws are fastened. ♦ Check that all the field wiring is properly connected. ♦ Check the supply voltage. If the power supply seems to be working correctly, but the startup routine does not appear on the display, check the fuse for damage. If the problem persists, and none of the checks appear to solve the problem, please contact your local sales representative to return the unit. Note: The whole machine, including the case, should be returned. On no account should the circuit boards be extracted and returned separately.

4.7.2 Removing and Replacing Plug-in Boards To remove or install a plug-in board from the FloBoss S600, refer to Section 2, Installation, for detailed procedures.

4.7.3 Changing the Fuse The fuse is located in a clip-in type holder on the CPU module.

8/01

Maintenance

4-7

FloBoss S600 Instruction Manual

FUSE

Figure 4-2. Fuse Location To change a suspect fuse, proceed as follows: 1. Switch off power. 2. Unscrew and remove the CPU module. 3. Use only light pressure to extract the fuse. 4. Check the fuse and, if necessary, replace it with a 20 mm x 5 mm 2.5 Amp anti-surge fuse only.

The use of a fuse with a higher current rating invalidates the warranty on the FloBoss S600. 5. Replace the fuse and check it is secure before replacing the CPU module into the case. 6. Replace the plug connectors. 7. Switch on the power supply.

4.7.4 Startup List The following table provides a list of possible solutions to problems that may be encountered during the startup sequence.

4-8

Maintenance

8/01

FloBoss S600 Instruction Manual Table 4-1. Startup List Symptom No Power No Initial I/O Red Led After Power On No Front Panel Backlight Front Panel Led Is Permanently Orange No I/O Red Led Showing Cold Start Menu Is Displayed Instead Of Expected Warm Start Menu I/O Fail Message Is Displayed

8/01

Possible Solution Check fuse. Power down, remove and reseat I/O board, reapply power. Check connector (J2) between front panel and main board. Reboot the FloBoss S600; if problem remains, return FloBoss S600 to factory. Depower, remove and reseat I/O board, reapply power. Check if cold start jumper (link) is fitted. Download configuration file. Check I/O links (refer to Section 5, Setup and Wiring).

Maintenance

4-9

FloBoss S600 Instruction Manual

4-10

Maintenance

8/01

FloBoss S600 Instruction Manual 1

SECTION 5 â&#x20AC;&#x201C; SETUP AND WIRING 5.1 Scope This section includes information on plug-in connector blocks, field wiring configurations (ANIN, PRT, and DPR signals), and link/jumper settings for the plug-in boards. It is recommended that all wiring be made with stranded wire that is no larger than 16 AWG. For the communication ports, wiring of 18 to 22 AWG is recommended. Power wiring is recommended to be 16 AWG. All local wiring practices and regulations should be observed. CAUTION Do not use a Megger or similar instrument to check for isolation or continuity between signals on any of the connectors of the FloBoss S600. These instruments produce voltages far in excess of design parameters and damage may occur. If any such instrument is used, the warranty on the FloBoss S600 will be invalidated.

5.2 Section Contents This section includes the following information: Information Scope Section Contents CPU Board Power Supply Watchdog Relay RS232 Modem Port RS422/485 Multidrop Port Ethernet LAN Port Front Panel Port On-Board Battery Backup Remote Display or PC P152 CPU On-board Connectors P152 CPU Berg Jumpers (Links) P144 I/O Board Analog Inputs Digital Inputs 8/01

Section 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.6 5.3.6 5.3.7 5.3.8 5.3.9 5.3.10 5.4 5.4.1 5.4.2 Setup and Wiring

Page Number 5-1 5-1 5-2 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-1

FloBoss S600 Instruction Manual Turbine Pulse Inputs Frequency Inputs PRT/RTD Inputs Analog Outputs Digital Outputs Pulse Outputs P144 I/O Berg Jumpers (Links) P154 Prover Board Digital Inputs Turbine Pulse Inputs Frequency Inputs Digital Outputs Pulse Outputs P154 Prover Berg Jumpers (Links)

5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6

5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3

5.3 CPU Board The P152 CPU board contains the host processor and associated peripherals, which form the heart of the system. Various plug-in connections are provided on the rear backplate of the CPU board. Additional connectors and jumpers (links) are also used on the board, which are set at the factory prior to shipping. Refer to Figure 5-1 for a detailed illustration of the CPU board backplate.

5-2

Setup and Wiring

8/01

FloBoss S600 Instruction Manual

TB-1 POWER COM 4 COM 3 COM 1-2

REMOTE I/O

TB-2 COM 5, 6, 7 RS 232/485 NETWORK

Figure 5-1. CPU Backplate

5.3.1 Power Supply Power is supplied to the FloBoss S600 via the P152 CPU board. Connection is made by a plug-in, standard 5-mm pitch screw terminal. The power supply connector is labeled TB-1. The FloBoss S600 should be powered by a nominal 24 VDC power source capable of supplying 2 amps. The unit will operate between 20 and 32 VDC. The startup in-rush current may draw 6 amps for approximately 100 milliseconds. This in-rush becomes significant when multiple flow computers are connected to the same power supply. An on-board anti-surge fuse (2.5 amp rating) protects the supply line should a fault occur within the unit. Fully regulated 15 and 24 VDC supplies are also available for applications such as powering loops or pre-amplifiers. These outputs are protected by resettable thermal fuses. The TB-1 pin connections are shown in Table 5-1.

8/01

Setup and Wiring

5-3

FloBoss S600 Instruction Manual Table 5-1. TB-1 Pin Connections Pin

Function

1 2 3 4 5

+24 VDC-INPUT 0 V (Return)-INPUT +24 VDC-OUTPUT (500 mA) +15 VDC-OUTPUT (100 mA) 0 V (Return)-OUTPUT

5.3.2 Watchdog Relay A single pole, double throw relay with Normally Open or Normally Closed terminals provides the watchdog status from pins 6, 7, and 8 of TB-1. A CPU failure causes the relay to de-energize. Connection is made by a plug-in, standard 5 mm-pitch screw terminals. Note: Contact is rated at 1A, 30 volts DC and 30 volts AC, and is a Form “C” contact. The TB-1 pin connections display in Table 5-2. Table 5-2. TB-1 Pin Connections Pin 6 7 8

Function Normally Closed Common Normally Open

The relay is energized during normal operation.

5-4

Setup and Wiring

8/01

FloBoss S600 Instruction Manual

5.3.3 RS232 Modem Port Two RS232D communications ports are provided on the backplate of the CPU board. The ports use FCC-68 RJ45 connectors and are labeled COM3 and COM4. Converters are commercially available to configure either 9-way D type or 25-way D type connection. The COM3 and COM4 pin connections are shown in Table 5-3. Table 5-3. COM3 and COM4 Pin Connections Pin 1 2 3 4 5 6 7 8

Function GND DTR RTS TX RX CTS DSR DCD

Figure 5-2. Pin Connections Maximum cable length is a function of the baud rate and quality of cable used. For example, a maximum length of 15 m (50 feet) should be used at 19.2 kBaud using unscreened cable. The ports should be connected to the peripheral devices using multi-conductor, shielded cable. It is recommended that the cable screen be connected to protective earth, keeping signal ground separate, particularly in noisy environments.

8/01

Setup and Wiring

5-5

FloBoss S600 Instruction Manual

5.3.4 RS422/485 Multidrop Port Three RS422/RS485 ports are located on the backplate of the CPU board and provide high speed/long distance links of up to 57.6 kBaud and 1200 meters (4000 feet). The ports use the connector labeled TB-2. Â&#x2122; Note: For two-wire RS422/ RS485 installations, jumper TX+ to RX+ and TX- to RX- on P152 CPU board TB-2. The COM5, COM6, and COM7 pin connections is shown in Table 5-4. Table 5-4. COM5, COM6, and COM7 Pin Connections Pin 1 2 3 4 5 6 7 8 9 10 11 12 13

Port COM5 COM5 COM5 COM5 COM6 COM6 COM6 COM6 COM7 COM7 COM7 COM7 COMPUTER GROUND

Function RXRX+ TXTX+ RXRX+ TXTX+ RXRX+ TXTX+ GND

5.3.5 Ethernet LAN Port This port is for high-speed communications using an Ethernet local area network architecture. The speed of data transfer is 10Mb/sec using a 10baseT twisted pair. The port uses a FCC-68 RJ45 connector labeled Network on the backplate of the CPU.

5-6

Setup and Wiring

8/01

FloBoss S600 Instruction Manual

5.3.6 Front Panel Port This is an alternative connection for COM2 and is used with the CONFIG 600 program to transfer configuration files. Pinouts display in Table 5-5. Table 5-5. COM2 Alternative Connections Pin 1 2 3 4 5 6

Function RTS TX GND GND RX CTS

Figure 5-3. COM2 Alternative Connections

5.3.7 On-Board Battery Backup Two battery options are available. A simple check should be made to ensure which type has been supplied: ♦ Rechargeable, board mounted, nickel metal hydride cell. ♦ Non-rechargeable, intrinsically safe cell. Note: The status of this battery is monitored by a voltage sensing circuit. An alarm is raised if the battery voltage drops below the predefined limit. This is a factory-fitted option. Only one type of battery can be installed. Once the IS or 1/2AA cell is installed, without line power to the FloBoss S600 unit, the battery life will become exhausted.

8/01

Setup and Wiring

5-7

FloBoss S600 Instruction Manual

5.3.8 Remote Display or PC The connector labeled COM1-2 on the backplate of the CPU board is used to connect the FloBoss S600 to a remote display (COM1) or the host PC (COM2). CAUTION Do not reconfigure Com1 and Com2. They are for internal use only. The COM1-2 pin connections display in Table 5-6. Table 5-6. COM1-2 Pin Connections Pin

Function

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

GND TX to R. Display GND SPEAKER OUT N/C TX to PC RTS to PC GND RX from R. Display CTS to R. Display GND N/C N/C RX from PC CTS to PC

The COM1-2 port uses a standard 15-way D-type female connector. Only shielded, multi-conductor cable should be used to connect to the COM1-2 port. It is recommended, particularly in noisy environments, that the cable shield is connected to earth ground, ensuring the signal ground is separate. Â&#x2122; Note: The cable length should not exceed 15 meters (49 feet).

5-8

Setup and Wiring

8/01

FloBoss S600 Instruction Manual

5.3.9 P152 CPU On-board Connectors The miscellaneous device connectors provided on the P152 CPU module are shown in Table 5-7. This information is for identification purposes only. Table 5-7. Miscellaneous Device Connectors for the P152 CPU Module Socket J2 J3 J4 J5 J6 J7 J8 J9

8/01

Description CPU cooling fan molex (12 VDC) PC/104 expansion bus (16- bit) Additional plug-in battery molex 3.6 VDC IDE Hard disk pin header Altera serial programming pin header (factory use only) Keyboard and mouse pin header Security bit link Optional communications LED backplate pin header

Setup and Wiring

5-9

FloBoss S600 Instruction Manual

5.3.10 P152 CPU Berg Jumpers (Links) The entries shown in boldface are the default configuration settings; however, these may not apply to your specific configuration. Table 5-8. Default Configuration Settings for the P152 CPU Berg Jumpers (Links) Jumper (Link) CPU & RADISYS LK3 LK4 LK5 LK6 LK7 LK8 LK9 LK10 LK11 LK12 LK13 LK14 Flash LK15 LK16 LK17 LK18

5-10

Position

Description

ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF

3 volt operation

1-2 2-3 1-2 2-3 1-2 2-3 1-2 2-3

Write Prohibited - Block 0 - 1M Write Enabled Write Prohibited - Block 1 - 2M Write Enabled Write Prohibited - Block 2 - 3M Write Enabled Write Prohibited - Block 3 - 4M Write Enabled

Internal RTC enabled Internal keyboard & mouse enabled Enabled 8 bit BIOS 7 DMA channel operation All interrupts available via MUX EIDE supported CS_USR1# supported COM1, COM2 supported: data & RTS/CTS only COMCLK enabled Cold Start forced on power up BIOS Monitor start enabled

Setup and Wiring

8/01

FloBoss S600 Instruction Manual Clock Multiply LK19

BIOS ROM Size LK20 SQFP 486 CPU LK21 Ethernet LK24 LK25 LK26 LK27 Cache Select LK28

LK29

ON OFF

DX2: Off DX4: On = Clk x3, Off = Clk x2 586: On = Clk x4, Off = Clk x3

1-2 2-3

1M EPROM 4M EPROM

ON OFF

Link to upgrade SQFP 486 CPU

ON OFF ON OFF ON OFF ON OFF

ENEEP

ON OFF

Non-Enhanced = Off Enhanced On = Writethrough Off = Writeback Link when write-back processor fitted

ON OFF

IOS 2 IOS 1 IOS 0

Table 5-9. Clock Speed Selection Clock Speed 33 MHz 40 MHz 50 MHz 66 MHz

8/01

Link 22 OFF ON ON OFF

Setup and Wiring

Link 23 OFF OFF ON ON

5-11

FloBoss S600 Instruction Manual

5.4 P144 I/O Board The P144 I/O board measures process signals used by the CPU while running the flow computer functions. The backplate has three low density D-type connectors for field wiring. These connectors are labeled SKT-A, SKT-B, and SKT-C. There is also a version available with standard plug-in screw terminal blocks.

SKT-A ANIN 1-10 ANOUT 1-4

SKT-B ANIN 11 - 12 DIGIN 1-6 DIGOUT 1 - 2 Freq Inputs Pulse Outputs SKT-C DIGIN 7-16 DIGOUT 3-12 Turbine Inputs

Figure 5-4. I/O Backplate

5.4.1 Analog Inputs There are two fully floating A/D converters per I/O board, each measuring five single-ended analog input (ANIN) channels. There are also two current-only inputs (ANIN 11 and 12). This provides a total of 12 analog inputs. The ANIN channels use the connectors labeled SKT-A and SKT-B, which are located on the backplate of the P144 board. Channels CH1 to CH10 are located on connector SKT-A and channels CH11 and CH12 are located on connector SKT-B. The primary measurement for ANIN 1-10 is voltage, which is compared to a stable reference source. 5-12

Setup and Wiring

8/01

FloBoss S600 Instruction Manual Each channel (ANIN 1-10) is configurable as a 0 to 5.25V or 0 to 22mA input range using a jumper (link) on the board to place a high accuracy calibrated shunt resistor in parallel with the input. Â&#x2122; Note: The channels for each A/D converter should be similarly configured to guarantee accuracy. The ANIN pin connections are shown in Table 5-10 and Table 5-11. Table 5-10. ANIN Pin Connections for SKT-A Pin 8 21 9 22 10 20 11 24 12 25 13 23

Function ANIN-CH1 ANIN-CH2 ANIN-CH3 ANIN-CH4 ANIN-CH5 RETURN CH1-5 ANIN-CH6 ANIN-CH7 ANIN-CH8 ANIN-CH9 ANIN-CH10 RETURN CH6-10

Table 5-11. ANIN Pin Connections for SKT-B Pin 7 8 20

Function ANIN-CH12 (current) ANIN-CH11 (current) GND

5.4.2 Digital Inputs There are 16 optically-isolated digital inputs (DIGIN) per plug-in board. The digital inputs have been grouped into four banks of 4-off single ended inputs with a common return to reduce the termination count. The DIGIN channels use the connectors labeled SKT-B and SKT-C, which are located on the backplate of the P144 board. Channels CH1 to CH6 are located on connector SKT-B, and channels CH7 through CH16 are located on connector SKT-C. The sample period is 500 milliseconds.

8/01

Setup and Wiring

5-13

FloBoss S600 Instruction Manual Note: The return lines (Ex. pin 17 on SKT-B) must be connected to a 24VDC source such as provided by the external termination board, while the DIGIN lines (Ex. pin 13 on SKT-B) expect typical “open collector” (referenced to GND) connections. The DIGIN pin connections are in Table 5-12 and Table 5-13. Table 5-12. DIGIN Pin Connections for SKT-B Pin 13 14 15 16 17 18 19

Function DIGIN-CH1 DIGIN-CH2 DIGIN-CH3 DIGIN-CH4 RETURN CH1-4 DIGIN-CH5 DIGIN-CH6

Table 5-13. DIGIN Pin Connections for SKT-C Pin 19 18 17 16 15 14 13 12 11 10 9 8 7

Function DIGIN-CH7 DIGIN-CH8 RETURN CH5-8 DIGIN-CH9 DIGIN-CH10 DIGIN-CH11 DIGIN-CH12 RETURN CH9-12 DIGIN-CH13 DIGIN-CH14 DIGIN-CH15 DIGIN-CH16 RETURN CH13-16

5.4.3 Turbine Pulse Inputs The four pulse inputs may be used either independently or in pairs of two. Generally, they are used for dual pulse measurement, such as turbine applications. In dual pulse mode, level A or B pulse checking can be enabled. Each input has an input range of 1 to 10,000 Hz. Each channel has live integrity checking. A circuit fail alarm is activated if cabling faults develop or the pre-amp power fails.

5-14

Setup and Wiring

8/01

FloBoss S600 Instruction Manual The electrical connection of these inputs is dependent on which DPR mezzanine is fitted to the P144 I/O module. For example, a P148 Mezzanine is suitable for Spectra-Tek pre-amp signals. The dual-pulse input channels use the connector labeled SKT-C, which is located on the backplate of the P144 board. The dual-pulse input pin connections are shown in Table 5-14. Table 5-14. Dual-pulse Input Pin Connections for SKT-C Pin 4 23 3 22 2 21 1 20

Function SINGLE/DUAL PULSE-CH1+ SINGLE/DUAL PULSE-CH1SINGLE/DUAL PULSE-CH2+ SINGLE/DUAL PULSE-CH2SINGLE/DUAL PULSE-CH3+ SINGLE/DUAL PULSE-CH3SINGLE/DUAL PULSE-CH4+ SINGLE/DUAL PULSE-CH4-

5.4.4 Frequency Inputs The three frequency inputs are typically used for density transducer signals. Each input has a an input range of 0 to 10,000 Hz. The frequency input channels use the connector labeled SKT-B, which is located on the backplate of the P144 board. The frequency input pin connections are shown in Table 5-15. Table 5-15. Frequency Input Pin Connections for SKT-B Pin 9 27 10 28 11 29

Function FREQUENCY-CH1+ FREQUENCY-CH1FREQUENCY-CH2+ FREQUENCY-CH2FREQUENCY-CH3+ FREQUENCY-CH3-

5.4.5 PRT/RTD Inputs There are three Platinum Resistance Thermometer (PRT)/Resistance Temperature Detector (RTD) inputs. The PRT inputs are suitable for Class A, 4-wire PRT devices that conform to the BS EN 60751:1996 standard. In CONFIG 600 there are two options: 8/01

Setup and Wiring

5-15

FloBoss S600 Instruction Manual ♦ DIN (coefficient of 0.00385 ohm/ohms degrees Celsius). ♦ AMERICAN (coefficient of 0.003926 ohm/ohms degrees Celsius). The “DIN” 43760 selection is typical in Europe and common in the United States, while the “AMERICAN” STANDARD coefficient (alpha) is still common for circumstances where a slightly more pure Platinum is used to effect a higher absolute accuracy. The temperature measurement range is -100 to +200° C (-148 to +392° F). The PRT input channels use the connector labeled SKT-B, which is located on the backplate of the P144 board. The PRT input pin connections are shown in Table 5-16. Table 5-16. PRT Input Pin Connections for SKT-B Pin 4 1 21 24 5 2 22 25 6 3 23 26

Function PRT-CH1 I+ PRT-CH1 V+ PRT-CH1 VPRT-CH1 IPRT-CH2 I+ PRT-CH2 V+ PRT-CH2 VPRT-CH2 IPRT-CH3 I+ PRT-CH3 V+ PRT-CH3 VPRT-CH3 I-

5.4.6 Analog Outputs There are four analog outputs (D/A Converter). Each D/A Converter channel is fully floating and provides its own floating supply. Loads up to a 650-ohm loop impedance can be connected directly. The D/A Converter output channels use the connector labeled SKT-A, which is located on the backplate of the P144 board. The D/A Converter output pin connections on the back of the I/O card are shown in Table 5-17. The unit can be used in either source or sink configuration.

5-16

Setup and Wiring

8/01

FloBoss S600 Instruction Manual Table 5-17. D/A Converter Output Pin Connections for SKT-A Pin 1 14 2 15 3 16 4 17 5 18 6 19

Function DAC-CH1 +15 V SOURCE DAC-CH1 SINK DAC-CH1 0 VDC DAC-CH2 +15 V SOURCE DAC-CH2 SINK DAC-CH2 0 VDC DAC-CH3 +15 V SOURCE DAC-CH3 SINK DAC-CH3 0 VDC DAC-CH4 +15 V SOURCE DAC-CH4 SINK DAC-CH4 0 VDC

Figure 5-5 shows an example of how Channel 1 would be used in the source or sink configuration. See drawing DE-20400 Field Wiring Model FloBoss S600 for external terminal board connection assignments.

Figure 5-5. Analog Output Channel 1 as a Source or Sink

8/01

Setup and Wiring

5-17

FloBoss S600 Instruction Manual

5.4.7 Digital Outputs There are 12 digital output channels. The DC polarity must be carefully checked. Use an external DC supply in series with the load. When using inductive loads, such as relay coils, place a diode across the load. The digital outputs (DIGOUT) are high current, open collector type. The maximum current rating is 100 mA at 24 VDC. Output frequencies up to 0.5 Hz are possible. The DIGOUT channels use the connectors labeled SKT-B and SKT-C, which are located on the backplate of the P144 board. Channels CH1 to CH2 are located on connector SKT-B and channels CH3 and CH12 are located on connector SKT-C. The DIGOUT pin connections are shown in Table 5-18 and Table 5-19. Table 5-18. DIGOUT Pin Connections for SKT-B Pin

Function

36 37

DIGOUT-CH1 DIGOUT-CH2

Table 5-19. DIGOUT Pin Connections for SKT-C Pin 37 36 35 34 33 32 31 30 29 28 27 26 25

5-18

Function DIGOUT-CH3 DIGOUT-CH4 RETURN CH1-4 DIGOUT-CH5 DIGOUT-CH6 DIGOUT-CH7 DIGOUT-CH8 RETURN CH5-8 DIGOUT-CH9 DIGOUT-CH10 DIGOUT-CH11 DIGOUT-CH12 RETURN CH9-12

Setup and Wiring

8/01

FloBoss S600 Instruction Manual

5.4.8 Pulse Outputs There are five programmable pulse outputs, typically used for electronic counters or sampler control. The pulse output channels (PULSEOUT) use the connector labeled SKT-B, which is located on the backplate of the P144 board. The PULSEOUT pin connections are shown in Table 5-20. Table 5-20. PULSEOUT Pin Connections for SKT-B Pin 30 31 32 33 35 34 12

Function PULSEOUT-CH1 PULSEOUT-CH2 PULSEOUT-CH3 PULSEOUT-CH4 RETURN CH1-4 PULSEOUT-CH5 RETURN CH5

5.4.9 P144 I/O Berg Jumpers (Links) The entries shown in boldface are the default configuration settings; these may not apply to your specific configuration. Refer to Table 5-21, Table 5-22, and Table 5-23. Table 5-21. Flash Link Setting Jumper (Link) LK1 LK2

8/01

Position ON OFF ON OFF

Description Write Enable Write Protected Point to Point mode enabled Point to Point mode off

Setup and Wiring

5-19

FloBoss S600 Instruction Manual Table 5-22. P144 I/O Berg Links MUX Address: LK3 LK4 LK5 LK6 LK7 LK8 LK9 LK10 1-2 2-3 LK12 LK13-15

7 ●

●

15 ●

●

● ● ●

● ●

●

● ●

●

Note: A/D Converter Shunts are configured in groups of five and must be used together as current OR voltage. Table 5-23. A/D Converter Shunt Mode A/D Shunts LK16

ON Current Mode OFF Voltage Mode LK17 ON Current Mode OFF Voltage Mode LK18 ON Current Mode OFF Voltage Mode LK19 ON Current Mode OFF Voltage Mode LK20 ON Current Mode OFF Voltage Mode **LK16-19 should be fitted as a set LK21 ON Current Mode OFF Voltage Mode LK22 ON Current Mode OFF Voltage Mode LK23 ON Current Mode OFF Voltage Mode LK24 ON Current Mode OFF Voltage Mode LK25 ON Current Mode OFF Voltage Mode **LK21-25 should be fitted as a set

5-20

Setup and Wiring

ADC-CH1 ADC-CH2 ADC-CH3 ADC-CH4 ADC-CH5

ADC-CH6 ADC-CH7 ADC-CH8 ADC-CH9 ADC-CH10

8/01

FloBoss S600 Instruction Manual

5.5 P154 Prover Board The P154 is a dedicated prover interface card that has been designed to work with compact or microprover, unidirectional and bi-directional provers, with 2 or 4 detector switches. In addition, it contains high resolution timing circuits so that dual chronometry methods can be utilized to increase the apparent resolution for instances when insufficient turbine pulses are present with the prover volume available. The prover can also be used in master meter proving and supplies 32 digital inputs, 12 digital outputs, 2 frequency (density) inputs, and 4 hardware-assisted pulse outputs. There are no analog functions on the prover board. The backplate has three low density D-type connectors for field wiring. These connectors are labeled SKT-D, SKT-E, and SKT-F. There is also a version available with standard plug-in screw terminal blocks.

SKT-D RAW IN 1-3 DENSITY 1-2 SPHERE SWITCH 1-4 PLLIN RAW OUT SKT-E DIGIN 1-6 AND 17-32 DIGOUT 1-2 Pulse Outputs 1-4 SKT-F DIGIN 7-16 DIGOUT 3-12 DUAL PULSE 1-4 PLLOUT

Figure 5-6. Prover I/O Backplate

5.5.1 Digital Inputs There are 32 optically-isolated digital inputs (DIGIN) per plug-in board. The digital inputs have been grouped into four banks of 4-off single ended inputs with a common return to reduce the termination count.

8/01

Setup and Wiring

5-21

FloBoss S600 Instruction Manual The DIGIN channels use the connectors labeled SKT-E and SKT-F, which are located on the backplate of the P154 board. Channels CH1 to CH6 are located on connector SKT-E, and channels CH7 through CH16 are located on connector SKT-F. The sample period is 500 milliseconds. Note: The return lines (Ex. pin 17 on SKT-E) must be connected to a 24VDC source such as provided by the external termination board, while the DIGIN lines (Ex. pin 13 on SKT-E) expect typical “open collector” (referenced to GND) connections. The DIGIN pin connections are shown in Table 5-24 and Table 5-25. Table 5-24. DIGIN Pin Connections for SKT-E Pin 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 20 21 22 23 24 25 26 27 28 29

5-22

Function DIGIN-CH1 DIGIN-CH2 DIGIN-CH3 DIGIN-CH4 RETURN CH1-4 DIGIN-CH5 DIGIN-CH6 DIGIN CH-17 DIGIN CH-18 DIGIN CH-19 DIGIN CH-20 RETURN CH-17-20 DIGIN CH-21 DIGIN CH-22 DIGIN CH-23 DIGIN CH-24 RETURN CH 21-24 DIGIN CH-25 DIGIN CH-26 DIGIN CH-27 DIGIN CH-28 RETURN CH 25-28 DIGIN CH-29 DIGIN CH-30 DIGIN CH-31 DIGIN CH-32 RETURN CH 29-32

Setup and Wiring

8/01

FloBoss S600 Instruction Manual Table 5-25. DIGIN Pin Connections for SKT-F Pin 19 18 17 16 15 14 13 12 11 10 9 8 7

Function DIGIN-CH7 DIGIN-CH8 RETURN CH5-8 DIGIN-CH9 DIGIN-CH10 DIGIN-CH11 DIGIN-CH12 RETURN CH9-12 DIGIN-CH13 DIGIN-CH14 DIGIN-CH15 DIGIN-CH16 RETURN CH13-16

5.5.2 Turbine Pulse Inputs The four pulse inputs may be used either independently or in pairs of two. Generally, they are used for dual pulse measurement, such as turbine applications. In dual pulse mode, level A or B pulse checking can be enabled. The dual-pulse input channels use the connector labeled SKT-F, which is located on the backplate of the P154 board. Each input has an input range of 1 to 10,000 Hz. Each channel has live integrity checking. A circuit fail alarm is activated if cabling faults develop or the pre-amp power fails. The electrical connection of these inputs is dependent on which DPR mezzanine is fitted to the P144 I/O module. For example, a P148 Mezzanine is suitable for Spectra-Tek pre-amp signals. The dual-pulse input pin connections are shown in Table 5-26. Table 5-26. Dual-pulse Input Pin Connections for SKT-F Pin 4 23 3 22 2 21 1 20

8/01

Function DUAL PULSE-CH1+ DUAL PULSE-CH1DUAL PULSE-CH2+ DUAL PULSE-CH2DUAL PULSE-CH3+ DUAL PULSE-CH3DUAL PULSE-CH4+ DUAL PULSE-CH4-

Setup and Wiring

5-23

FloBoss S600 Instruction Manual

5.5.3 Frequency Inputs There are two frequency inputs, typically used for density transducer signals. Each input has an input range of 0 to 10,000 Hz. The frequency input channels use the connector labeled SKT-D, which is located on the backplate of the P154 board. The frequency input pin connections are shown in Table 5-27. Table 5-27. Frequency Input Pin Connections for SKT-D Pin

Function

9 21 10 22

FREQUENCY-CH1+ FREQUENCY-CH1FREQUENCY-CH2+ FREQUENCY-CH2-

5.5.4 Digital Outputs There are 12 digital output channels. The DC polarity must be carefully checked. Use an external DC supply in series with the load. When using inductive loads, such as relay coils, place a diode across the load. The digital outputs (DIGOUT) are high current, open collector type. The maximum current rating is 100 mA at 24 VDC. Output frequencies up to 0.5 Hz are possible. The DIGOUT channels use the connectors labeled SKT-E and SKT-F, which are located on the backplate of the P154 board. Channels CH1 to CH2 are located on connector SKT-E and channels CH3 and CH12 are located on connector SKT-F. The DIGOUT pin connections are shown Table 5-28 and Table 5-29. Table 5-28. DIGOUT Pin Connections for SKT-E Pin 36 37

5-24

Function DIGOUT-CH1 DIGOUT-CH2

Setup and Wiring

8/01

FloBoss S600 Instruction Manual Table 5-29. DIGOUT Pin Connections for SKT-F Pin 37 36 35 34 33 32 31 30 29 28 27 26 25

Function DIGOUT-CH3 DIGOUT-CH4 RETURN CH1-4 DIGOUT-CH5 DIGOUT-CH6 DIGOUT-CH7 DIGOUT-CH8 RETURN CH5-8 DIGOUT-CH9 DIGOUT-CH10 DIGOUT-CH11 DIGOUT-CH12 RETURN CH9-12

5.5.5 Pulse Outputs There are five programmable pulse outputs, typically used for electronic counters or sampler control. The pulse output channels (PULSEOUT) use the connector labeled SKT-E, which is located on the backplate of the P154 board. The PULSEOUT pin connections are shown Table 5-30. Table 5-30. PULSEOUT Pin Connections for SKT-E Pin 31 32 33 34 35

8/01

Function PULSEOUT-CH1 PULSEOUT-CH2 PULSEOUT-CH3 PULSEOUT-CH4 RETURN CH1-4

Setup and Wiring

5-25

FloBoss S600 Instruction Manual

5.5.6 P154 Prover Berg Jumpers (Links) The entries shown in boldface in Table 5-31 are the default configuration settings; these may not apply to your specific configuration. Table 5-31. P154 Prover Berg Jumpers (Links) Link

Position

Descriptions

Flash LK1

ON Write Enable Write Protected OFF Node Address (see Table 5-32) LK2 ON Multiplexed mode (MUX) OFF LK11 ON Multiplexed mode (MUX) OFF MUX Address: 1 2 3 4 5 6 7 LK3 ● LK4 ● LK5 ● LK6 ● LK7 ● LK8 ● LK9 ● LK10 1-2 ● ● ● ● ● ● ● 2-3

15 ●

● ● ● ● ● ● ●

●

Altera Voltage LK12

1-2 3.465V 5V - Vcc 2-3 Raw Pulse Output Mode LK13/14 1-2 RS422 differential driver Open collector 2-3 Raw Pulse Input #3 – Line Determination LK15/16 ON Line determination resistors connected: +ve pulled up to Vcc and –ve down to 0V Lines undetermined OFF

5-26

Setup and Wiring

8/01

FloBoss S600 Instruction Manual Table 5-32. Node Addressing: Communications Mode Selection Node Addressing: Communications Mode Selection Mode Link 2 Link 11 Link 3-10 Point-to-point Multi-dropped Multiplexed (MUX)

8/01

ON ON OFF

OFF ON OFF

Setup and Wiring

IGNORED IGNORED ADDRESS

5-27

FloBoss S600 Instruction Manual

5-28

Setup and Wiring

8/01

FloBoss S600 Instruction Manual

SECTION 6 â&#x20AC;&#x201C; SOFTWARE INTERFACE 6.1 Scope This section introduces the FloBoss S600 user interface and lists the system requirements, software installation instructions, and file locations on the host PC. Information on using the FloBoss S600 software is only provided via the online help files. The following sections apply to IPL 600, Config 600 Lite and Config 600 Professional, except where noted.

6.2 Section Contents This section includes the following information: Information Scope Section Contents System Requirements System Requirements Software Installation Procedure File Locations StartUp Connecting to the FloBoss S600

8/01

Section 6.1 6.2 6.3 6.3 6.4 6.5 6.6 6.7

Software Interface

Page Number 6-1 6-1 6-2 6-2 6-2 6-3 6-4 6-4

6-1

FloBoss S600 Instruction Manual

6.3 System Requirements The FloBoss S600 optional software is supplied on CD-ROM. The software is a Windows-based program package. To install and operate the FloBoss S600 software, you require either a portable or desktop PC that meets the following minimum requirements: Table 6-1. System Requirements Component CPU Memory Free Disk Space Operating System CD-ROM Serial Port Display Resolution Selection Device

Required Minimum Pentium 133 MHz Windows 95: 16MB Windows NT: 32 MB 50MB Windows 95 2x speed 1 No. (38400 Baud) Super VGA: 800x600 with 256 colors Pointing device compatible with Windows operating systems

Suggested Pentium 233 MHz > 32 MB of RAM 100MB Windows 95 with Internet Explorer 4 16x speed 1 No. (38400 Baud) Super VGA: 1024 x 768 with 256 colors or greater Mouse recommended

6.4 Software Installation Procedure If you are installing the software from a remote CD-ROM drive, ensure you map a network drive letter to the path of the CD-ROM drive before you begin installation. To install on a Windows 95/98 or NT 4.0 operating system: 1. Insert the FloBoss S600 software disc into your CD-ROM drive. The CD should â&#x20AC;&#x153;autorunâ&#x20AC;?.

However, if this does not occur, continue with the following steps. 2. Click the Start button on the Task bar. 3. Click the Run button and the Run Window displays. Refer Figure 6-1.

Figure 6-1. Run Dialog

6-2

Software Interface

8/01

FloBoss S600 Instruction Manual 4. Type x:\Setup (where x is your designated CD-ROM drive) in the Open field and then

click OK. 5. Windows opens the setup file and the Installation Wizard begins. Follow the instructions

provided on each screen.

6.5 File Locations All files associated with the FloBoss S600 software are located in the respective default directory paths noted: Config Pro=C:\Program Files\Daniel Ltd\Config Pro Config Lite=C:\Program Files\Daniel Ltd\Config Lite IPL600=C:\Program Files\Daniel Ltd\IPL600, unless you specified a different drive or directory during installation. The configuration files containing the settings that appear in the database manager window are located in the Configs directory. A separate sub-directory is then used for each configuration. When you receive new configuration files, they are typically in the form of a self-executing .exe file. Place this file in the Configs directory. Run (execute) the file. Running the executable files creates a unique new subdirectory within the Configs directory that contains all of the required directories, .txt, .pcs, .1c and .cfg files for the new configuration. The files that define the report format are located in the Reports directory, and the files specifying the Modbus settings are located in the Modbus directory. The following files are downloaded to the FloBoss S600 during the configuration process: vxworks.bin.x.x.x.x. – the operating system and task firmware binary file (where x.x.x.x. is the version number of the vxworks file). s600conf.cfg – the main configuration file for the metering database and all the initialization values. display.txt – the configuration file for the display menus and data pages. Mbxx.txt – the Modbus configuration files including Slave register maps and Master polling sequences (where xx indicates the file name is application-specific). Mbpseq.txt – the prover sequence configuration file. Repxx.txt – the report format configuration files (where xx indicates the file name is application-specific).

8/01

Software Interface

6-3

FloBoss S600 Instruction Manual

6.6 StartUp After the FloBoss S600 software as been successfully installed, use Start > Programs to start the program. Â&#x2122; Note: Refer to the online help for detailed instructions on using CONFIG 600. To start the program directly from the executable file, use the directory path you specified when installing the software. The default setting is: C:\Program Files\Daniel Ltd\Config Pro\ Config 600 Pro.exe C:\Program Files\Daniel Ltd\Config Lite\Config 600 Lite.exe C:\Program Files\Daniel Ltd\IPL600\IPL600.exe

6.7 Connecting to the FloBoss S600 A special serial cable is required to connect the host PC to the FloBoss S600 unit. A ready-made link cable is available for a PC with a 9-pin serial port. Alternatively, you may fabricate your own link cable using the wiring details in Figure 6-2. Â&#x2122; Note: Due to the high baud rate used for the communications between the host PC and the FloBoss S600, it is recommended that the maximum cable length be restricted to 5 meters (15 feet).

Figure 6-2. Link Cable

6-4

Software Interface

8/01

FloBoss S600 Instruction Manual

APPENDIX A â&#x20AC;&#x201C; TECHNICAL DATA A.1 Scope This appendix contains a complete list of physical, performance, and environmental specifications of the FloBoss S600 and its plug-in boards. The FloBoss S600 unit consists of an 80486 microprocessor-controlled CPU board, an I/O board, and a power supply back-plane, all fitted inside a zinc-coated pressed mild steel case with a display and keypad in the front panel of the unit.

A.2 Section Contents This section includes the following information: Information Scope Section Contents Mechanical and Environmental Power Supply P152 CPU Battery Backup Communications Other Peripherals Watchdog Relay P144 I/O Analog Inputs (voltage or current type) PRT Inputs Frequency/Density Inputs Turbine Pulse Inputs Digital Status Inputs Analog Outputs Digital Outputs Pulse Outputs Raw Pulse Outputs P154 Prover Frequency/Density Inputs Turbine Pulse Inputs Digital Status Inputs Digital Outputs 8/01

Section A.1 A.2 A.3 A.4 A.5 A.5.1 A.5.2 A.5.3 A.5.4 A.6 A.6.1 A.6.2 A.6.3 A.6.4 A.6.5 A.6.6 A.6.7 A.6.8 A.6.9 A.7 A.7.1 A.7.2 A.7.3 A.7.4 Technical Data

Page Number A-1 A-1 A-2 A-3 A-4 A-4 A-5 A-6 A-7 A-7 A-8 A-9 A-9 A-10 A-10 A-11 A-11 A-12 A-12 A-13 A-13 A-14 A-14 A-15 A-1

FloBoss S600 Instruction Manual Pulse Outputs Raw Pulse Outputs Display-Keypad Mezzanine Boards Spectra-Tek DPR Mezzanine Daniel Mezzanine

A.7.5 A.7.6 A.8 A.9 A.9.1 A.9.2

A-15 A-16 A-16 A-16 A-16 A-16

A.3 Mechanical and Environmental Table A-1 and Table A-2 display the computer case and mounting specifications. Table A-1. Computer Case and Mounting Display Keypad Moulding Case Panel Cutout Pitch Between Cases Max Panel Thickness Weight Structure Circuit Boards Access

85 mm (3.35") width x 269 mm (10.59") height x 28 mm (1.10") deep 84.5 mm (3.327") width x 270 mm (10.63") height x 303.8 mm (11.94") deep 66 mm (2.6") width x 150 mm (5.9") height (both with ±1 mm tolerance) 110 mm (4.33") giving 25 mm (0.98") air gap 10 mm (0.39") 4.3 kg (9.48 lb) approx. with a single I/O board space configuration Painted, welded steel outer case with plastic front panel Eurocard-compatible which slide in and out from the rear Allow 300 mm (11.81") clearance directly behind case for maintenance

Table A-2. Environmental Conditions Operating Temperature Storage Temperature Relative Humidity Safety Classification EMC

A-2

0° C to +60° C (32° F to 140° F) -40° F to 158° F (-40° C to +70° C) 90% non-condensing For use in a classified safe electrical area Complies with European Union EMC regulations

Technical Data

8/01

FloBoss S600 Instruction Manual

A.4 Power Supply Table A-3 details power inputs. Table A-3. Power Inputs Supply Voltage Inrush Current Supply Isolation Hold-up Period Input Fuse Maximum Input Ripple DC Input Power Fail Flag

20-32VDC, 24W nominal, 48W maximum; typically 18W with single I/O board Thermistor protection providing 6A at 25째 C Three-way, galvanically isolated from input to computer, supply and earth 4 ms after power fail flag 2.5A anti-surge 20 mm 2V pk-pk 17-19V

Table A-4. Power Outputs - 24 Volts Regulation Output Current Output Protection Isolation Level Isolation Type

Fully regulated 24V 500mA Resettable fuse and electronic current limit 50VDC Isolated from both the input 24VDC and the computer 0V, but shared with 15V output

Table A-5. Power Outputs - 15 Volts Regulation Output Current Output Protection Isolation Level Isolation Type

8/01

Full linear regulation 100mA Resettable fuse and electronic current limit 50VDC Isolated from both the input 24VDC and the computer 0V, but shared with 24V output

Technical Data

A-3

FloBoss S600 Instruction Manual

A.5 P152 CPU The CPU module is based on a PC-compatible architecture. The P152 CPU contains a complete set of PC peripherals, such as interrupt controllers (PICs), timer (PIT) DMA controllers, RTC, and PC104 (ISA compatible) expansion bus. Table A-6. CPU Module Components Processor DRAM Memory SRAM Memory Flash Memory Monitor/BIOS Real Time Clock Expansion Bus

Intel 50 MHz 80486 DX2/50 (208 Pin SQFP) with built-in floating point maths co-processor 16MByte standard, with 32-bit data path using 2 off 64Mbit 3V EDO expandable up to 32MByte max 1MByte standard, optional 2 MByte on 16-bit wide ISA bus. Battery backed 4MByte standard on 16-bit ISA bus, write protected in 1MByte blocks 128KByte on 8-bit ISA bus Battery supported calendar clock chip, maintains system time during power loss PC/104 format; power restrictions - contact factory for details

A.5.1 Battery Backup The battery backup is used to retain the contents of the SRAM on the CPU, the PC compatible BIOS CMOS memory area and the calendar clock. The standard battery is a Ni-MH rechargeable 3.6V, 140mAh unit. To ensure that the battery is fully functional, a regular load test is performed on the unit.

Table A-7. Standard Ni-MH Rechargeable Charging Time Hold-up Time (without recharge) Battery Life (Typical) Battery Backup Holdup Time (after battery has failed its load test)

A-4

(20%-80%) 48 hours 3 months at 20° C (68° F), 1 month at 40° C (104° F) 5-7 years 2 weeks at 20° C (68° F)

Technical Data

8/01

FloBoss S600 Instruction Manual

A.5.2 Communications The following tables detail communications ports. Â&#x2122; Note: Ports 3 through 7 are configurable for remote communications by the customer. Table A-8. In Total Port Type

Location

Total Number of Serial Ports RS232 Ports RS422 Ports Dedicated Port

8 2 uncommitted + front panel + configuration port 3 uncommitted Link to I/O / RIO boards

Port Number

Location

Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8

Keypad PC download RS 232 RS 232 RS 422/485 RS 422/485 RS 422/485 I/O Remote Connection

Table A-9. Front Panel Port Connector Type Communication Standard Signals Supplied Baud Rate Format

20-pin IDC header RS232D Tx, Rx, CTS, Enter Interlock Control, GND 9600 Baud 8 bit data, 1 stop bit, odd parity

Â&#x2122; Note: Located on the back side of the front panel, and connects to a dedicated 20-pin connector on the P155 power supply, and routes the configuration port to a bottom mounted RJ12. Table A-10. Configuration Port (bottom side of front panel) Connector Type Communication Standard Signals Supplied Baud Rate Format

8/01

6 pin RJ12 RS232D Tx, Rx, RTS, CTS, GND 300, 600, 1200, 2400, 4800, 9600, 19200, 38400 Config 600 protocol

Technical Data

A-5

FloBoss S600 Instruction Manual Table A-11. RS232 Ports Connector Type Communication Standard Signals Supplied Baud Rate Format Data Protocol

FCC-68 RJ45 RS232D Tx, Rx, RTS, CTS, DTR, DSR, GND, DCD 300, 600, 1200, 2400, 4800, 9600, 19200, 38400 Software configurable ASCII, MODBUS (ASCII, RTU)

Table A-12. RS422/RS485 Ports Connector Type Communications

Signals Supplied Baud Rate Format Data Protocol

standard screw terminals, 3.5 mm pitch, 13-pin RS422 - point-to-point - 4 wire RS422 â&#x20AC;&#x201C; Multidrop (RS485 4 wire) - 4 wire RS485 - Multimaster - 2 wire Tx+, Tx-, Rx+, Rx-, Common Shield 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600 Software controlled on each channel ASCII, MODBUS (ASCII, RTU)

A.5.3 Other Peripherals The following tables detail other peripherals. Table A-13. Ethernet Speed Media Connectivity

10 Mbit/second 10baseT, twisted pair utilizing standard RJ45

Table A-14. Clock Facilities Time Clock Accuracy (battery supported) Clock Accuracy (powered on) Watchdog Period

A-6

Battery-supported calendar clock 10 seconds per day 0.5 seconds per day 2.5 seconds maximum

Technical Data

8/01

FloBoss S600 Instruction Manual

A.5.4 Watchdog Relay Table A-15 details the watchdog relay. Table A-15. Watchdog Relay Contact Form Max Current Max Voltage Maximum Power Control

Change-over contacts 1A 50VDC 30VA Released on de-power, or watchdog restart, or software controlled

A.6 P144 I/O The P144 Intelligent I/O board is the data gathering component in a hierarchical flow computer. Up to seven P144 I/O boards, or other expansion boards, can be addressed by a single P152 486 processor board. The P144 can be case or rack mounted. Table A-16. P144 I/O I/O Connection Analog Inputs ANINS Analog Outputs Digital Inputs Digital Outputs Dual Pulse Inputs Frequency Inputs PRT Inputs Pulse Outputs Raw Pulse Output

8/01

Qty

Description

12 2 4 16 12 2 3 3 5 1

Single-ended, 1-5V or 4- 20mA DC type. Two of these are current only Current only 4-20mA DC type Voltage sensing Open collector type Turbine inputs, 0 to 10,000Hz Density period / frequency 0 to 10,000Hz 4-wire RTD (IEC 751) Programmable DC to 100Hz Raw pulse output for proving: DC to 5 kHz

Technical Data

A-7

FloBoss S600 Instruction Manual

A.6.1 Analog Inputs (voltage or current type) The following tables detail the AI voltage and AI current types. Table A-17. Analog Inputs Type of Inputs Scan Rate Conversion Method Effective Resolution Conversion Time Series Mode Rejection Voltage Common Mode Range Common Mode Rejection Signal Level Input Impedance Temperature Drift Calibration Period

Two groups of 5 single-ended voltage or current inputs, each group sharing a common return; channels 11 and 12 are current input only All channels can be acquired in under 1 second Integrating charge - balance More than 16 bits, auto zero, auto calibrate Less than 100ms per channel >100dB at 50Hz and 60Hz ±50V as a group relative to computer ground >100dB at 50Hz and 60Hz 0 to 5.125V or 0 to 22mA >10M-Ohms (voltage mode), approx 250 Ohms (current mode) <100 ms per channel, all channels 500 ms 2 years to 0.005% of voltage 5 years to 0.01% of voltage

Table A-18. A/D Converter Inputs Voltage Mode Type of Inputs Input Range Accuracy Ambient Temperature Effect

Single-ended voltage inputs 0 to 5.2V ±0.005% of FSD at 23° C (73° F) ± 7 ppm/°C (± 4 ppm/° F) from 23°C (73° F) in the range 0 to 45° C (32 to 113° F)

Table A-19. A/D Converter Inputs Current Mode Type of Inputs Input Range Accuracy Ambient Temperature Effect Common Mode Range

A-8

Single-ended current inputs 0 to 22mA ± 0.02% of FSD at 23°C (73°F) ± 10 ppm/° C (± 5.5 ppm/° F) from 23° C in the range 0 to 45° C (32 to 113° F) Not Applicable

Technical Data

8/01

FloBoss S600 Instruction Manual

A.6.2 PRT Inputs Table A-20 details PRT inputs. Table A-20. PRT Inputs Type of Input PRT Resistance Excitation Current Measuring Range Resolution Accuracy PRT Cables Barriers Security

4 wire connection using Pt 100 transducers 100 Ohms (Pt 100 to IEC 751) 1mA nominal 60 to 216 Ohms (-100° C to +300° C) (-148° F to +572° F) 0.01° C (0.018° F) -100° C to 200° C (-148° F to 392° F) ± 0.01% -200° C to 300° C (392° F to 572° F) ± 0.02% Core resistance up to 600 Ohms 9V, 100 Ohms are satisfactory Continuous cable/PRT integrity tests for earths/open circuits

A.6.3 Frequency/Density Inputs Table A-21 details frequency and density inputs. Table A-21. Frequency/Density Inputs Configuration Number of Inputs Signal Level Maximum Input Voltage Current Limit Frequency Range Accuracy of Frequency Measurement Resolution

8/01

DC coupled, galvanically isolated 3 3V min pk-pk 12V pk-pk Internally limited to 3mA DC to 10kHz 10 ppm 5 nanoseconds

Technical Data

A-9

FloBoss S600 Instruction Manual

A.6.4 Turbine Pulse Inputs Table A-22 details turbine pulse inputs. Table A-22. Turbine Pulse Inputs Number of Inputs Input Type Signal Level Frequency Range Security Monitoring

2 dual pulse stream or 4 single pulse streams Spectra-Tek differential or Daniel preamp mode depending on mezzanine type fitted Dependent on mezzanine fitted DC to 10kHz IP 252/76 (ISO 6551), level A or B

Â&#x2122; Note: Refer to Section A.9, Mezzanine Boards, on page A-16 for mezzanine details.

A.6.5 Digital Status Inputs Table A-23 describes the digital status inputs. Table A-23. Digital Status Inputs Configuration Max Input Voltage Min Input On Voltage Max Input Off Voltage Input Impedance Protection

A-10

16 opto-isolated inputs, arranged in 4 groups of 4 with common positive connection to allow simple interface to Open Collector outputs 30V 12V 3.0V 2-2.5k Ohms typical Reverse voltage protection

Technical Data

8/01

FloBoss S600 Instruction Manual

A.6.6 Analog Outputs Table A-24 describes analog outputs. Table A-24. Analog Output Type of Input Resolution Accuracy Temperature Coefficient Load Loop Resistance Maximum External Supply Output Form Number of Field Connections Update Time

Four galvanically-isolated 4 to 21 mA outputs 12 bit minimum ± 0.1% at 23° C (73° F) 20ppm/° C (11ppm/° F) 650 Ohms maximum when powered by local isolated source, 470W 1000W when powered from +24V external supply 32V Controlled active current sink to ground return of local floating supply 3 terminals per channel 100ms to within 1%

A.6.7 Digital Outputs Table A-25 describes digital outputs. Table A-25. Digital Outputs Configuration Number of Outputs Frequency Range Max Output Saturation Voltage Low current Saturation Voltage

8/01

Galvanically isolated in 3 groups of 4 with common negative 12 DC to 0.5 Hz 1.5V @ 100mA 600mV @ 1mA to suit TTL style input, with 4.7kΩ pull up to 5 V

Max Output Standoff Voltage

42V limited by Transorb

Max Output Current Reset/Power on State

100mA All digital outputs - OFF

Technical Data

A-11

FloBoss S600 Instruction Manual

A.6.8 Pulse Outputs Table A-26 details pulse outputs. Table A-26. Pulse Outputs Number of Outputs Configuration Frequency Range Max Output Current Max Output Saturation Voltage Low Current Saturation Voltage Max Output Standoff Voltage

5 driven from TPU channels Opto-isolated open collectors in a group of 4 and one single DC to 100Hz 100mA 1.5V @ 100mA 600mV @ 1mA to suit TTL style input 42V limited by Transorb

A.6.9 Raw Pulse Outputs Table A-27 details raw pulse outputs. Table A-27. Raw Pulse Outputs Configuration Gating Max Output Saturation Max Output Standoff Voltage Max Output Current Frequency Range Minimum On Period Use

A-12

Digital ground referenced open collector Software controlled 1.5V 26V (limited by Transorb) 100mA DC to 5kHz 100Âľs (microsecond) To bus together several streams to a common prover computer

Technical Data

8/01

FloBoss S600 Instruction Manual

A.7 P154 Prover The P154 is a dedicated prover interface board that has been designed to work with compact or microprover, unidirectional and bi-directional provers with 2 or 4 sphere switches. Table A-28. P154 Prover I/O Connection Digital Inputs Digital Outputs Dual Pulse Inputs Frequency Inputs Pulse Outputs Raw Pulse Output Raw Pulse Input Phase Loop Lock Input Switch Detect

Qty

Description

32 12 2 2 4 1 3 2

Voltage sensing Open collector type Turbine inputs, 0 to 10,000Hz Density period / frequency 0 to 10,000Hz Programmable DC to 100Hz Raw pulse output for proving: DC to 5 kHz

A.7.1 Frequency/Density Inputs Table A-29 details Frequency/Density Inputs. Table A-29. Frequency/Density Inputs Configuration Number of Inputs Signal Level Maximum Input Voltage Current Limit Frequency Range Accuracy of Frequency Measurement Resolution

8/01

DC coupled, galvanically isolated 3 3V min pk-pk 12V pk-pk Internally limited to 3mA DC to 10kHz 10 ppm 5 nanoseconds

Technical Data

A-13

FloBoss S600 Instruction Manual

A.7.2 Turbine Pulse Inputs Table A-30 describes Turbine Pulse Inputs. Table A-30. Turbine Pulse Inputs Number of Inputs Input Type Signal Level Frequency Range Security Monitoring

Â&#x2122; Note: Refer to Section A.9, Mezzanine Boards, on page A-16 for mezzanine details.

A.7.3 Digital Status Inputs Table A-31 describes Digital Status Inputs. Table A-31. Digital Status Inputs Configuration Max Input Voltage Min Input On Voltage Max Input Off Voltage Input Impedance Protection

A-14

16 opto-isolated inputs, arranged in 4 groups of 4 with common positive connection to allow simple interface to Open Collector outputs 30V 12V 3.0V 2-2.5k Ohms typical Reverse voltage protection

Technical Data

8/01

FloBoss S600 Instruction Manual

A.7.4 Digital Outputs Table A-32 details Digital Outputs. Table A-32. Digital Outputs Configuration Number of Outputs Frequency Range Max Output Saturation Voltage Low current Saturation Voltage

Galvanically isolated in 3 groups of 4 with common negative 12 DC to 0.5 Hz 1.5V @ 100mA 600mV @ 1mA to suit TTL style input, with 4.7kâ&#x201E;Ś pull up to 5 V

Max Output Standoff Voltage

42V limited by Transorb

Max Output Current Reset/Power on State

100mA All digital outputs - OFF

A.7.5 Pulse Outputs Table A-33 details pulse outputs. Table A-33. Pulse Outputs Number of Outputs Configuration Frequency Range Max Output Current Max Output Saturation Voltage Low Current Saturation Voltage Max Output Standoff Voltage

8/01

5 driven from TPU channels Opto-isolated open collectors in a group of 4 and one single DC to 100Hz 100mA 1.5V @ 100mA 600mV @ 1mA to suit TTL style input 42V limited by Transorb

Technical Data

A-15

FloBoss S600 Instruction Manual

A.7.6 Raw Pulse Outputs Table A-34 details the Raw Pulse Output. Table A-34. Raw Pulse Outputs Configuration Gating Max Output Saturation Max Output Standoff Voltage Max Output Current Frequency Range Minimum On Period Use

Digital ground referenced open collector Software controlled 1.5V 26V (limited by Transorb) 100mA DC to 5kHz 100Âľs (microsecond) To bus together several streams to a common prover computer

A.8 Display-Keypad Table A-35 details the Display and Keypad. Table A-35. Display-Keypad Graphics Display Alarm/Status Keyboard Configuration Port Connectivity Watchdog Watchdog Time-out Period Connection to FloBoss S600 Communications to FloBoss S600 Display Test

A-16

LCD 128 x 64 pixel (8 lines of 20 alpha-characters) with LED backlight, using a Toshiba T6963 LCD controller 3 color LED: green, amber, red 29 self-colored silicon rubber keys with tactile feel RJ12 connector for the CONFIG 600 package on the bottom face of the front panel moulding Front panel signals the user if no update or poll occurs after the time-out period 10 seconds 20-pin ribbon cable 9600 baud, 8 bit, odd parity User initiated

Technical Data

8/01

FloBoss S600 Instruction Manual

A.9 Mezzanine Boards The following sections detail the mezzanine boards.

A.9.1 Spectra-Tek DPR Mezzanine Table A-36 details the Spectra-Tek DPR Mezzanine board. Table A-36. P148 Spectra - Tek Pre-amp Mezzanine Configuration Input Signal Levels Input Current Minimum Frequency Range Line Integrity

Opto-coupled inputs +/- 3.5V to +/- 12V 5mA DC to 10kHz Dual back-to-back optos, allowing full quiescent line and electronic integrity testing, when used with S-Tek pre-amps and pulsers IP 252/76 level A or B

Dual Pulse Compliance

A.9.2 Daniel Mezzanine This section details the Daniel Mezzanine board. Table A-37. P148 US Version Mezzanine Configuration Input Signal Levels Input Current Minimum Frequency Range Line Integrity Dual Pulse Compliance

8/01

Opto-coupled inputs +/- 10V to +/- 24V 5mA DC to 10kHz Dual back-to-back optos, allowing full quiescent line and electronic integrity testing, when used with S-Tek pre-amps and pulsers IP 252/76 level A or B

Technical Data

A-17

FloBoss S600 Instruction Manual

A-18

Technical Data

8/01

FloBoss S600 Instruction Manual

APPENDIX B – ENGINEERING DRAWINGS B.1 List of Engineering Drawings ♦ DE-20400

Field Wiring Diagram Model DS600 (Sheets 1-3)

♦ DE-20438

Outline and Dimensional and Mounting Instructions S600 (Sheets 1-2)

♦ DE-20472

CPU Remote Terminal Board Layout (Optional)

♦ DE-20473

Intelligent I/O Remote Terminal Board Layout (Optional)

♦ DE-20474

P152 CPU Board S600 Connection Diagram

♦ DE-20475

P144 I/O Board S600 Connection Diagram

♦ DE-20476

P154 Prover Board S600 Connection Diagram

♦ BE-20477

Template Panel Cutout S600

8/01

Engineering Drawings

B-1

FloBoss S600 Instruction Manual

GLOSSARY Glossary for the FloBoss S600 A ADC – Analog to Digital Converter, also known as A/D Converter. ADDRESS – A character, or group of characters, used in order to identify a particular item, e.g. particular area of memory or particular computer on a communication link with many computers. AGA – American Gas Association. ALPHANUMERIC – Consisting of only the letters A to Z and the numerals 0 to 9. ANALOG – A signal that has no defined steps, its value being determined by its size. ANIN – Analog input, also known as AI. ANOUT – Analog output, also known as AO. API – American Petroleum Institute. ASCII – American Standard Code (for) Information Interchange. The representation of alphanumeric characters and control codes as a single byte within the range 0 to 127. ASTM – American Society for Testing and Materials.

B BAUD – Refers to the rate of serial data transfer, e.g. baud rate of 10 = 10 bits per second. BINARY – Numbers in base 2, i.e. only numbers 0 and 1 are used. BIT – A binary digit. BITSWITCH – Switches that represent data bits by on or off state. BTU – British Thermal Unit. BUFFER – A device inserted between devices to match impedance, equipment speeds or to supply additional drive capability. BUS – One or more conductors used as a path over which information is transmitted. BYTE – Block of 8 bits, can define 256 states (0 thru 255).

8/01

Glossary

G-1

FloBoss S600 Instruction Manual

C COMPRESS – Compressibility calculated using AGA8. CONFIG 600 LITE – Tool for configuring the FloBoss S600. CONFIG 600 PROFESSIONAL – Tool for creating new applications. CONSTANTS – Numbers which are only infrequently changed. CONTROL BUS – Bus Connections for Control Signals, e.g. Read/Write. CPU – P152 Central Processing Unit module. CTS – Clear to Send. CURRENT LOOP – Serial Communication Technique (0mA/20mA). CV – Calorific Value calculated using AGA5 or ISO6976.

D DAC – Digital to Analog Converter, also known as D/A Converter. DATABUS – A group of bi-directional lines capable of transferring data to and from the CPU storage and peripheral devices. DCU – Data Concentrator Unit. DI – Digital input. DIGITAL – A signal that has only two states e.g. On/Off

1/0

5V/0V.

DO – Digital output. DP – Differential Pressure. DPR – Dual Pulse Receiver or turbine input. DRAM – Dynamic Random Access Memory. Volatile storage memory used by the FloBoss S600. When power is removed from the FloBoss S600, the contents of the DRAM memory are assumed to be lost. DSR – Data Set Request. DTR –Data Terminal Ready.

E EEPROM – Electrically Erasable Programmable Read Only Memory. G-2

Glossary

8/01

FloBoss S600 Instruction Manual EEROM – Electrically Erasable Read Only Memory. E-FORMAT – Mathematical notation where the mantissa is between 1 and 9 and the exponent is the multiplier. ETHERNET – Network hardware connection. EXPONENT – Base 10 Multiplier.

F FCU – Flow computer unit. FLASH MEMORY – Non-volatile storage memory. Although slower to access than SRAM and DRAM, once its contents have been programmed, it requires no further attention to support that data. The configuration files and operating system are kept here. Write protect jumpers are used to prevent accidental programming of this memory. FRQ – Frequency or period input. FTP – File transfer protocol. Used to copy a file or multiple files from one computer to another.

H HEX – Numbers in base 16, i.e. numbers 0 to 9 and letters A to F are used.

I, J, K INTEGER – A whole number. INTELLIGENT I/O – P144 Intelligent Input Output module, also known as IIO. I/O – Input and Output. IP – Institute of Petroleum. IP – Ingress protection standard, refer to British standard 5420 or International Electro-Technical commission standard 144. IPL 600 – Interactive program loader tool for transferring application programs from the PC to the FloBoss S600. IS – Intrinsically safe to CENELEC standard EN50020.

L LED – Light Emitting Diode (an indicator).

8/01

Glossary

G-3

FloBoss S600 Instruction Manual

M MANTISSA – Numerically significant part of a floating point number. MICRO – Microcomputer is the complete microprocessor based instrument. MNEMONIC – Grouping of characters used to aid memory. MODBUS – Modbus is the communication protocol utilized on the station supervisory computer data link. MODEM – Modulator Demodulator. MODULATE – The superimposing of one signal upon another. MULTIPLEXOR – Multiple Input Selector.

N NOISE – Random Electrical Interference. NON-VOLATILE – Memory type that retains data when the power supply is disconnected.

O OCTAL – Numbers in base 8, i.e. numbers 0 to 7 are used. OPEN COLLECTOR – Digital output that is driven by a transistor and requires external power. OPTO-ISOLATOR – Optical Device for connecting signals while maintaining electrical isolation. OVERRANGE – Over the present current limit for ADC.

P, Q PCB – Printed Circuit Board. PERIPHERAL – Equipment connected outside the main processor. PID – Three term control action. Using Proportional, Integral and Derivative components to modify a control output, with the goal of achieving a measured process variable at a set point. PORT – A group of inputs or outputs to the computer. PROGRAM – Series of instructions. PROM – Programmable ROM. PROTOCOL – Precise description of data interchange over a telemetry link. G-4

Glossary

8/01

FloBoss S600 Instruction Manual PRT – Platinum Resistance Thermometer. PSU – Power Supply Unit.

R ROM – Read Only Memory (fixed storage). RS232 – Voltage standard for serial data transmission. RTD – Resistance Thermometer Device. RTS – Request to Send. RTU – Remote Terminal Unit. RX – Received information.

S SECURITY CODE – Security Codes are used to limit access by operators to parameters retained in the micro memory. SRAM – Static Random Access Memory (battery backed). S600 –FloBoss S600 Flow Computer.

T TAGNAME – Alphanumeric string of up to twelve characters used to associate data with I/O points. TCP/IP – Transfer Control Program/Internet Protocol. TOTALIZER – Area of RAM for integrating totals. TRANSDUCER – Device which converts energy from one form to another. TRI-REG – Triple Register - area of RAM where data is stored in triplicate. TX – Transmitted information.

U UNDERRANGE – Under preset current limit for A/D Converter.

V VARIABLES – Changeable values.

8/01

Glossary

G-5

FloBoss S600 Instruction Manual VOLATILE – Memory - unstable in the absence of power. VDU – Visual Display Unit.

W, X, Y, Z WATCHDOG – A hardware circuit that monitors correct program operation and causes program restart in the event of malfunction.

G-6

Glossary

8/01

FloBoss S600 Instruction Manual

INDEX Config Report ............................................................ 3-20 Configuration Port ...................................................... A-5 Constants Log............................................................ 3-20 Contrast ..................................................................... 3-21 CPU P152 ....................................................................... A-4 CPU Board .................................................................. 5-2 CPU On-board Connectors P152 ........................................................................ 5-9 Current Alarms .......................................................... 3-20 Current Report ........................................................... 3-20

A A/D Converter Inputs Current Mode.......................... A-8 A/D Converter Inputs Voltage Mode ......................... A-8 Accept Alarm.................................................................... 3-18 Alarm......................................................................... 3-22 Accept................................................................... 3-18 Alarm Light............................................................... 3-17 Alarm Light and Keys ................................................. 3-4 Alarms ....................................................................... 3-17 View ..................................................................... 3-17 All Alarms................................................................. 3-20 AMERICAN ............................................................. 5-16 Analog Inputs ............................................................ 3-11 (voltage or current type) ........................................ A-8 ANIN .................................................................... 5-12 Analog Outputs ............................................... 5-16, A-11 Archived Reports....................................................... 3-20 Asterisk ....................................................................... 3-6

D Daniel Mezzanine ..................................................... A-17 Data Entering ................................................................ 3-12 Data Pages ................................................................... 3-7 Date & Time .............................................................. 3-21 Decimal Point .............................................................. 3-6 Default Display.......................................................... 3-22 Density Inputs................................................... A-9, A-13 Digital Inputs DIGIN................................................................... 5-21 DIGIN................................................................... 5-13 Digital Outputs ............................................... A-11, A-15 DIGOUT ......................................................5-18, 5-24 Digital Status Inputs ....................................... A-10, A-14 DIN............................................................................ 5-16 Disp ....................................................................3-5, 3-12 Display......................................................................... 3-5 LCD ........................................................................ 3-6 Navigating ............................................................ 3-11 Display Dump............................................................ 3-20 Display Matrix....................................................3-7, 3-21 Display Setup............................................................. 3-21 Display T/O ............................................................... 3-21 Display Test............................................................... 3-21 display.txt .................................................................... 6-3 Display-Keypad........................................................ A-16 Download and Reflash Config File ............................. 4-4

B Backup Battery ................................................................... A-4 On-Board Battery ................................................... 5-7 Battery Backup........................................................... A-4 On-Board ................................................................ 5-7 Boards Removing and Replacing Plug-in........................... 4-7

C Cable ........................................................................... 5-5 Calculations................................................................. 3-7 Change ........................................................................ 3-6 Change Mode ............................................................ 3-22 Change Value ............................................................ 3-22 Changing a Value ...................................................... 3-12 Changing Mode ......................................................... 3-14 Changing the Fuse....................................................... 4-7 Chng ............................................................................ 3-6 Clear ................................................................... 3-5, 3-22 Clear SRAM................................................................ 4-5 Clock Facilities........................................................... A-6 Cold Start .............................................. 3-9, 4-1, 4-2, 4-4 COM1.......................................................................... 5-8 COM2................................................................... 5-7, 5-8 Communications................................................ 3-21, A-5 Config 600 Lite ........................................................... 1-6 Config 600 Professional .............................................. 1-6 8/01

E Enter ............................................................................ 3-6 Entering Data............................................................. 3-12 Environmental Specifications......................................................... A-2 Environmental Considerations..................................... 2-2 Ethernet ...................................................................... A-6 Ethernet LAN Port....................................................... 5-6 Index

I-1

FloBoss S600 Instruction Manual Example Mode Change ........................................................3-15 Value Change ........................................................3-13 Exponent ..................................................................... 3-5 Exponential Format....................................................3-16 Expt .................................................................... 3-5, 3-16

Format..................................................................... 4-6 Reflash.................................................................... 4-4 Flash Failed ................................................................. 4-3 FloBoss S600 Flow Computer.............................. 1-1, 1-3 Format Flash................................................................ 4-6 Frequency Inputs .............................................. 5-15, 5-24 Frequency/Density Inputs................................. A-9, A-13 Front Panel .................................................................. 2-3 Reinstalling............................................................. 2-9 Front Panel Port................................................... 5-7, A-5 Function Keys Program ................................................................ 3-22 Fuse Changing................................................................. 4-7

F F Keys ......................................................................... 3-3 Factory Setup ....................................................... 4-3, 4-5 Figure 1-1. The FloBoss S600 System....................... 1-2 Figure 1-2. CPU Board .............................................. 1-3 Figure 1-3. Intelligent I/O Board................................ 1-5 Figure 2-1. All Parts of the Basic FloBoss S600 System ................................................................................... 2-2 Figure 2-2. Removing the Front Panel ....................... 2-4 Figure 2-3. Lift up Panel ............................................ 2-4 Figure 2-4. Remove Connector .................................. 2-5 Figure 2-5. Panel Mount ............................................ 2-6 Figure 2-6. Unscrewing the Retention Screws ........... 2-7 Figure 2-7. Preparing to use the pull tabs for board release........................................................................ 2-8 Figure 2-8. Using the Pull Tabs ................................. 2-8 Figure 2-9. Board Ready for Removal or Final Insertion ................................................................................... 2-9 Figure 3-1. Front Panel .............................................. 3-3 Figure 3-10. Standard DENS ....................................3-15 Figure 3-11. Calculated.............................................3-15 Figure 3-12. Confirm ................................................3-16 Figure 3-13. Alarm Display ......................................3-17 Figure 3-14. Print Options.........................................3-18 Figure 3-15. Print Options 2......................................3-19 Figure 3-16. Print Options 3......................................3-19 Figure 3-17. Print Options 4......................................3-20 Figure 3-18. Display Setup Menu .............................3-21 Figure 3-2. LCD Display............................................ 3-6 Figure 3-3. Status ID Line.......................................... 3-7 Figure 3-4. Database Matrix....................................... 3-8 Figure 3-5. Startup Screen.......................................... 3-9 Figure 3-6. Main Menu .............................................3-10 Figure 3-7. Submenu.................................................3-11 Figure 3-8. Analog Inputs .........................................3-11 Figure 3-9. Alarm Limits ..........................................3-13 Figure 4-1. Startup Menu ........................................... 4-2 Figure 4-2.................................................................... 4-8 Figure 5-1. CPU Backplate ........................................ 5-3 Figure 5-2. Pin Connections....................................... 5-5 Figure 5-3. COM2 Alternative Connections .............. 5-7 Figure 5-4. I/O Backplate..........................................5-12 Figure 5-5. Analog Output Channel 1 as a Source or Sink ..........................................................................5-17 Figure 5-6. Prover I/O Backplate ..............................5-21 Figure 6-1. Run Dialog .............................................. 6-2 Figure 6-2. Link Cable ............................................... 6-4 File Locations.............................................................. 6-3 Flash..................................................................... 3-9, 4-3 I-2

I I/O ............................................................................... 3-7 Ident T/O ................................................................... 3-21 Initial Checks............................................................... 4-7 Initialization ................................................................ 3-9 Installation................................................................... 2-3 Boards..................................................................... 2-7 Panel-Mounted Unit ............................................... 2-5 Plug-In Boards........................................................ 2-9 Preparing................................................................. 2-1 Reinstalling the Front Panel.................................... 2-9 Removing the Front Panel ...................................... 2-3 Software.................................................................. 6-2 Tools ....................................................................... 2-3 Unpacking............................................................... 2-2 IPL 600........................................................................ 1-6

K Keypad .......................................................3-2, 3-3, A-16

L LAN Port Ethernet................................................................... 5-6 LCD Display ........................................................ 3-2, 3-6 Navigating ............................................................ 3-11 Logout T/O................................................................ 3-21

M Main Menu Return ................................................................... 3-22 Maintenance ................................................................ 4-1 Matrix Display.................................................................... 3-7 Mbpseq.txt................................................................... 6-3 Mbxx.txt ...................................................................... 6-3 Mechanical and Environmental .................................. A-2 Menu Keys .................................................................. 3-4 Menus .......................................................................... 3-6 Index

8/01

FloBoss S600 Instruction Manual Mezzanine Boards .................................................... A-17 Modbus Maps............................................................ 3-20 Mode Change Example................................................... 3-15 Changing .............................................................. 3-14 Modem Port................................................................. 5-5 Multidrop Port RS422/485 .............................................................. 5-6

R RAM............................................................................ 3-9 RAM Disc Start ........................................................... 4-6 Raw Pulse Outputs ......................................... A-12, A-16 Reflash Config............................................................. 4-3 Reflash Config File...................................................... 4-4 Reflash Firmware ........................................................ 4-3 Reinstalling the Front Panel ........................................ 2-9 Remote Display or PC ................................................. 5-8 Removal of the Boards ................................................ 2-7 Removing and Replacing Plug-in Boards.................... 4-7 Repxx.txt ..................................................................... 6-3 Requirements System .................................................................... 6-2 Return to Main Menu ................................................ 3-22 RS232 Modem Port ..................................................... 5-5 RS232 Ports ................................................................ A-6 RS422/485 Multidrop Port .......................................... 5-6 RS422/RS485 Ports .................................................... A-6 RTD Inputs ................................................................ 5-16 Run Mode .................................................................... 4-2

N Network Setup...................................................... 4-2, 4-5 Numeric Keys.............................................................. 3-5

O On-Board Battery Backup ........................................... 5-7 Operation..................................................................... 3-1 Overview ..................................................................... 1-1

P P144 I/O Berg Jumpers (Links)................................. 5-19 P144 I/O Board ................................................. 5-12, A-7 P152 CPU................................................................... A-4 P152 CPU Berg Jumpers (Links) .............................. 5-10 P152 CPU Board ......................................................... 5-2 P152 CPU On-board Connectors ................................ 5-9 P154 Prover.............................................................. A-13 P154 Prover Berg Jumpers (Links) ........................... 5-26 P154 Prover Board .................................................... 5-21 Panel-Mounted Unit Installation .............................................................. 2-5 Peripherals.................................................................. A-6 Plant I/O .................................................................... 3-11 Plug-in Boards Removing and Replacing........................................ 4-7 Plug-In Boards Installation .............................................................. 2-9 Power Inputs............................................................... A-3 Power Outputs - 15 Volts ........................................... A-3 Power Outputs - 24 Volts ........................................... A-3 Power Supply ...................................................... 5-3, A-3 Print....................................................3-5, 3-8, 3-18, 3-22 Program Function Keys............................................. 3-22 Prover P154..................................................................... A-13 Prover Board P154...................................................................... 5-21 PRT Input .................................................................... 3-8 PRT Inputs ................................................................. A-9 PRT/RTD Inputs ....................................................... 5-16 Pulse Inputs Turbine ....................................5-14, 5-23, A-10, A-14 Pulse Outputs ................................................. A-12, A-15 PULSEOUT................................................. 5-19, 5-25

8/01

S s600conf.cfg ................................................................ 6-3 Scientific Notation..................................................... 3-22 Security...................................................................... 3-21 Security Code ............................................................ 3-16 Security Dump........................................................... 3-20 Setup Factory .................................................................... 4-5 Setup and Wiring......................................................... 5-1 Software....................................................................... 1-5 Config 600 Lite....................................................... 1-6 Config 600 Professional.......................................... 1-6 Installation .............................................................. 6-2 IPL 600 ................................................................... 1-6 Special Pages ............................................................. 3-20 Spectra-Tek DPR Mezzanine ................................... A-17 SRAM.......................................................................... 3-9 Clear........................................................................ 4-5 StartUp......................................................................... 6-4 Startup List .................................................................. 4-8 Status/ID Line.......................................................3-4, 3-7 Summary of Operation .............................................. 3-21 System Requirements .................................................. 6-2

T Table 1-1. I/O Functions............................................. 1-4 Table 4-1. Startup List ................................................ 4-9 Table 5-1. TB-1 Pin Connections ............................... 5-4 Table 5-10. ANIN Pin Connections for SKT-A ....... 5-13 Table 5-11. ANIN Pin Connections for SKT-B........ 5-13 Table 5-12. DIGIN Pin Connections for SKT-B ...... 5-14 Table 5-13. DIGIN Pin Connections for SKT-C ...... 5-14 Index

I-3

FloBoss S600 Instruction Manual Table 5-14. Dual-pulse Input Pin Connections for SKTC ...............................................................................5-15 Table 5-15. Frequency Input Pin Connections for SKTB ...............................................................................5-15 Table 5-16. PRT Input Pin Connections for SKT-B .5-16 Table 5-17. D/A Converter Output Pin Connections for SKT-A ......................................................................5-17 Table 5-18. DIGOUT Pin Connections for SKT-B...5-18 Table 5-19. DIGOUT Pin Connections for SKT-C...5-18 Table 5-2. TB-1 Pin Connections............................... 5-4 Table 5-20. PULSEOUT Pin Connections for SKT-B..... ..................................................................................5-19 Table 5-21. Flash Link Setting..................................5-19 Table 5-22. P144 I/O Berg Links ..............................5-20 Table 5-23. A/D Converter Shunt Mode ...................5-20 Table 5-24. DIGIN Pin Connections for SKT-E .......5-22 Table 5-25. DIGIN Pin Connections for SKT-F .......5-23 Table 5-26. Dual-pulse Input Pin Connections for SKTF ...............................................................................5-23 Table 5-27. Frequency Input Pin Connections for SKTD...............................................................................5-24 Table 5-28. DIGOUT Pin Connections for SKT-E. ..5-24 Table 5-29. DIGOUT Pin Connections for SKT-F ...5-25 Table 5-3. COM3 and COM4 Pin Connections ......... 5-5 Table 5-30. PULSEOUT Pin Connections for SKT-E525 Table 5-31. P154 Prover Berg Jumpers (Links)........5-26 Table 5-32. Node Addressing Communications Mode Selection..........................5-27 Table 5-4. COM5, COM6, and COM7 Pin Connections ................................................................................... 5-6 Table 5-5. COM2 Alternative Connections ............... 5-7 Table 5-6. COM1-2 Pin Connections......................... 5-8 Table 5-7. Miscellaneous Device Connectors for the P152 CPU Module .................................................... 5-9 Table 5-8. Default Configuration Settings for the P152 CPU Berg Jumpers (Links) ......................................5-10 Table 5-9. Clock Speed Selection .............................5-11 Table 6-1. System Requirements ................................ 6-2 Table A-1. Computer Case and Mounting .................A-2 Table A-10. Configuration Port (bottom side of front panel).........................................................................A-5 Table A-11. RS232 Ports ...........................................A-6 Table A-12. RS422/RS485 Ports ...............................A-6 Table A-13. Ethernet..................................................A-6 Table A-14. Clock Facilities ......................................A-6 Table A-15. Watchdog Relay.....................................A-7 Table A-16. P144 I/O.................................................A-7 Table A-17. Analog Inputs.........................................A-8 Table A-18. A/D Converter Inputs Voltage Mode.....A-8 Table A-19. A/D Converter Inputs Current Mode .....A-8 Table A-2. Environmental Conditions .......................A-2 Table A-20. PRT Inputs .............................................A-9

I-4

Table A-21. Frequency/Density Inputs ..................... A-9 Table A-22. Turbine Pulse Inputs............................ A-10 Table A-23. Digital Status Inputs ............................ A-10 Table A-24. Analog Output..................................... A-11 Table A-25. Digital Outputs .................................... A-11 Table A-26. Pulse Outputs ...................................... A-12 Table A-27. Raw Pulse Outputs .............................. A-12 Table A-28. P154 Prover......................................... A-13 Table A-29. Frequency/Density Inputs ................... A-13 Table A-3. Power Inputs............................................ A-3 Table A-30. Turbine Pulse Inputs............................ A-14 Table A-31. Digital Status Inputs ............................ A-14 Table A-32. Digital Outputs .................................... A-15 Table A-33. Pulse Outputs ...................................... A-15 Table A-34. Raw Pulse Outputs .............................. A-16 Table A-35. Display-Keypad................................... A-16 Table A-36. P148 Spectra - Tek Pre-amp MezzanineA17 Table A-37. P148 US Version Mezzanine .............. A-17 Table A-4. Power Outputs - 24 Volts ........................ A-3 Table A-5. Power Outputs - 15 Volts ........................ A-3 Table A-6. CPU Module Components ...................... A-4 Table A-7. Standard Ni-MH Rechargeable ............... A-4 Table A-8. In Total.................................................... A-5 Table A-9. Front Panel Port....................................... A-5 Technical Data............................................................ A-1 Tools............................................................................ 2-3 Totals........................................................................... 3-7 Troubleshooting........................................................... 4-6 Flash Failed ............................................................ 4-3 Startup List ............................................................. 4-8 Turbine Pulse Inputs.....................5-14, 5-23, A-10, A-14

U Unpack ........................................................................ 2-2

V Value Changing............................................................... 3-12 Changing Example ............................................... 3-13 Vector and Menu Keys................................................ 3-4 View Alarm ............................................................... 3-17 View Parameter ......................................................... 3-22 vxworks.bin.x.x.x.x ..................................................... 6-3

W Warm Start ........................................................... 3-9, 4-2 Watchdog Relay .................................................. 5-4, A-7 Wiring.......................................................................... 5-1

Index

8/01

FloBoss S600 Instruction Manual

8/01

Index

I-5

FloBoss S600 Instruction Manual

For information, contact your local sales representative or: Emerson Process Management Flow Computer Division Marshalltown, Iowa 50158 U.S.A. Website: www.EmersonProcess.com/flow

I-6

Index

8/01