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A6114 FloBoss 103 and 104 Instruction Manual

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1. mmm emm a CD Closed Closed Closed Closed diff dsf Differential Pressure static dsf Static Pressure Figure 8 3 Pressure Calibration Open Close Orientation 6 If you are calibrating a temperature input disconnect the RTD sensor and connect a decade box or comparable equipment to the RTD terminals of the FloBoss 7 Click Calibrate under the desired input to calibrate Diff Press Stat Press or Temperature This displays the Set Zero calibration window as in Figure 8 4 Rev Aug 04 Calibration 8 3 FloBoss 103 and 104 Instruction Manual 10 11 12 13 Point Line Press Dead Weight Tester Value Mmmm Live Reading fessa 335 Difference fessa 395 z Live Act Span H Set Zero X Cancel Figure 8 4 Set Zero Calibration Example Apply the low zero value For a pressure input this would typically be open to atmosphere Enter the applied value in the Dead Weight Tester Value field of the Set Zero dialog Refer to Figure 8 4 For static pressure on an absolute pressure device remember to enter the actual current atmospheric pressure such as 14 73 psi When the displayed Live Reading is stable click Set Zero to calibrate the zero reading The Set Span window then appears as in Figure 8 5 Point Line Pres
2. Rev Aug 04 Input Output amp RTD Input 5 7 FloBoss 103 and 104 Instruction Manual 5 6 1 How to Wire the Discrete Output The terminals for connecting the DO wiring are shown in Figure 5 1 oe 99 The terminal is the normally open contact and the terminal is the common Refer to Figure 5 7 DO Induction load solenoid or T i relay using a Back EMF ontro diode is required ll y External power CoR 1 i Lu S FET Switch Figure 5 7 Solid State Relays Discrete Outputs 5 7 Pulse Input Pulse Inputs PI count pulses from pulse generating devices The FloBoss 100 Series Pulse Input circuits are physically the same as the Discrete Inputs The Pulse Input after the isolation routes to a pulse accumulator where the pulses are counted and accumulated The selectable Pulse Inputs Discrete Inputs are configured as Pulse Inputs through ROCLINK 800 software Refer to Section 5 1 1 5 7 1 How to Wire the Pulse Input The terminals for connecting the DI wiring are shown in Figure 5 1 Ce 66 The terminal is a positive source voltage the terminal is the signal return To use the channel as a Pulse Input shown in Figure 5 8 connect the and field wires to terminals PI 1 or PI 2 and PULSE DEVICE OPEN COLLECTOR OR DRY CONTACT DOCO493A Figure 5 8 Pulse Input Wiring Rev
3. The recommended cable for I O signal wiring is an insulated shielded twisted pair The twisted pair and the shielding minimize signal errors caused by EMI electromagnetic interference RFI radio frequency interference and transients 3 2 2 How to Install Grounding for the FloBoss 100 Series The FloBoss 100 Series unit has two grounding screws inside the enclosure and one grounding screw outside the enclosure For the grounding screw locations refer to Figure 3 1 The grounding installation method for the FloBoss 100 Series depends on whether the pipeline has cathodic protection On pipelines with cathodic protection the FloBoss must be electrically isolated from the pipeline Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the meter run In this case the FloBoss 100 Series could be flange mounted or saddle clamp mounted directly on the meter run and grounded with a ground rod or grid system Rev Aug 04 Power Connections 3 2 FloBoss 103 and 104 Instruction Manual On pipelines without cathodic protection the pipeline itself may provide an adequate earth ground and the FloBoss 100 Series could mount directly on the meter run using an orifice plate Test with a ground system tester to make sure the pipeline to earth impedance is less than 2 ohms If the pipeline provides an adequate ground you may not need to install a separate ground rod or grid system All grounding should terminate
4. e Flow dependent time weighted formulaic averaging e Flow weighted linear averaging Flow weighted formulaic averaging The Averaging Technique is selected by using ROCLINK 800 software The selected Averaging Technique is applied to the meter inputs Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 1 2 2 1 Minute Historical Log The FloBoss has a 60 minute historical log for every history point The Minute Historical Log stores the last 60 minutes of data from the current minute Each history point has Minute Historical Log entries unless the history point is configured for FST controlled logging 1 2 2 2 Hourly Historical Log The FloBoss has a total of 35 days of hourly historical logs available for every history point The Hourly Historical Log is also called the Periodic database Normally the Hourly Log is recorded at the beginning of every hour The exceptions are FST Minute and FST Second logging The time stamp for periodic logging consists of the month day hour and minute The exception is for FST Second logging in which the time stamp consists of the day hour minute and second 1 2 2 3 Daily Historical Log The FloBoss has a total of 35 daily historical logs for every history point The Daily Log is recorded at the configured contract hour every day with a time stamp that is the same as the Hourly Log Each history point has daily historical log entries unless the history point is configur
5. 4 4 1 How to Wire the Dial Up Modem Communications Card Signal wiring connections to the communications card are made through the terminal block located on the termination board A nine terminal removable connector is used for the wiring of external device communications A label on the termination board denotes the usage of each pin on the connector The dial up modem card interfaces to a PSTN line through the screw terminals with two wires The dial up modem card provides for a telephone interface on the host port that is capable of both answering and originating phone calls The dial up modem card also provides electronics that conserve power when the phone line is not in use The dial up modem card provides some protection from transients on the phone lines however if the potential for lightning damage is high additional surge protection for the phone lines should be installed outside the FloBoss enclosure Table 4 5 displays the connector signals and their functions Table 4 5 Dial Up Modem Communications Card Wiring Pin Signal Label 9 Tip Transmit data TX 8 Ring Receive data RX NOTE Tip and Ring are the telephone interface signals Rev Aug 04 Communications 4 5 FloBoss 103 and 104 Instruction Manual 4 5 Radio Communications Cards The Radio module consists of three parts the spread spectrum wireless radio an interface card and a logic card Two models of Spread Spectrum
6. 5 to 95 non condensing Vibration Meets SAMA PMC 31 1 Radiated Conducted Transmissions Meets requirements of IEC 61326 Electrical Equipment for Measurement Control and Laboratory Use Radiated Emissions Meets FCC Part 15 Class A DIMENSIONS Enclosure 160 mm H by 150 mm W by 135 mm D 6 3 in H by 5 9 in W by 5 3 in D excludes mounting flange and sensor Pipestand Mounting Mounts on a 2 inch pipe with U bolt mounting kit optional APPROVALS Evaluated per the following North American standards CSA C22 2 No 30 CSA C22 2 No 213 UL 1203 UL 1604 Meets CSA standards for hazardous locations as Model W40106 with enclosure plug Type 4 enclosure Class I Division 1 Groups C amp D Class I Division 2 Groups A B C amp D Temp T3 Model W40112 with optional solar panel mast assembly Type 4 enclosure Class I Division 2 Groups A B C amp D Temp T3 Rev Aug 04 General Information 1 19 FloBoss 103 and 104 Instruction Manual FloBoss 104 Specifications PROCESSOR INFORMATION 32 bit running at 3 68 MHz Program Memory 2 MB flash EPROM programmable for firmware and configuration Data Memory 512 KB SRAM Boot Memory 128 KB Flash EPROM TIME FUNCTIONS Clock Real Time Year Month Day and Hour Minute Second Battery Backed Automatically adjusts for Daylight Savings Time selectable DIAGNOSTICS These conditions are monitored and alarmed Pulse Interface Module and RTD point fail batter
7. NOTE Keep in mind that a solar panel size may violate certain CSA Class I Division 1 ratings Be sure to use approved connectors on the FloBoss 100 Series enclosure for routing the power wiring These connections provide the input voltage and power for the battery charging circuitry The maximum voltage that can be applied to the CHG CHG terminals is 28 volts dc 3 7 How to Backup Configuration and Log Data Perform this backup procedure before removing power to the FloBoss 100 Series unit for repairs troubleshooting removing or adding components or upgrades This procedure preserves the current flow computer configuration and log data held in RAM When installing equipment in a hazardous area ensure that all components are approved for use in such areas Check the product labels Change components only in an area known to be non hazardous Performing these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working inside the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Launch ROCLINK 800 software and connect to the FloBoss unit 2 Ensure that the configuration is saved in flash memory by performing a Save to Flash Memory ROC gt Flags This saves all configuration settings including the current states of the ROC Flags and calibration values 3 Select ROC gt Collect Data and select the All checkbox Click
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9. 18 8 stainless steel fasteners and washers are recommended 10 Remove the two dowel pins In their place install two 5 16 18 x 7 8 long bolts and lock washers Securely tighten all bolts attaching the FB104 to the meter The Pressure transducers will be attached to the process after the Pulse Interface Module has been installed on the meter Refer to How to Make Process Connections in Section 7 Rev Aug 04 Installation and Use 2 8 FloBoss 103 and 104 Instruction Manual 2 4 Startup and Operation Before starting the FloBoss 100 Series unit perform the following checks to ensure the unit is properly installed e Check the field wiring for proper installation Refer to Sections 3 and 4 Make sure the input power has the correct polarity Make sure the input power is fused at the power source Plug the input power into the connector labeled CHG CHG When installing equipment in a hazardous area ensure that all components are approved for use in such areas Check the product labels Change components only in an area known to be non hazardous Performing these procedures in a hazardous area could result in personal injury or property damage 2 4 1 How to Start the FloBoss 100 Series The FloBoss 100 Series unit ships with the reset jumper in the OFF position to prevent unnecessary battery drainage To apply power to the FloBoss 100 Series unit 1 Unscrew the front end cap cover LCD end 2 Place the power
10. 5 2 Analog Input Wiring 5 4 Analog Output The Analog Output AO on the new 6 Point I O termination board provides a 4 20 mA current source The analog outputs use a 12 bit D A converter with A D values of 0 and 4095 NOTE The switch for the selectable Analog Output Discrete Output should be in the AO position when configured for use as an Analog Output The Analog Output AO on the older 4 Point I O termination board provides either a 1 5 volt signal or a 4 20 mA current control The analog outputs use a 8 bit D A converter with A D values of 0 and 250 The AO is located at Point Number B2 5 4 1 How to Wire the Analog Output on the 6 Point I O Termination Board The Analog Output provided on the I O termination board connects as follows AO Positive AO Common Rev Aug 04 Input Output amp RTD Input 5 4 FloBoss 103 and 104 Instruction Manual Figure 5 3 shows wiring for the Analog Output AO VsourcE OO D A 4 20mA C DEVICE DOCO0495A Figure 5 3 Analog Output Wiring 5 4 2 How to Wire the Analog Output on the Older 4 Point I O Termination Board The Analog Output provided on the I O termination board connects as follows AO Positive IC Current control AO Common Figure 5 3 shows wiring for the Analog Output 1 5V 4 20mA current device ey output External power Figure 5 4 4 20 mA Analog Ou
11. 5 7 Solid State Relays Discrete Outputs 5 8 Figure 5 8 Pulse Input Wiring 0 0 0 eee eeeeeeeeeeee 5 8 Figure 7 1 FloBoss 104 Assembly cesses 7 2 Figure 8 1 Meter Calibration eeeeeeeecreeeeeee 8 2 Figure 8 10 Set Zero Shift 8 7 Figure 8 11 Meter Calibration Wmdow 8 8 Figure 8 12 Verify Calibration eee eeeeeeeee 8 9 Figure 8 2 Removing the DVS from Service 8 3 Figure 8 3 Pressure Calibration Open Close 8 3 Figure 8 4 Set Zero Calibration 0 0 eee eeeeeeeeeeeeee 8 4 Figure 8 5 Set Spam ssccsccessessessvsrsesevonenneseonenes 8 4 Figure 8 6 Set Midpoint 1 8 5 Figure 8 7 Set Midpoint 7 8 5 Figure 8 8 Set Midpoint 3 8 5 Figure 8 9 Returning the DVS to Service 8 6 Figure 9 1 Backplane with 34 Pin Interface Connector esting dE deer 9 7 Figure 9 2 34 Pin Interface Connector eee 9 7 FIT E 1 6 1 8 Flash Mem ry sisanne s 1 15 Flash ROM EE 1 5 FloBoss T04 sssrinin aanne 7 1 FloBoss Flow Manager 1 1 Le 1 11 Flow and Energy Accumulation cs eeeeeeeeeeeees 1 10 Flow Calculations REENEN Aubin Rate en 1 10 Flow Measurement 200 0 ee eeceeeesecesecesecneecneeeneeees 1 9 Flow Ke 1 9 Flowing Minutes s sssssesesesceeseseserenssneevenes 1 10 Function Sequence Tables cs ceesesesecseereeeeenees 1 13 Functions nosei e a eter cate 1 8 G Grid Impedance sisi Seiad traitas Raar ser anaes 3 2 Ground RO sss ssssscessesevebescsentoetsaseasssesaseosssvevseas
12. Aug 04 Input Output amp RTD Input 5 8 FloBoss 103 and 104 Instruction Manual 5 8 RTD Input The temperature is input through the Resistance Temperature Detector RTD probe and circuitry The RTD temperature probe mounts directly to the piping using a thermowell outside the FloBoss enclosure The RTD probe is then wired to the FloBoss RTD connections The RTD wires should be protected either by a metal sheath or by conduit connected to a liquid tight field conduit wiring fitting on the enclosure The RTD signal will be monitored by a 16 bit A D converter and then be read by the microprocessor 5 8 1 How to Wire the RTD Input The RTD wires connect to the three screw terminals designated RTD on the Termination Board The FloBoss 100 Series unit provides terminations for a three wire or two wire 100 ohm platinum RTD with a DIN 43760 curve The RTD has an alpha equal to 0 00385 Wiring between the RTD probe and the FloBoss unit should be shielded wire with the shield grounded only at one end to prevent ground loops Ground loops can cause RTD input signal errors Table 5 2 displays the connections at the RTD terminals for the various RTD probes Table 5 2 RTD Signal Routing Terminal Designation 3 Wire RTD 2 Wire RTD Signal positive input RTD RTD Signal positive input RTD Jumper to RTD RET Return reference RTD RET RTD RET Rev Aug 04 Input Output amp RTD Input 5 9
13. Bell 212 compatible Data Rate 1200 or 2400 baud asynchronous software selectable Parity None odd or even software selectable Format 8 9 10 or 11 bits including start stop and parity software selectable Modulation V2 1 and 103 binary phase coherent FSK V2 2 and 212A 4 point DPSK at 600 baud V2 2bis 16 point QAM at 600 baud Transmit Carrier Frequencies Originate 1200 Hz 0 1 Answer 2400 Hz 0 1 Receive Carrier Frequencies Originate 2400 Hz 7 Hz Answer 1200 Hz 7 Hz Telephone Line Impedance 600 ohm typical RTS to Transmission Delay Configurable in 50 millisecond periods software selectable Receiver Sensitivity Off to On threshold 45 dBm On to Off threshold 48 dBm Maximum Output Level 0 dBm nominal into 600 ohms Surge Protection Conforms to FCC part 68 and DOC Surge Isolation 1000 V ac and 1500 volt peak Certification FCC Part 68 approved Rev Aug 04 DIMENSIONS See Serial Card Specifications ENVIRONMENTAL See Serial Card Specifications POWER REQUIREMENTS 3 3 Vdc 0 25 W maximum supplied by processor board APPROVALS Same as the FloBoss 100 Series unit in which it is installed FCC registered modem chip Registration Number US FSRMRO6B103 REN 0 6B Communications 4 9 FloBoss 103 and 104 Instruction Manual 4 6 3 Radio Cards Specifications FreeWave M Series Radio Card Specifications RADIO LINK Frequency Range 902 928 M
14. INCLUDING WITHOUT LIMITATION FOR CAPITAL FUEL AND POWER AND CLAIMS OF THIRD PARTIES Bristol Inc Bristol Canada BBI SA de CV and Emerson Process Management Ltd Remote Automation Solutions division UK are wholly owned subsidiaries of Emerson Electric Co doing business as Remote Automation Solutions RAS a division of Emerson Process Management FloBoss ROCLINK Bristol Bristol Babcock ControlWave TeleFlow and Helicoid are trademarks of RAS AMS PlantWeb and the PlantWeb logo are marks of Emerson Electric Co The Emerson logo is a trademark and service mark of the Emerson Electric Co All other trademarks are property of their respective owners The contents of this publication are presented for informational purposes only While every effort has been made to ensure informational accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability RAS reserves the right to modify or improve the designs or specifications of such products at any time without notice All sales are governed by RAS terms and conditions which are available upon request RAS does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any RAS product remains solely with the purchaser and end user 2002 2010 Remote Automation Solutions division of Emerson Process M
15. OK This action saves event logs alarm logs report data and history You can specify your own file name and path if desired 4 Select File gt Save The Save As dialog box appears 5 Type the desired File name for the backup file or use the default 6 Click Save The file is saved in the default directory C Program Files ROCLINK 800 Data unless you changed the directory Rev Aug 04 Power Connections 3 9 FloBoss 103 and 104 Instruction Manual SECTION A COMMUNICATIONS The FloBoss communicates to external devices through its local operator interface port LOD the Comm 1 EIA 485 RS 485 port or the optional Comm 2 EIA 232 RS 232 dial up modem spread spectrum wireless radio port The communications terminals and communication cards provide communications between the FloBoss 100 Series and a host system or external devices The communications cards install directly onto the backplane board and activate the host port Comm 2 when installed You may use the EIA 232 RS 232 Serial Communications Card the Dial up Modem Communications Card or the Spread Spectrum Wireless Radio Module NOTE To enable or disable the Comm 2 port select Configure gt Radio Power Control and select the Enabled or Disabled radio button under Radio Power Control This section contains the following information Section Page 4 1 EIA 485 RS 485 Communications Wiring 4 2 Local Operator Interface Port Wiring 4 3 Serial Communications Card 4 4 D
16. Set Midpoint 2 window as in Figure 8 7 17 If you are performing a three point calibration click Done Calibration for this input is complete 18 To calibrate additional Midpoints apply the desired pressure or temperature and enter the Set Mid 2 ES Point Line Press Dead Weight Tester Value EWAMMMA Live Reading Do 406 Difference fai 57 838 Live AcL Z Span H Set Mid 2 K Cancel Vv Done Figure 8 7 Set Midpoint 2 applied value in the Dead Weight Tester Value field 19 When the Live Reading is stable click Set Mid 2 to calibrate this reading The display advances to the Set Midpoint 3 window as in Figure 8 8 Rev Aug 04 Set Mid 3 ES Point Line Press Dead Weight Tester Value UD Live Reading Do 406 Difference EE sl J Live ct Span SetMid3 Xl Cancel Vv Done Figure 8 8 Set Midpoint 3 Calibration 8 5 FloBoss 103 and 104 Instruction Manual 20 If you are performing a four point calibration click Done Calibration for this input is complete 21 To calibrate a third Midpoint apply the desired pressure or temperature and enter the applied value in the Dead Weight Tester Value field 22 When the Live Reading is stable click Set Mid 3 to calibrate this reading The calibration is complete and the display returns to the Meter Calibration window 23 When the calibration for a selected point i
17. TRANSMITTER Output Power 100 mW RECEIVER Sensitivity 110 dBm POWER REQUIREMENTS Input Voltage Range 5 Vdc 0 25 V Current Consumption Transmit 150 mA nominal Receive 50 mA nominal Other cyclic power down modes available ANTENNA CONNECTOR Straight SMA jack female DIMENSIONS 91 mm H by 86 mm W by 10 mm D 3 6 in H by 3 4 in W by 0 4 in D ENVIRONMENTAL Operating Temperature Standard 0 to 70 C 32 to 158 F Industrial Version 40 to 75 C 40 to 167 F APPROVALS Same as the FloBoss 100 Series unit in which it is installed Rev Aug 04 Communications 4 10 FloBoss 103 and 104 Instruction Manual SECTION 5 INPUT OUTPUT amp RTD INPUT This section describes the optional Input Output I O termination points available on the termination board The I O termination points provide additional inputs and outputs for implementing expanded monitoring and control applications This section also describes the RTD Input on the termination board This section contains the following information Section Page 5 1 VO Description 5 1 5 2 I O Wiring Requirements 5 3 5 3 Analog Input 5 3 5 4 Analog Output 5 4 5 4 2 Discrete Input 5 5 5 7 5 6 Discrete Output 5 7 Pulse Input 5 8 5 8 RTD Input 5 9 5 9 VO Termination Point Specifications 5 10 5 1 I O Description The I O uses the microprocessor for monitoring control and acquisition of data from external devices connec
18. antennas when using cellular phones or radios Rev Aug 04 Installation and Use 2 3 FloBoss 103 and 104 Instruction Manual 2 3 1 Mounting the FloBoss 103 The FloBoss enclosure assembly can mount directly to an orifice plate by using a 3 or 5 valve manifold or by using the standard Rosemount 2 pipe mounting kit with impulse tubing connecting the FloBoss 103 to the meter run The Dual Variable Sensor factory mounts directly on a flat flange to the FloBoss enclosure with a 4 bolt pattern An adapter coupling provides the mounting interface between the enclosure and the DVS See Section 4 for additional information The optional blank plate is available when the FloBoss 103 is ordered without a DVS The blank plate factory mounts directly on a flat flange to the FloBoss enclosure with a 4 bolt pattern The blank plate mounts onto a pipestand using the standard Rosemount 2 inch pipe mounting kit and 2 user supplied bolts 5 16 X 1 3 8 and lock washers Mounting of the FloBoss 103 can be accomplished using either of the following methods Pipestand mounted The FloBoss 103 can mount to a 2 inch pipestand Ensure that the pipestand meets all weight requirements and installation conforms to local building codes Orifice Plate Directly mount to an orifice plate via a 3 or 5 valve manifold With either mounting method the pressure inputs must be piped to the process connections on the DVS For more information on process connections re
19. are labeled for use in such areas Installation and maintenance must be performed only when the area is known to be non hazardous Installation in a hazardous area could result in personal injury or property damage Power Installation Requirements 3 1 Power installation Requirements Typical sources of primary power for FloBoss 100 Series installations are DC voltage sources and solar power Care must be taken to route power away from hazardous areas sensitive monitoring devices and radio equipment Local and company codes generally provide guidelines for power installations Adhere rigorously to all local and National Electrical Code NEC requirements for power installations The FloBoss 100 Series accepts input voltages from 8 0 volts to 28 volts at the charge CHG CHG terminals on the termination board The maximum power for DC voltage sources is 130 mWatts for FloBoss 103 and 300 mWatts for FloBoss 104 not including battery charging NOTE Do not allow the batteries to fully discharge If the batteries are fully discharged the battery charger board may enter thermal limiting Rev Aug 04 Power Connections 3 1 FloBoss 103 and 104 Instruction Manual 3 2 Grounding Installation Requirements Grounding wiring requirements for DC voltage sources equipment are governed by the National Electrical Code NEC When the equipment uses DC voltage sources the grounding system must terminate at the service disconn
20. at a single point If the pipeline to earth impedance is greater than 2 ohms the FloBoss installation should be electrically isolated and a ground rod or grid grounding system installed DO 1 AO 1 COMI tla gt RTD SPSS S A TA a Agaln o 3 ek scl fet 2 g Paj o o D WI Internal S pral 2 l se Grounding H A H Cp Screws en R E E 3 AIEN EA 14 CHa DOC0492B Figure 3 1 Location of Grounding Screws 3 3 How to Determine Power Requirements To adequately meet the needs of the FloBoss system it is important to determine the total power consumption and size of solar panel requirements accordingly For total FloBoss power consumption be sure to add the power consumption in mW of any other devices used with the FloBoss in the same power system The maximum power for DC voltage sources is 130 mWatts for the FloBoss 103 and 300 mWatts for the FloBoss 104 not including the battery charging Convert the total value in mW to Watts by dividing it by 1000 mW 1000 Watts For selecting an adequate power supply use a safety factor SF of 1 25 to account for losses and other variables not factored into the power consumption calculations To incor
21. changes The Event Log and Alarm Log are stored separately to prevent recurring alarms from overwriting configuration audit data The FloBoss 100 Series has the ability to limit the AGA calculation related events to only critical events This can keep unnecessary events from being logged and filling the event log The events which will not be logged are temperature pressure Reynolds number and warnings for orifice diameter pipe diameter and beta ratio Rev Aug 04 General Information 1 12 FloBoss 103 and 104 Instruction Manual 1 2 3 Security The FloBoss provides for security within the unit A maximum of 16 log on identifiers IDs may be stored In order for the unit to communicate the log on ID supplied to ROCLINK 800 software must match one of the IDs stored in the FloBoss The Local Operator Interface port Security on LOD has security Enabled by default The Comm 1 and Comm 2 can likewise be configured to have security protection but is disabled by default 1 2 4 Function Sequence Tables FST The FloBoss supports FST user programmability Two FST programs can be developed with a maximum length of 3000 bytes each typically 300 lines of code The number of FST lines per execution cycle can be configured in ROCLINK 800 software The number set on the ROC gt Information screen will determine both FST programs The FST code resides in static RAM and is backed up to flash memory when the Save Configuration function is issued thr
22. connector into the backplane connector Make sure that the connector shell faces away from the backplane and toward the termination board See Figure 9 1 Once the connection has been made to the backplane use the connector shell to guide the pins of the 34 pin interface connector into the termination board connector See Figure 9 2 Use caution you will not be able to see the connection being made within the housing NOTE If the 34 pin interface connector and boards are not re assembled in this manner the pins may be misaligned and not make a full connection The FloBoss 103 will not function correctly Depending on which connections are made the unit may appear to be working if the LCD is present Rev Aug 04 Troubleshooting 9 6 FloBoss 103 and 104 Instruction Manual Figure 9 1 Backplane with 34 Pin Interface Connector Attach this end to termination board second Attach this end to backplane first Figure 9 2 34 Pin Interface Connector Rev Aug 04 Troubleshooting 9 7 FloBoss 103 and 104 Instruction Manual GLOSSARY OF TERMS A AGA American Gas Association Association that oversees the AGA3 AGAS AGA7 AGA8 and AGA11 gas flow calculations AI Analog Input AO Analog Output Analog Analog data is represented by a continuous variable such as an electrical current signal AP Absolute Pressure ASCII American National Standard Code for Information Interchange B Bu
23. history The FloBoss also has 2 MB of programmable read only memory flash ROM for storing operating system firmware applications firmware and configuration parameters The charger board controls the charging of the internal batteries if installed The batteries are three D size lead acid batteries providing 2 5 Amp hours of current at 6 2 volts nominal The charger board also serves as the interface to the optional LCD assembly as well as supporting the On Off and Norm Reset jumpers A backup battery provides backup power for the Static RAM and the Real Time Clock This battery is field replaceable Under normal conditions the battery has a functional life in excess of five years The Dual Variable Sensor DVS of the FloBoss 103 measures static pressure and differential pressure for orifice flow calculation by converting the applied pressure to electrical signals and making the readings available to the processor board The DVS housing fastens to a flanged adapter which in turn mounts with four bolts to the bottom of the enclosure The DVS cable connects into the backplane board Refer to Section 6 Dual Variable Sensor The Pulse Interface Module of the FloBoss 104 measures the flow of natural gas using turbine metering or rotary metering by converting the applied pressure to electrical signals and counting the number of pulses from rotary meter and making the readings available to the processor board The module housing fastens to a fl
24. leie BE DO 1 AO 1 O O O O O O O Ol O O O O S O Rx EI EI e IF MODEM INSTALLED US F8RMAO6B103 WDE E3 a eilo Metal YW E RET Ke e aon yy Standoff N S e Ly lt A DOC0477B Figure 4 3 Termination Board 1 Ifthe FloBoss 100 Series unit does not have a communications logic card you will need to install one Refer to Section 4 5 2 2 Remove the termination end cap cover 3 Use a Phillips head screwdriver to unscrew the lower grounding screw to the right of the termination board Screw the metal standoff into the hole Refer to Figure 4 3 4 Push plastic standoffs into holes at top and bottom of the left side of the termination board Refer to Figure 4 3 5 Tuck the LOI interface cable and connector off to the upper right corner of the termination board Refer to Figure 4 3 6 Signal wiring connections to the communications card are made through the terminal block located on the termination board A nine terminal removable connector is used for the wiring of external device communications A label on the termination board denotes the usage of each pin on the connector Pin 1 will connect to COM The nine terminal connector is attached to the ribbon cable of the radio interface card 7 Center the card over the standoffs 8 Use a small Phillips head screwdriver to screw the card down to the
25. not include any of the clearing options available in a Cold Start performed using ROCLINK 800 software NOTE This type of reset restores the communications ports to the factory configuration defaults Some user entered configuration parameters may be lost Therefore try to back up any required data before performing this reset 1 Refer to Section 9 3 1 and perform the backup procedure 2 Unscrew the front end cap cover LCD end 3 Place the reset jumper located on the LCD if installed or on the Battery Charger Board at 4 5 J2 in the RST position Cycle the power Remove the reset RST jumper and install it in the normal NORM position NOTE It is good practice to lubricate the end cap covers every time they are removed for maintenance 6 TA Replace the front end cap cover LCD end Screw the cover on until metal contacts metal Do not over tighten the cover Refer to Section 9 3 3 and perform the Restart and Reconfigure procedure This reset action loads the factory default values into the communication ports Rev Aug 04 Troubleshooting 9 5 FloBoss 103 and 104 Instruction Manual 9 3 3 How to Restart and Reconfigure After removing power to the FloBoss unit and performing maintenance or repair as needed perform the following steps to start your FloBoss unit and reconfigure your data The procedure assumes you are using ROCLINK 800 software Ensure all input devices output devices and pro
26. plastic standoffs 9 Use the larger screw to attach the card to the metal standoff Rev Aug 04 Communications 4 7 FloBoss 103 and 104 Instruction Manual 10 11 Plug the Reverse Polarity SMA connector into a user supplied antenna cable This cable will have to be threaded through one of the side ports to a user supplied antenna Replace the back end cap cover 4 5 2 How to Install a Radio Communications Logic Card If the FloBoss 100 Series unit does not have a radio communications logic card you will need to install one to use the Comm 2 port A different card is used for the optional EIA 232 RS 232 and dial up modem If you ordered an optional Comm 2 radio module with your FloBoss 100 Series unit the communications logic card was installed at the factory and you will not need to use this procedure SS tz ir et en E Unscrew the front end cap cover LCD end Place the power jumper located at J1 on the Battery Charger Board in the OFF position Remove the ribbon cable from the Battery Charger Board to the Backplane Board Remove the four screws from the Battery Charger Board Remove the Battery Charger Board Remove the screws holding the retaining bar in front of the processor card Insert a communications logic card into the communications card slot beside the processor card See Figure 1 3 in Section 1 Replace the retaining bar over the communications card and the processor card 9 Replace the Batt
27. sleep mode thus staying awake all the time Rev Aug 04 General Information 1 17 FloBoss 103 and 104 Instruction Manual Wake up from Sleep occurs when the FloBoss 100 Series unit receives a e Timed interrupt from the Real Time Clock Signal from one of the communication ports 1 4 Additional Information The following manual includes additional information not found in this manual ROCLINK SOU Configuration Software User Manual Form A6121 Part Number D301159X12 Rev Aug 04 General Information FloBoss 103 and 104 Instruction Manual 1 5 FloBoss 103 and 104 Specifications FloBoss 103 Specifications PROCESSOR INFORMATION 32 bit running at 3 68 MHz Program Memory 2 MB flash EPROM programmable for firmware and configuration Data Memory 512 KB SRAM Boot Memory 128 KB Flash EPROM TIME FUNCTIONS Clock Real Time Year Month Day and Hour Minute Second Battery Backed Automatically adjusts for Daylight Savings Time selectable DIAGNOSTICS These conditions are monitored and can be configured for alarming sensor point fail battery and internal voltages and internal temperature COMMUNICATIONS Local Operator Interface EIA 232 RS 232C format Software configurable 1200 to 19 200 bps rate selectable EIA 485 RS 485 Software configurable 1200 to 19 200 bps rate selectable Host EIA 232 RS 232 or Modem interface when optional communications card is installed Protocols ROC or M
28. the FCC if you believe it necessary The telephone company may make changes to its facilities equipment operations or procedures that could affect the operation of the equipment If this happens the telephone company will provide advance notice so you can make the necessary modifications to maintain uninterrupted service If trouble is experienced with this equipment dial up modem for repair or warranty information please contact Emerson Process Management Flow Computer Division 641 754 3923 If the equipment is causing harm to the telephone network the telephone company may request that you disconnect the equipment until the problem is resolved 1 2 Product Functions This section describes the functions of the FloBoss 100 Series most of which is determined by firmware The features and applications provided by the firmware which must be configured by using ROCLINK 800 software include e Flow calculations for an orifice meter AGA3 or rotary or turbine meter AGA7 Extensive historical data archival Memory logging of 240 alarms and 240 events Security with local and remote password protection Logic and sequencing control using a user defined FST program et Spontaneous Report by Exception SRBX capability Rev Aug 04 General Information 1 8 FloBoss 103 and 104 Instruction Manual 1 2 1 Flow Measurement The primary function of the FloBoss 100 Series is to measure the flow of natural gas through a
29. to Verify a Calibration ROCLINK 800 software can verify the calibration to check if the DVS requires re calibration To verify perform the following steps 1 Launch ROCLINK 800 software and connect to the FloBoss 100 Series unit 2 Select Meter gt Calibration 3 Click Freeze This opens the Meter Calibration window Refer to Figure 8 11 The current reading displays under each meter input as the Freeze Value The FloBoss uses these values in the flow calculations while verifying the points Meter Calibration 27 x Meter ID fi zj Meter Tag Meter 1 freeze Valos Diff Pressure Stat Pressure Temperature jo 000000 o 4055 423 31 497 Manual brate Calibrate Calibrate Calibrate Figure 8 11 Meter Calibration Window CAUTION Open the by pass valve on the valve manifold prior to isolating the sensor from the process to protect the differential cell of the Dual Variable Sensor This keeps one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied This is required when calibrating either differential or static pressure Refer to Figure 8 2 on page 8 3 for the recommended sequence 4 While observing the previous Caution apply the desired pressure setting to the input 5 Click Verify listed under the input you desire to calibrate Rev Aug 04 Calibration 8 8 FloBoss 103 and 104 Instruction Ma
30. 00 Configuration Software Refer to ROCLINK 800 Configuration Software User Manual Form A6121 9 2 2 Serial Communications If you are experiencing troubles with a serial communications connection LOI EIA 232 or EILA 485 e Check to make sure power is applied to the FloBoss unit Check the ON OFF jumper the wiring connections at CHG and CHG and the wiring at the power source Check the wiring to the termination block or connector Refer to Section 4 Check the communication port settings in ROCLINK 800 Configuration Software Refer to ROCLINK SOU Configuration Software User Manual Form A6121 9 2 3 Optional I O If you are experiencing troubles with an optional I O point Analog Input Analog Output Discrete Input Discrete Output or Pulse Input e Check to see how the channel is configured using ROCLINK 800 software Ifthe configuration looks correct then simulate an input within the range of the input or force an output to be produced using ROCLINK 800 software Ifthe types of I O available for configuration do not match the type of I O wired to the I O terminations check the I O Setup screen Refer to Section 5 for wiring schematics and instructions e If an input channel is in question you may be able to use one of the outputs known to be in working order to simulate the required input Likewise if an output channel is in question you may able to connect it to a working input channel and check the resul
31. 03 is the perfect solution to electronically replace traditional paper charting The FloBoss 100 Series unit records the corrected gas flow across an orifice plate or meter stores the data and has the ability to send the data to a remote host The FloBoss 100 Series unit computes gas flow for both volume and energy The FloBoss provides on site functionality and supports remote monitoring measurement data archival communications and control The FloBoss design allows you to configure specific applications including those requiring logic and sequencing control using a Function Sequence Table FST The FloBoss 100 Series unit provides the following components and features Weather tight enclosure Termination Board 32 bit Processor Board Battery Charger Board Backplane Board 2 MB of flash ROM Random Access Memory which is field upgradeable 512 KB of battery backed up RAM Random Access Memory storage gt gt gt Oe gt o Rev Aug 04 General Information 1 1 FloBoss 103 and 104 Instruction Manual e Integral Dual Variable Sensor DVS for static pressure and differential pressure measurement using orifice metering FloBoss 103 e Pulse Interface Module for line pressure and pulse counts using turbine or rotary metering FloBoss 104 Support for a three wire 100 ohm Resistance Thermal Detector RTD input Internal lead acid batteries optional Local Operator Interface LOT port EIA 232 RS 232 EIA 48
32. 1 2 FloBoss 103 and 104 Instruction Manual Optional Solar oe Panel mounts here Field Conduit Entry SE E Se if Liquid Crystal Display LCD Field Conduit Entry Dual Variable Sensor DVS W6874 Figure 1 1 FloBoss 103 Flow Manager with LCD Optional Solar Panel Liquid Crystal Display LCD Pulse Interface Module Pressure Transducer Figure 1 2 FloBoss 104 Flow Manager Rev Aug 04 General Information 1 3 FloBoss 103 and 104 Instruction Manual Battery Pack If Ordered Battery Charger Board Optional Liquid Crystal Display LCD Rev Aug 04 990006 IF MODEM INSTALLED US FSRMRO6B108 REN 0 6B ALS Al 1 Jl DO 1 AO 1 COM1 o gt sssesvv09 RTD a m 4 CHa I DOC0492B Figure 1 4 Wiring Terminals General Information Termination Board Connectors Processor Board Backplane Optional Communications Logic Card RAM Backup 1 4 FloBoss 103 and 104 Instruction Manual 1 1 1 Hardware The backplane board provides the power regulation the routing of the signals to the termination board the processor board the backup battery board the optional communications board the Dual Variable Sensor DVS the Pulse Interface Module and the battery charger board Refer to Figure 1 3 The termination board provides connections to
33. 5 RS 485 on Comm 1 port Communications card using EIA 232 RS 232 dial up modem or spread spectrum radio on Comm 2 port optional gt e e Extensive applications firmware Physically the FloBoss 100 Series unit consists of a termination board with or without optional I O points RAM battery backup board optional Comm 2 communications card processor board charger board backplane board and optional display housed in a compact weather tight case The FloBoss is packaged in a NEMA 4 windowed enclosure that mounts on a pipestand to an orifice plate via a three or five valve manifold to a turbine meter or to a rotary meter The aluminum enclosure protects the electronics from physical damage and harsh environments Refer to Figure 1 1 Figure 1 3 and Figure 1 4 The enclosure is fabricated from die cast aluminum alloy with iridite plating and paint The NEMA 4 enclosure protects the electronics from physical damage and harsh environments The caps at either end of the enclosure can be unscrewed to allow field maintenance The FloBoss has two 34 14 pipe threaded holes for field conduit wiring and communications The DVS flange has bracket holes that allow the enclosure and DVS to be mounted on a pipestand or mounting bracket The Pulse Interface Module on a FloBoss 104 has a universal mounting plate that also has bracket holes to allow the enclosure and Interface to be mounted on a meter Rev Aug 04 General Information
34. A in the inactive off state Filter Slow pulse input debounce filter Software selectable Filter times from 0 025 to 5 sec RTD INPUT STANDARD Quantity Type Single input for a 2 or 3 wire RTD element with alpha of 0 00385 Terminals RTD current source RTD signal positive input and RTD RET signal negative input Sensing Range 40 to 240 C 40 to 464 F Accuracy 0 2 C 0 64 F over sensing range includes linearity hysteresis repeatability Ambient Temperature Effects per 28 C 50 F 0 50 C 0 90 F for process temperatures from 40 to 240 C 40 to 464 F Filter Band pass hardware filter Resolution 16 bits Sample Period 1 sec minimum CLASSIFICATION FCC Class A and CISPR 22 computing device ENVIRONMENTAL Same as the FloBoss unit in which it is installed APPROVALS Same as the FloBoss unit in which it is installed 5 10 FloBoss 103 and 104 Instruction Manual SECTION 6 DUAL VARIABLE SENSOR This section describes the Dual Variable Sensor DVS which provides differential pressure and static pressure inputs to the FloBoss 103 for orifice flow calculation Note that the DVS is not equipped to provide a temperature input to the FloBoss this input comes directly into the FloBoss by means of the RTD input on the termination board This section contains the following information Section Page 6 1 Dual Variable Sensor 6 1 6 2 DVS Specifications 6 3 6 1 Dual V
35. FloBoss 103 and 104 Instruction Manual 5 9 I O Termination Point Specifications UO Termination Points Specifications ANALOG INPUT OPTIONAL Type Single ended voltage sense analog inputs current loop if resistor is switched On Signal 0 to 5 V dc software configurable 4 to 20 mA with 250Q resistor switched to On Accuracy 0 5 over 40 to 65 C 40 to 149 F range Isolation None Input Impedance 1 MQ Filter Single pole Resolution 12 bits Sample Period 1 0 second minimum ANALOG OUTPUT OPTIONAL Type 4 20 mA high side source current Resolution 12 bits Accuracy 0 1 of full scale output Reset Action Output goes to last value or low scale software configurable on power up warm start or on watchdog time out DISCRETE INPUT OPTIONAL Type Contact sense discrete input Current Rating 35 uA in the active on state 0 uA in the inactive off state Isolation None Frequency 0 5 Hz maximum Sample Period 1 0 second minimum DISCRETE OUTPUT OPTIONAL Type Solid state switch Switch Rating 50 V dc 0 2 Amaximum Isolation 3000 V from processor Reset Action Output goes to last value or off software configurable on power up warm start or on watchdog time out Rev Aug 04 Input Output amp RTD Input PULSE INPUT OPTIONAL Type High speed pulse counter inputs dry contact Frequency 10 KHz maximum Signal Current 65 uA in the active on state 0 u
36. Form A6114 Part Number D301153X012 December 2010 FLOBOSS 103 AND 104 FLOW MANAGERS Instruction Manual Flow Computer Division EMERSON Process Management Website www EmersonProcess com flow FloBoss 103 and 104 Instruction Manual Revision Tracking Sheet December 2010 This manual is revised 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 Revision Chapter 7 Dec 10 applies to FloBoss 104 All Pages Aug 04 applies to FloBoss 104 All Pages 4 04 applies to version 1 30 All Pages 12 03 applies to version 1 20 All Pages 10 02 applies to version 1 10 All Pages 04 02 applies to version 1 0 NOTICE Remote Automation Solutions RAS division of Emerson Process Management shall not be liable for technical or editorial errors in this manual or omissions from this manual RAS MAKES NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND IN NO EVENT SHALL RAS BE LIABLE FOR ANY INCIDENTAL PUNITIVE SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PRODUCTION LOSS OF PROFITS LOSS OF REVENUE OR USE AND COSTS INCURRED
37. Hz Type Frequency hopping Spread Spectrum Channel Capacity 50 to 112 user selectable Hopping Patterns 15 per band 105 total user selectable Hopping Bands 7 user selectable Baud Rate 2400 to 19 2K bps selectable Radio Data Throughput 115 2K bps standard speed 38 4 K bps low speed Range 96 km 60 mi line of sight TRANSMITTER Output Power 100 mW 1 W 30 dBm RECEIVER Sensitivity 106 dBm for 10 BER 108 dBm for 10 BER ANTENNA CONNECTOR Straight SMA jack female POWER REQUIREMENTS Input Voltage Range 5 5 to 7 5 Vdc Current Consumption At 6 Vdc Transmit 1000 mA Receive 152 mA Idle 40 mA Sleep 8 mA At 30 Vdc Transmit 200 mA Receive 43 mA Idle 12 mA Sleep 3 mA DIMENSIONS 91 mm H by 86 mm W by 15 mm D 3 6 in H by 3 4 in W by 0 6 in D ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F APPROVALS Same as the FloBoss 100 Series unit in which it is installed 1 Line of Sight signifies a path that is free of natural and man made obstacles MaxStream 9XStream Radio Card Specifications RADIO LINK Frequency Range 902 to 928 MHz unlicensed ISM band Type Frequency hopping Spread Spectrum transceiver Channel Capacity 25 channels Hopping Patterns 7 hopping sequences Baud Rate 9600 bps Radio Data Throughput 9600 bps Range Indoor 182 457 m 600 1500 ft Outdoor 11 km 7 mi with dipole and 32 km 20 mi with high gain antenna
38. Interface Port Wiring Signal Label Transmit TX Receive RX Ready to Send RTS Common COM Not Used RP Common COM 1 Transmit is the FloBoss 100 Series unit s EIA 232 RS 232 transmission that connects to the PC s receive White Red Black This end connects to LOI terminal block DOC0485A Figure 4 1 PC Comm Port Wiring Rev Aug 04 Communications 4 2 FloBoss 103 and 104 Instruction Manual Table 4 2 PC Comm Port Wiring Signal Pin Label Transmit 2 TX Receive 3 RX Ground 5 GND 1 Transmit TX connects to the FloBoss 100 Series unit s receive Receive RX connects to the FloBoss 100 Series unit s transmit 4 3 Serial Communications Card The EIA 232 communications card meets all EIA 232 specifications for single ended RS 232 asynchronous data transmission over distances of up to 15 m 50 ft The EIA 232 RS 232 communications card provides transmit receive and modem control signals The EIA 232 RS 232 communications logic card activates Comm 2 The EJA 232 RS 232 communications card defaults are 9600 baud rate 8 data bits 1 stop bit no parity 10 millisecond Key On Delay and 10 millisecond Key Off Delay The maximum baud rate is 19 200 bps The EIA 232 RS 232 communications card signals include RX TX and RTS signal control lines Refer to Table 4 3 Table 4 3 Communication
39. R Ee 6 1 RA 6 1 Upstream Ueage ee a e 6 2 E E1 E2 and ES EE 1 17 EIA 232 Communications Cards 4 3 Electrical Isolation eeeeeeeeeeeeeeeeeeeeeeeereresrsesrrrrerereere 3 2 Electromagnetic Interference 3 2 Blectronies iana nann ii e De 1 14 Electronics Board 1 7 EMD on ahaa a Bie dates Dee 3 2 Enclosure EE 1 2 Energy E ts Aube loa as 1 11 Energy Accumulation ecesescseeeceeeeeeecneeeens 1 10 Environmental UE EE 2 2 Event og geogr ege nits 1 12 Expansion JCT Rome visa ced de ats hives Aas tel wets 5 1 Extended History Log 1 12 Extension Calculapon 1 9 F Figure 1 1 FloBoss 103 Flow Manager with LCD 1 3 Figure 1 2 FloBoss 104 Flow Manager 1 3 Figure 1 3 Inside the FloBoss 100 Series Enclosure 1 4 Figure 1 4 Wiring Temmals 1 4 Figure 2 1 Outline and Mounting Dimensions without Solar ane Aen EES 2 4 Figure 2 2 Outline and Mounting Dimensions with 2 Watt Solar Panel and LCD 0 0 eeeeeeeteees 2 5 l 1 FloBoss 103 and 104 Instruction Manual Figure 2 3 Mounting Styles s s s 2 6 Figure 3 1 Location of Grounding Screws 3 3 Figure 3 2 Solar Insolation in Hours for the United EEN 3 5 Figure 3 3 Termination Board 3 8 Figure 4 1 PC Comm Port Wiring 4 2 Figure 5 1 Termination Board with Optional I O 5 3 Figure 5 2 Analog Input 5 4 Figure 5 3 Analog Output 5 5 Figure 5 5 1 5 Volts Analog Output Voltage Control 5 5 Figure 5 6 Discrete Input Wmng eee ee eeeeeeee 5 6 Figure
40. a Zero Shift adjustment 8 2 1 1 How to Adjust for Zero Shift To check or adjust for Zero Shift leave the sensor by pass valve open to simulate a no flow condition with either line pressure or a normal operating static pressure from the calibrator applied to the sensor This applies the same pressure to both sides of the differential pressure diaphragm to give a zero differential pressure reading Perform the following steps 1 Ensure ROCLINK 800 software is connected to the FloBoss 100 Series unit and running the calibration procedure 2 Ifthe meter inputs were already released from the freeze condition click Freeze This returns the Meter Calibration window as shown in Figure 8 11 3 Under the Diff Press input click Zero Shift to open the Set Zero Shift window shown in Figure 8 10 Set Zero Shift ES Point Al Default Live Reading 00 0000000 Figure 8 10 Set Zero Shift 4 Check the Reading to determine if you need to perform a Zero Shift correction 5 Ifthe reading is not zero click Set Zero Shift to adjust the Zero Shift If adjustment is zero click Done or after you click Set Zero Shift click Done 6 The Meter Calibration window displays Refer to Figure 8 1 Click OK to close the calibration window cancel the freeze values and cause the FloBoss 100 Series unit to begin using live readings for the flow calculations Rev Aug 04 Calibration 8 7 FloBoss 103 and 104 Instruction Manual 8 3 How
41. a ee eit 2 2 l 2 FloBoss 103 and 104 Instruction Manual O Operation 0 nce nt eee eee 2 10 Operator Interface Port 1 15 E ER 1 7 Mm lege a etea ee ia EEEE EES o iy 4 2 ODIOS e tee reee Reat siren E deni EE siene 1 7 Bet E 6 1 OV ereen eea tions aici ees pach ere optional 1 1 P Periodic Log See Hourly Historical Log 1 11 PID Control moenie a a ri E ie eis 1 13 PIPINE ee Seet ener ee ees 2 4 6 2 7 3 Polarity reae S E EEES RES 1 17 Ports Commi J endea e a S 4 1 ComM seen Sie eh dees Eeer 4 1 Power Before Removing cc eeseesecseeeecteeeeeeseeeeeseeaeeees 3 9 OPEPatN 8 nhrin See ht deele Ee 1 17 REqUITEMENIS ab irei seele ois 3 1 3 3 Sleep Modesa ergeet eens 1 17 Solar POWER ER 3 4 Surge Protection 25 2503 cgsissisiiuyapaaindan pease 3 2 KT 3 8 Power WIENS sipaan ENEEN EE dete 3 1 Pressure Connectons 6 2 7 3 Pressure Transducer esee e aa 7 1 Process Connections ccccccccceesseceesseeeees 2 4 6 2 7 3 PLOCESSOT esspsreisii ses ergi A AEA A ERR 1 5 Processor Board 209 eEEEAE Ee ER 1 5 Product Overview n ea 1 1 Public Switched Telephone Networks e N EE 4 5 P lse Cousinen naa aa a 7 1 Pulse Inputs soecsrpisisinioinn iiih 1 9 5 8 7 1 7 2 Winng 1 O Card resinae ieii ies 5 8 Pulse Interface Module 7 1 R Radio Frequency Interference 0 cscs eeeeeceeneeeeeeeees 3 2 RAM Gs cin tege a ened aide aie 1 5 RBX Functon eeceeeecesceesecececeeeseeeeeeeeeeereesrensees 1 13 Real Time Clock ercer nne aE 1 17
42. al pressure or Pressure Static pressure or Auxiliary pressure and RTD temperature The RTD input is the only one of these to be wired refer to Section 5 8 1 The Analog Input AJ on the termination board monitors current loop and voltage input devices The A D signal input range is 0 to 5 volts or 4 to 20 mA with 12 bit resolution The AI is configured through ROCLINK 800 software NOTE External power is required to power the devices sending the 4 to 20 mA signals to the FloBoss unit Rev Aug 04 Input Output amp RTD Input 5 3 FloBoss 103 and 104 Instruction Manual 5 3 1 How to Wire the Analog Input The terminals for connecting the Analog Input wiring are shown in Figure 5 1 oe 99 The terminal is the positive signal input and the terminal is the signal common These terminals accept a voltage signal in the 0 to 5 volt range Because the terminal is internally connected to common the Analog Input channels function as single ended inputs only Current inputs of 4 20 mA can be used when the switch for a 250 ohm resistor is in the resistor installed position This switch is located below the terminations Refer to Figure 5 1 d NOTE When connecting the analog input channel to a voltage device be sure to set the 250 ohm resistor switch to the 250 Ohm Resistor Active position on the termination board EXTERNAL POWERED DEVICE DOC0494A Figure
43. anagement All rights reserved Rev Aug 04 i FloBoss 103 and 104 Instruction Manual TABLE OF CONTENTS Mounting Startup an Rev Aug 04 Table of Contents iii FloBoss 103 and 104 Instruction Manual Rev Aug 04 Table of Contents iv FloBoss 103 and 104 Instruction Manual SECTION 1 GENERAL INFORMATION This section describes the FloBoss 100 Series Flow Managers part of the family of FloBoss flow computers manufactured by Emerson Process Management It focuses on function and electronics This section contains the following information Section Page 1 1 Product Overview 1 1 1 2 Product Functions 1 8 1 3 Product Electronics 1 15 1 4 Additional Information 1 18 1 5 FloBoss 103 and 104 Specifications 1 19 1 1 Product Overview The FloBoss 100 Series unit is a 32 bit microprocessor based Electronic Flow Computer The FloBoss 100 Series Flow Manager electronically measures monitors and manages gas flow for a single meter run using orifice plate rotary meter or tubine meter techniques This economical flow computer reliably and accurately performs gas flow calculations temperature measurements data archival and remote communications with an optional communications card installed The FloBoss 100 Series unit performs minute hourly periodic daily and minimum maximum historical data archivals for standard history and a configurable time interval archival for extended history The FloBoss 1
44. ances Also referred to as RS 232 EIA 485 Serial Communications Protocol requiring only two signal lines Can allow up to 32 devices to be connected together in a daisy chained fashion Also referred to as RS 485 EMI Electro magnetic interference EU Engineering Units F Firmware Internal software that is factory loaded into a form of ROM In the FloBoss the firmware supplies the software used for gathering input data converting raw input data calculated values storing values and providing control signals Flash ROM A type of read only memory that can be electrically re programmed It is a form of permanent memory and requires no backup power FSK Frequency shift keyed FST Function Sequence Table a type of program that can be written by the user in a high level language designed by Emerson Process Management Flow Computer Division G GFA Ground fault analysis GND Electrical ground such as used by the FloBoss power supply GP Gauge Pressure Rev Aug 04 Glossary of Terms G 2 FloBoss 103 and 104 Instruction Manual H hw Differential pressure I J VO Input Output IEC Industrial Electrical Code K KB Kilobytes kHz Kilohertz L LCD Liquid Crystal Display Display only device used for reading data LOI Local Operator Interface Refers to the serial RS 232 port on the FloBoss through which local communications are establishe
45. and the terminal is the signal common The Discrete Input operates by providing a closed contact across terminals and Refer to Figure 5 6 The Discrete Input is designed to operate only with non powered discrete devices such as dry relay contacts open collector devices or isolated solid state switches Use of the DI channel with powered devices may cause improper operation or damage Discrete device Figure 5 6 Discrete Input Wiring Rev Aug 04 Input Output amp RTD Input 5 6 FloBoss 103 and 104 Instruction Manual 5 6 Discrete Output The Discrete Output DO provides a solid state switch to control relays and to power small electrical loads The DO circuitry is optically coupled to help isolate the processor board from the input signal Refer to Figure 5 7 DO functions include Sustained discrete outputs Momentary discrete outputs Slow pulse train outputs The Discrete Output channel is a normally open FET switch The Discrete Output is a solid state switch enabled by individual signals from the processor I O lines and capable of handling 50 V dc at 0 2 A maximum The Discrete Output on the I O termination board can be used in Toggle mode e Latched mode Timed discrete output TDO mode NOTE The switch for the selectable Analog Output Discrete Output DO 1 should be in the DO position when configured for use as an Discrete Output
46. anged adapter which in turn mounts with four bolts to the bottom of the enclosure A cable connects into the backplane board Refer to Section 7 Pulse Interface Module Rev Aug 04 General Information 1 5 FloBoss 103 and 104 Instruction Manual An RTD temperature probe typically mounts in a thermowell on the meter run The RTD measures the flowing temperature RTD wires should be protected either by a metal sheath or by conduit connected to a liquid tight conduit fitting on the enclosure The RTD wires connect directly to the RTD connector on the termination board inside the enclosure Refer to Section 5 Input Output and RTD The built in inputs and outputs I O on the FloBoss consist of a 2 or 3 wire 100 ohm Resistance Thermal Detector RTD input interface and a port for either a Dual Variable Sensor DVS or a Pulse Interface Module Three diagnostic analog inputs AI monitor the battery voltage logical voltage and enclosure battery temperature Refer to Section 5 Input Output and RTD The Local Operator Interface LOD port provides for a direct local link between the FloBoss and a personal computer PC through a Local Operator Interface Cable using EIA 232 RS 232 communications With a PC running ROCLINK 800 software you can configure the functionality of the FloBoss and monitor its operation The Comm 1 allows for EIA 485 RS 485 serial communication protocols The optional communications logic card for EIA 232 RS 232 or d
47. ard in the OFF position Remove the ribbon cable from the Battery Charger Board to the Backplane Board Remove the four screws from the Battery Charger Board Remove the Battery Charger Board Replace the Battery Charger Board Replace the four screws from the Battery Charger Board Replace the ribbon cable from the Backplane Board to the Battery Charger Board Or OO EAD OP Oh ee CS Place the power jumper located at J1 on the Battery Charger Board in the ON position Rev Aug 04 Power Connections 3 6 FloBoss 103 and 104 Instruction Manual 10 Replace the front end cap cover Screw the cover on until metal contacts metal Do not over tighten the cover 3 6 Wiring Connections The following paragraphs describe how to connect the FloBoss 100 Series unit to power I O devices and communications devices Use the recommendations and procedures described in the following paragraphs to avoid damage to equipment NOTE It is important to check the input power polarity before turning on the power The external connections or field terminals are all located on the termination board The terminal block accepts wires up to 16 AWG in size Always turn off the power to the FloBoss unit before you attempt any type of wiring Wiring of powered equipment could result in personal injury or property damage To avoid circuit damage when working inside the unit use appropriate electrostatic discharge precautions such as wearing a grounded wris
48. are calibrating a pressure input read the following Caution and then isolate the pressure sensors from the process If you are calibrating a RTD temperature input proceed to Step 6 If you are calibrating the optional AI AI Point Number B1 proceed to Step 8 CAUTION Open the by pass valve on the valve manifold prior to isolating the sensor from the process to protect the differential cell of the Dual Variable Sensor This keeps one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied This is required when calibrating either differential or static pressure Refer to Figure 8 2 for the recommended sequence Rev Aug 04 Calibration 8 2 FloBoss 103 and 104 Instruction Manual Pressure Remains Operating Shutdn2 Shutdown Sequence Figure 8 2 Removing the DVS from Service 5 If you are calibrating a pressure input set up the pressure calibrator and make the necessary connections to the DVS Refer to Figure 8 3 for the line orientation during the calibration CAUTION Do not exceed the Differential Pressure range on the DVS to protect the differential cell of the Dual Variable Sensor Refer to the Specifications table in Section 7 for the range Sek Or Closed Sam Open
49. ariable Sensor The DVS which uses Rosemount sensor technology measures differential pressure and absolute or gauge static pressure by converting the applied pressure to electrical signals and making the readings available to the processor board The sensor housing screws into an adapter The adapter in turn mounts with four bolts to the bottom of the FloBoss enclosure NOTE The DVS Sensor should only be installed and removed at the factory NOTE The DVS cable plugs directly into the backplane board The DVS cable should only be installed and removed at the factory The readings from the Dual Variable Sensor are stored in analog inputs on the FloBoss If the alarm for the AI point is enabled and the DVS fails to communicate during either initialization or operation an alarm is entered in the Alarm Log The DVS uses an interrupt to inform the processor board that it is ready for an update This must occur at least once per second The FloBoss then converts this value and stores it in the proper analog input for access by other functions within the unit If an update does not occur in the one second interval the sensor is re initialized A point fail alarm is set if the DVS does not respond to the initialization The DVS pressure sensors mount to the base of the explosion proof housing and provide the measurement of the P1 pressure and the differential pressure for orifice plate flow measurement applications The Specifications tab
50. ariable Sensor Specifications DIFFERENTIAL PRESSURE INPUT PROCESS CONNECTIONS Range Options 1 4 18 NPT on 2 1 8 in centers located on bottom of 0 62 2 kPa 0 250 in H O Coplanar flange 0 248 8 kPa 0 1000 in H20 Reference Accuracy 0 075 of span with a 10 1 turndown includes linearity hysteresis and repeatability effects CONSTRUCTION 316 SST Wetted O rings are glass filled TFE Coupler is stainless steel CF8M ENVIRONMENTAL AND OTHER SPECS Meets the Environmental specifications of the FloBoss 103 unit including Temperature and Voltage Surge specifications STATIC PRESSURE INPUT Range Options Either Absolute or Gauge 0 5516 kPa 0 800 psia psig 0 25 000 kPa 0 3626 psia psig Reference Accuracy 0 075 of span with a 6 1 turndown includes linearity hysteresis and repeatability effects For spans with less than 6 1 turndown contact factory Stability 0 1 of upper range limit for 12 months Note Consult factory for special ranges and materials that may be available Rev Aug 04 Dual Variable Sensor 6 3 FloBoss 103 and 104 Instruction Manual SECTION 7 PULSE INTERFACE MODULE This section describes the Pulse Interface Module which provides pressure inputs and pulses counts to the FloBoss 104 for AGA7 flow calculation with AGA8 compressibility The Pulse Interface Module is intended for applications with Rotary Meters and Turbine Meters This section contains the fo
51. ation Use ROCLINK 800 configuration software to configure the DVS e The differential pressure is configured at Analog Input Point Number A1 The static pressure gauge or absolute is configured at Analog Input Point Number A2 The Analog Input Points A1 A4 can be configured for fault mode operation on the Advanced tab of the Analog Input Setup screen The Action on Failure field will determine whether the FloBoss unit should hold the last known value or set to a specified fault value The defaults contained within the DVS are the initial pressures read The initial range of the differential pressure and the static pressure are listed in the Specifications table in Section 6 2 You can re range each sensor through the calibration routines The turndown on the range should not be greater than the turndown value in the Specifications table on page 6 3 The DVS also supports the conversion of values to metric units In metric mode both the differential pressure and the static pressure are in kPa To enter metric mode use ROCLINK 800 software The FloBoss automatically adjusts the units of the differential pressure static pressure RTD and enclosure battery temperature to the Metric mode NOTE When selecting metric mode the FloBoss adjusts the Units only You must manually change all values to the proper unit of measurement Rev Aug 04 Dual Variable Sensor 6 2 FloBoss 103 and 104 Instruction Manual 6 2 DVS Specifications Dual V
52. besevessscatuiosedatvases 3 5 Chatti ee ees keeerere tere kees eege 1 7 C Calculations FOV E E dee 1 9 Input and Extension cc eeeeesscseeeeeeecneeeeeeeeeees 1 9 Instantaneous Rate 1 9 RH Te EE 8 1 WO Channel E 2 10 Cathodic Protection 0 ccccccccccesssececsssceceesseeceseseeees 3 3 Charger Board E 1 5 Class De uerger eege 2 3 Clock R a Time EE 1 17 CMOS Microptrocessor 1 5 Comm Tests tasted lateness 1 6 1 15 1 16 Ke EE 4 1 COmMent 1 6 1 15 1 16 4 3 Comm Port Operator Interface 1 15 Communication Porte 1 15 Communications MEIERS Eege 4 1 Communications Cards 0 ccccccscceeeseeeeneees 1 7 1 16 Descrptons rece n ere a i 4 1 Dial Up Modem cnie enseres 4 5 DE EE 4 3 Rev Aug 04 pe bie ageng sne ereraa e Ee ere oar aia 4 8 WALD A EERTE ATA 4 4 4 5 Confeuranon 2 10 9 4 9 6 Dual Variable Sensor 6 2 Pulse Interface Module 7 3 D Daily Historical Logs 0 cccecceesseeseeesceeeeeseeseeeteenees 1 11 Liane eege enee E NEE 1 6 TM PUts issn ane ER e DEE eebe cations 1 17 Dial Up Modem Communications Cards 4 5 WIIS yacine e e ee guns 4 5 Differential Pressure cccccccccceesscceenteceeeseeees 1 9 6 2 Discrete Inputs 200 EES ENEE 5 6 e EE 5 6 Discrete Outputs WIPE iii gea 5 7 DIVISIO 2 0 4 iaiieuiianiot was E E 2 3 Dual Variable Sensor cc esseeeeceeeeecsseeeceeeeeeeenees 1 5 Configurations i eeii are ES en iE p isi 6 2 Description hoere oR arei E E E
53. cesses remain in a safe state upon restoring power An unsafe state could result in property damage When installing equipment in a hazardous area ensure that all components are approved for use in such areas Check the product labels Change components only in an area known to be non hazardous Performing these procedures in a hazardous area could result in personal injury or property damage 1 Reconnect power to the FloBoss unit by inserting the CHG CHG power terminal block 2 Launch ROCLINK 800 software log in and connect to the FloBoss unit 9 El Sr hy a Verify that the configuration is correct If it is not continue by configuring the required items If major portions or the entire configuration needs to be reloaded perform the remaining steps Select File gt Download From the Open dialog box select the backup configuration file has extension 800 Select the portions of the configuration you want to download restore Click Download to restore the configuration 9 3 4 How to Connect the Termination Board to the Backplane Older FloBoss 103 units were shipped with the termination board connected to the backplane through a 34 pin interface connector You may have a shrouded connector which ensures the correct polarity If for any reason you must disconnect the termination board from the backplane be careful to re connect the shrouded connector using the following steps 1 Insert the 34 pin interface
54. cted via EIA 485 RS 485 on the Comm 1 port of the first FloBoss 100 Series unit and then all the FloBoss 100 Series units can use the one radio to communicate to the host NOTE Comm 2 may only use a Dial up modem if it is receiving Pass Through messages It cannot transmit to other field devices via Dial up modem Rev Aug 04 General Information 1 13 FloBoss 103 and 104 Instruction Manual NOTE The Device Group of the FloBoss 100 Series receiving the data must match the Device Group of the FloBoss 100 Series unit s to which the data will be passed If the Device Group does not match the data will not be forwarded The Device Group may be found on the General tab of the ROC gt Information screen 1 2 8 Protocol Automatic Switching The FloBoss 100 Series has the capability to communicate with ROC or Modbus protocol With the standard version of FloBoss firmware Modbus Slave is standard If you require Modbus Host functionality contact your local sales representative 1 2 9 User C Capability The FloBoss 100 Series has User C capability that allows special features to be written which can be loaded into the FloBoss unit to enhance the function of the FloBoss unit User programs typically provide the ability to interface with alternate metering equipment perform alternate calculation methods or communicate with alternate protocols Consult your local sales representative for User C applications 1 3 Product Electronics Thi
55. d RTD During operation the RTD is read once per second The value from the RTD is linearized and then it is sent to processing as Analog Input AI Point Number A3 The AI routine converts this value to engineering units and checks alarming To conserve power the RTD power is switched on and off During calibration the RTD power will be on constantly Once calibration is completed the RTD will cycle power again Rev Aug 04 General Information 1 16 FloBoss 103 and 104 Instruction Manual 1 3 6 Real Time Clock The real time clock provides the FloBoss 100 Series with the time of day month year and day of the week The real time clock automatically switches to backup power when the FloBoss loses primary input power Backup power for the real time clock is adequate for a period in excess of five years with no power applied to the FloBoss 1 3 7 Diagnostic Monitoring The electronics board has three diagnostic inputs incorporated into the circuitry for monitoring battery voltage logical voltage and board temperature Access these analog inputs using the I O function of ROCLINK 800 software The three values are available as the following Analog Input AI points e El logical voltage e E2 battery voltage e E5 board battery temperature 1 3 8 Automatic Self Tests The FloBoss 100 Series unit performs the following self tests on a periodic basis Software and hardware watchdog Sensor operation Memory val
56. d typically for configuration software running on a PC mA Milliamp s one thousandth of an ampere mW Milliwatts or 0 001 watt mV Millivolts or 0 001 volt N NEC National Electrical Code NEMA National Electrical Manufacturer s Association O OH Off Hook modem communications signal Off line Accomplished while the target device is not connected by a communications link For example off line configuration is configuring a FloBoss in an electronic file that is later loaded into the FloBoss Ohms Units of electrical resistance Rev Aug 04 Glossary of Terms G 3 FloBoss 103 and 104 Instruction Manual On line Accomplished while connected by a communications link to the target device For example on line configuration is configuring a ROC while connected to it so that current parameter values are viewed and new values can be loaded immediately Opcode Type of message protocol used by the FloBoss to communicate with ROCLINK software as well as host computers with ROC driver software P Q Parameter A property of a point that typically can be configured or set by the user For example the Point Tag ID is a parameter of an Analog Input point Parameters are normally edited by using configuration software running on a PC PC Personal computer Pf Flowing pressure PI Pulse Input Point Software oriented term for an I O channel or some other funct
57. ding atmosphere Division 1 locations are presumed to be hazardous Division 2 locations are areas where gas dust or vapors can exist under abnormal conditions Group defines the hazardous material in the surrounding atmosphere Groups A to D are defined as follows Group A Atmosphere containing acetylene gases or vapors of equivalent hazards Group B Atmosphere containing hydrogen gases or vapors of equivalent hazards Group C Atmosphere containing ethylene gases or vapors of equivalent hazards Group D Atmosphere containing propane gases or vapors of equivalent hazards For the FloBoss 100 Series to be approved for hazardous locations it must be installed according to the National Electrical Code NEC Article 501 and any local code requirements if applicable When installing units in a hazardous area make sure all installation components selected are labeled for use in such areas Installation and maintenance must be performed only when the area is known to be non hazardous Installation in a hazardous area could result in personal injury or property damage 2 3 Mounting When choosing an installation site be sure to check all clearances Provide adequate clearance for wiring and service The optional LCD should be visible and accessible for the on site operator When using a solar panel allow adequate clearance and view of the sun should not be obstructed Allow adequate clearance and an obstructed location for
58. e batteries for voltage The battery pack contains three D size lead acid batteries providing 2 5 Amp hours of current at 6 2 volts nominal If the batteries are below the nominal voltage replace them Refer to Section 3 9 2 6 DVS If your Dual Variable Sensor DVS is not responding Launch ROCLINK software Select Configure gt I O gt AI Points Select Analog Input 1 Ensure that the DVS is not in manual mode by setting the Scanning field to Enabled hee gt ee If the DVS is still not responding reset the DVS to factory defaults to clear invalid calibration data 6 If the input shows a Point Fail alarm then the sensor is not communicating with the FloBoss No field repair or replacement parts are associated with the DVS or DVS input Return the FloBoss to your local sales representative for repair or replacement NOTE The DVS should only be installed and removed at the factory 9 2 7 Pulse Interface Module If your Pulse Interface Module is not responding 1 Launch ROCLINK software 2 Select Configure gt I O gt AI Points Select Analog Input 1 or 2 Analog Input is the Meter Pressure Analog Input 2 is the Auxiliary pressure If the Auxiliary pressure is not installed this point will show inactive Ensure that the Pulse Interface Module is not in manual mode by setting the Scanning field to Enabled Rev Aug 04 Troubleshooting 9 3 FloBoss 103 and 104 Instruction Manual 3 Go to the Utilities gt Pu
59. e oldest entry when the buffer is full The Alarm Log provides an audit history trail of past alarms The Alarm Log and the Event Log are stored separately to prevent recurring alarms from overwriting configuration audit data 1 2 2 7 Event Log The Event Log contains changes to any parameter within the FloBoss made through the protocol This Event Log also contains other FloBoss events such as power cycles cold starts and disk configuration downloads The Event Log provides an audit history trail of past operation and changes The system Event Log has the capacity to maintain and store up to 240 events in a circular log The Event Log has information fields that includes point type parameter number time and date stamp point number if applicable the operator identification and either the previous current parameter values and either the Tag name of the point or a 14 byte detail string in ASCII format In addition to providing functionality for appending new events to the log the Event Log allows host packages to request the index of the most recently logged event entry Event logging is available internally to the system to external host packages and to the FST Event Logs are not stored to flash ROM when Save Configuration is issued in ROCLINK 800 software The Event Log operates in a circular fashion with new entries overwriting the oldest entry when the buffer is full The Event Log provides an audit trail history of past operation and
60. ect All equipment grounding conductors must provide an uninterrupted electrical path to the service disconnect e The National Electrical Code Article 250 83 1993 paragraph c defines the material and installation requirements for grounding electrodes e The National Electrical Code Article 250 91 1993 paragraph a defines the material requirements for grounding electrode conductors e The National Electrical Code Article 250 92 1993 paragraph a provides installation requirements for grounding electrode conductors The National Electrical Code Article 250 95 1993 defines the size requirements for equipment grounding conductors 3 2 1 Grounding for the FloBoss 100 Series Proper grounding of the FloBoss 100 Series unit helps to reduce the effects of electrical noise on the unit s operation and protects against lightning The FloBoss provides lightning protection for built in field wiring inputs and outputs Install a surge protection device at the service disconnect on DC voltage source systems to protect against lightning and power surges for the installed equipment You may also consider a telephone surge protector for the optional dial up modem communications card All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured with a ground system tester The grounding conductor should have a resistance of 1 ohm or less between the FloBoss enclosure ground and the earth ground rod or grid
61. ected through the LOI port Remote monitoring is performed through Comm 1 or Comm 2 of the FloBoss using ROCLINK 800 software or a host system 2 5 Configuration The FloBoss 100 Series Flow Manager has a number of software settings called parameters which must be configured before it is calibrated and placed into operation Configuration must be performed using ROCLINK 800 software which runs on an IBM compatible personal computer The personal computer is normally connected to the LOI port of the flow computer to transfer configuration data into the FloBoss 100 Series although much of the configuration can be done off line and later loaded into the unit Default values for all parameters exist in the firmware of the flow computer If the default is acceptable for your application it can be left as it is Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 Rev Aug 04 Installation and Use 2 10 FloBoss 103 and 104 Instruction Manual SECTION 3 POWER CONNECTIONS This section describes wiring of power from a DC voltage source solar panel It also describes batteries and grounding This section contains the following information Section Page 3 1 3 1 3 2 Grounding Installation Requirements 3 2 3 4 Solar Powered Installations 3 4 3 Batteries 3 5 5 3 6 Wiring 3 7 3 7 How to Backup Configuration and Log Data 3 9 When installing units in a hazardous area make sure all installation components selected
62. ed contract hour the flow and energy are then stored to the Daily Historical Log and zeroed for the start of a new day contract hour 1 2 1 2 Flow Calculations for Turbine Metering The turbine flow calculation is in accordance with 1996 AGA Report No 7 1993 API Chapter 21 1 The FloBoss performs 1992 AC AN compressibility calculations in accordance with AGA Report No 8 1992 API Chapter 14 2 Once every Scan Period the FloBoss unit processes the pulse counts determines the number of pulse counts since the last reading and calculates a rate Next the static pressure and auxiliary pressure values are read Then the temperature is read and linearizing compensation is applied to the pressure readings if necessary All resultant values are stored in the current value database The values are taken from the current value database and used to calculate the Minute Hour and Daily historical values Once a minute and once an hour the values are logged along with other configured values to the Historical Database At the configured Contract Hour the values are stored to the Daily Historical Log and zeroed for the start of a new day 1 2 2 History Points History is saved to 2 databases Standard and Extended History The number of entries logs available to Standard and Extended History is configurable The Standard history archives up to 35 points 8 are pre configured of min max minute hourly and daily values The min max values are
63. ed for FST controlled logging 1 2 2 4 Min Max Historical Log The Min Max database displays the minimum and the maximum values for the database points over a 24 hour period for today and yesterday The Min Max historical log can be viewed but not saved to disk Rev Aug 04 General Information 1 11 FloBoss 103 and 104 Instruction Manual 1 2 2 5 Extended History Log The FloBoss has configurable archive times which in turn determine the number of entries The four default 10 Minute history points include differential pressure static pressure flowing temperature and an auxiliary Analog Input 1 2 2 6 Alarm Log The Alarm Log contains the change in the state of any alarm signal that has been enabled for alarms The system Alarm Log has the capacity to maintain and store up to 240 alarms in a circular log The Alarm Log has information fields that include time and date stamp alarm clear or set indicator and either the Tag name of the point or a 14 byte detail string in ASCII format In addition to providing functionality for appending new alarms to the log the Alarm Log allows host packages to request the index of the most recently logged alarm entry Alarm logging is available internally to the system to external host packages and to FSTs Alarm Logs are not stored to the flash ROM during the Save Configuration function in ROCLINK 800 software The Alarm Log operates in a circular fashion with new entries overwriting th
64. ery Charger Board and then replace the ribbon cable to the Battery Charger 10 11 Board Place the power jumper located at J1 on the Battery Charger Board in the ON position Replace the front end cap cover Screw the cover on until metal contacts metal Do not over tighten the cover 4 6 Communication Cards Specifications This section lists the specifications for each communications card Rev Aug 04 Communications 4 8 FloBoss 103 and 104 Instruction Manual 4 6 1 Serial Card Specifications Serial Card Specifications EIA 232D CARD Meets EIA 232 standard for single ended data transmission over distances of up to 50 feet 15 m Data Rate Selectable from 1200 to 19 200 bps Format Asynchronous 7 or 8 bit software selectable with full handshaking Parity None odd or even software selectable POWER REQUIREMENTS 3 3 Vdc 0 03 W maximum supplied by processor board When EIA 232D card is switching power the requirement will be higher DIMENSIONS 18 mm H by 51 mm W by 70 mm L 0 7 in H by 2 0 in W by 2 75 in L ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F Storage Temperature 50 to 85 C 58 to 185 Operating Humidity To 95 relative non condensing APPROVALS Same as the FloBoss 100 Series unit in which it is installed 4 6 2 Dial up Modem Card Specifications Dial up Modem Card Specifications OPERATION Mode Full duplex 2 wire for dial up PSTN
65. fer to Section 6 Refer to Figure 2 1 and Figure 2 2 for dimensions If the FloBoss unit will be used with a 5 Watt solar panel the dimensions are 22 86 mm W by 48 01 mm H by 31 12 mm D 9 00 in W by 18 90 in H by 12 25 in D wy UD gea Figure 2 1 Outline and Mounting Dimensions without Solar Panel Rev Aug 04 Installation and Use 2 4 FloBoss 103 and 104 Instruction Manual 21 67 21 59 MAX 8 53 8 50 MAX 39 37 MAX 45 50 MAX gt Me u a DOCO418B Figure 2 2 Outline and Mounting Dimensions with 2 Watt Solar Panel and LCD cm inch 2 3 1 1 How to Install the FloBoss 103 on a Pipestand To install the FloBoss 103 on a 2 inch pipestand 1 Install the pipestand per the directions included with the pipestand 2 Remove the orifice meter run from service 3 Install the FloBoss 103 on the pipestand using clamps or mounting brackets Refer to Figure 2 3 2 3 1 2 How to Install the FloBoss 103 on an Orifice Plate To install the FloBoss 103 on an orifice plate 1 Remove the orifice meter run from service 2 Install the FloBoss 103 on the meter run using a manifold and hardware to secure the FloBoss 103 to the orifice flanges Refer to Figure 2 3 Rev Aug 04 I
66. from today and yesterday the minute values are from the last 60 minutes the hourly values are from the last 35 days and the daily values are from the last 35 days The Extended History database creates 1 entry for up to 15 points at a user specified interval see Specifications table All the points in the Extended History will be logged at the same interval The default setting for Extended history archives 4 points of 10 minute values from the last 35 days 10 minute archiving provides a monitoring resolution similar to a chart recorder The first eight history points are pre configured for flow metering history and cannot be changed They are as follows 1 Flowing Minutes Today Accumulate archive type 2 Differential Pressure for AGA3 Average or Accumulated Raw Pulses for AGA7 Totalize 3 Static or Line Pressure Average 4 Flowing Temperature Average Rev Aug 04 General Information 1 10 FloBoss 103 and 104 Instruction Manual 5 IMV Integral Multiplier Value for AGA3 Average or BMV Base Multiplier Value for AGA7 Average 6 Pressure Extension for AGA3 Average or Today s Total for AGA7 Totalize 7 Instantaneous Flow Accumulate 8 Instantaneous Energy Accumulate History Point 2 AGA3 History Point 3 History Point 4 and History Point 6 AGA3 are all set up as an Average Archive Type that employs one of the following techniques e Flow dependent time weighted linear averaging default
67. fter restoring power and if the unit is disassembled The following tools are required for troubleshooting e IBM compatible personal computer ROCLINK 800 software e Flat head and Philips screwdrivers Section Page 9 1 Troubleshooting Guidelines 9 2 Troubleshooting Checklists 9 3 Procedures 9 1 Troubleshooting Guidelines When you are attempting to diagnose a problem with a FloBoss 100 Series unit Remember to write down what steps you have taken Save the configuration and log data see Section 9 3 1 Note the order in which you remove components gt gt gt Note the orientation of the components before you alter or remove them Read and follow all Cautions in this manual When you are done troubleshooting perform the restart procedure in Section 9 3 3 9 2 Troubleshooting Checklists 9 2 1 Dial up Modem If you are experiencing troubles with an internal dial up modem e Check to make sure power is applied to the FloBoss unit Check the ON OFF jumper the wiring connections at CHG and CHG and the wiring at the power source Check the wiring to the modem Refer to Section 4 Check the communication port settings in ROCLINK 800 Configuration Software Refer to ROCLINK SOU Configuration Software User Manual Form A6121 Rev Aug 04 Troubleshooting 9 1 FloBoss 103 and 104 Instruction Manual e Check the modem INIT string It will be displayed in the communication port settings in ROCLINK 8
68. he functionality of the FloBoss and monitor its operation The optional Liquid Crystal Display LCD provides the ability to view data and configuration parameters while on site without using the local operator interface LOI and a PC The LCD display plugs into the battery charger board and is visible through the window on the front of the FloBoss The LCD can be rotated 90 in either direction The LCD two line display shows one line for a value and the other line for a five character alphanumeric description of the value The display operates from the internal 3 3 Volt supply Through this display you can view predetermined information stored in the FloBoss Up to 16 items can be defined for display The display automatically cycles through the configured list of items displaying a new value approximately every three seconds An external solar panel can be installed to recharge the backup batteries it connects to the CHG CHG inputs on the termination board An integral solar panel 2 W or 5 W is available from the Flow Computer Division of Emerson Process Management it will connect directly to the charger board assembly Circuitry on the battery charger board monitors and regulates the charge based on battery voltage charging voltage and temperature The FloBoss requires a minimum 8 volt 200 mA solar panel Rev Aug 04 General Information 1 7 FloBoss 103 and 104 Instruction Manual The optional input output I O termination points pro
69. he shaft adaptor until the top of the magnet is between 0 68 0 71 inches above the meter housing Refer to Figure 2 6 The magnet set screw should be positioned over a flat in the hex shaft adaptor Tighten the set screw to lock the magnet assembly in place Refer to Figure 2 4 and Figure 2 5 NOTE Align the magnet assembly to a position so that the magnet set screw contacts one of the shaft adaptor flats and NOT the shaft adaptor set screw or threaded areas Rev Aug 04 Installation and Use 2 7 FloBoss 103 and 104 Instruction Manual INL Dowel Pins f 8 l Extend 1 25 in Min or 0 68 0 71 in DNCO543B Figure 2 6 Shaft Adaptor Magnet and Dowel Pins Installed 6 Insert 0 25 inch diameter dowel pins user supplied in two of the 5 16 18 UNC threaded holes on the top of the rotary meter These pins should extend at least 1 25 inches above the meter housing so that they can be easily removed later 7 Place the gasket provided over the dowel pins and rest it flatly on the meter housing 8 Position the FB104 assembly over the meter housing and carefully lower into place using the dowel pins to guide alignment 9 Loosely install two 5 16 18 x 7 8 long bolts with lock washers user supplied into the two threaded meter holes which do not have dowel pins
70. ial up Modem Communications Card 4 5 Radio Communications Cards 4 6 Communication Cards Specifications 4 1 EIA 485 RS 485 Communications Wiring The EIA 485 communications provides for RS 485 signals on the Comm 1 port The Comm 1 port is on the termination board 4 1 1 How to Wire EIA 485 RS 485 Communications Wiring should be twisted pair cable The terminals and their functions are Pin 1 is Terminal B and Pin 2 is Terminal A Refer to Figure 4 3 Connect A on the FloBoss to A or and connect B on the FloBoss to B or Should you encounter difficulties establishing a connection try reversing the connections Rev Aug 04 Communications 4 1 FloBoss 103 and 104 Instruction Manual 4 2 Local Operator Interface Port Wiring The Local Operator Interface LOI port provides connections for a built in E A 232 RS 232 communications interface to a local configuration and monitoring device The configuration and monitoring device typically is an IBM compatible personal computer A prefabricated operator interface cable is available as an accessory Refer to Figure 4 1 The LOI port is intended for use with a PC running ROCLINK 800 software This LOI port is compatible with ETA 232 RS 232 levels 4 2 1 Howto Wire the LOI Port The Table 4 1 shows the signal routing of the Termination Board connections The FloBoss 100 Series unit s EIA 232 RS 232 transmit connects to the PC s receive Table 4 1 Local Operator
71. ial up modem and the optional communications logic card for wireless radio activate Comm 2 Refer to Section 4 Communication Cards The I O parameters DVS inputs flow calculations power control security and FST programmability are configured and accessed using ROCLINK 800 software Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 for details concerning software capabilities 1 1 2 Firmware The firmware contained in flash ROM on the processor board determines the functionality of the FloBoss 100 Series and includes e 1992 AGA 3 flow calculations with user selectable AGA8 compressibility Detail Gross I or Gross II for a single meter run e 1996 AGA 7 flow calculations with user selectable AGA8 compressibility for a single meter run Memory logging of 240 alarms and 240 events Archival of minute data from the last 60 minutes for up to 35 points Standard History Archival of 35 days of hourly data for up to 35 points Standard History Archival of 35 days of daily data for up to 35 points Standard History Archival of Min Max historical data for today and yesterday Standard History Archival of 5040 entries for up to 15 points at user specified interval Extended History Power control wake up on ring on optional internal modem Logic and sequencing control using a user defined Function Sequence Table FST e gt gt A Closed loop PID control capabilities requires op
72. idity The FloBoss 100 Series unit will operate with its internal batteries down to 5 4 volts dc The LCD becomes active when input power with the proper polarity and startup voltage typically set greater than 8 0 volts is applied to the CHG CHG connector provided the power input fusing protection is operational The battery and logical voltage tests ensure that the FloBoss unit is operating in the optimum mode The software watchdog is controlled by the central processor unit CPU The software will arm the watchdog timer every second If the watchdog timer is not armed for a period of 9 seconds then the watchdog timer forces the FloBoss unit to reset If necessary the software automatically resets The hardware watchdog is controlled by the CPU and monitors the power to the hardware If the battery voltage drops below 5 4 volts the FloBoss unit automatically shuts down The FloBoss 103 monitors its orifice metering Dual Variable Sensor for accurate and continuous operation The FloBoss 104 monitors its Pulse Interface Module 1 3 9 Low Power Mode Sleep mode is used to place the CPU in a low power mode The battery voltage is monitored by low voltage detection circuitry and the low voltage limit value is set at 5 4 volts During Sleep mode sub modules are powered down The FloBoss 100 Series unit enters Sleep mode after one minute of inactivity on the communication ports The FloBoss 100 Series units have the option of not uusing the
73. ilt in I O I O channels that are fabricated into the FloBoss and do not require a separate option Also called on board I O C Configuration Typically the software setup of a device such as a FloBoss that can often be defined and changed by the user Can also mean the hardware assembly scheme CSA Canadian Standards Association CTS Clear To Send modem communications signal D DB Database dB Decibel A unit for expressing the ratio of the magnitudes of two electric signals on a logarithmic scale DCD Data Carrier Detect modem communications signal DI Discrete Input Discrete Input or output that is non continuous typically representing two levels such as on off DO Discrete Output Download To send data a file or a program to the FloBoss unit DP Differential Pressure Rev Aug 04 Glossary of Terms G 1 FloBoss 103 and 104 Instruction Manual DSR Data Set Ready modem communications signal DTR Data Terminal Ready modem communications signal Duty Cycle Proportion of time during a cycle that a device is activated A short duty cycle conserves power for I O channels radios and such DVM Digital voltmeter DVS Dual Variable Sensor Provides static and differential pressure inputs to a FloBoss 103 E ESD Electronic Static Discharge EJA 232 Serial Communications Protocol using three or more signal lines intended for short dist
74. ing these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working inside the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Launch ROCLINK 800 software and connect to the FloBoss 100 Series unit 2 Ensure that the configuration is saved in flash memory by performing a Save to Flash Memory ROC gt Flags This saves all configuration settings including the current states of the ROC Flags and calibration values Rev Aug 04 Troubleshooting 9 4 FloBoss 103 and 104 Instruction Manual 3 Select ROC gt Collect Data and select the All checkbox Click OK This action saves event logs alarm logs report data and history You can specify your own file name and path if desired 4 Select File gt Save Configuration The Save As dialog box appears 5 Type the desired File name for the backup file or use the default 6 Click Save The file is saved in the default directory C Program Files ROCLINK 800 Data unless you changed the directory 9 3 2 How to Reset the FloBoss 100 Series Unit The Reset jumper is located on the LCD if installed or on the Battery Charger Board It can be used to perform a special type of cold start This jumper permits a power up reset to re establish a known operating point This includes re initializing the Communication Ports to the factory default configuration This cold start does
75. ion period is defined to be the number of seconds for which the differential pressure exceeded the low flow cutoff Input and Extension Calculation Each second the FloBoss 103 stores the measured input for differential pressure static pressure and temperature and calculates the Integral Value IV IV is the square root of the absolute upstream static pressure times the differential pressure Flow time averages of the inputs and the IV over the configured calculation period are calculated unless there is no flow for an entire calculation period Linear Averages of the inputs are recorded to allow monitoring during no flow periods Instantaneous Rate Calculations The instantaneous value of the Integral Value IV is used with the previous calculation period s Integral Multiplier Value IMV to compute the instantaneous flow rate The IMV is defined as the value resulting from the calculation of all other factors of the flow rate equation not included in the IV The instantaneous flow rate is used with the volumetric heating value to compute the instantaneous energy rate Rev Aug 04 General Information 1 9 FloBoss 103 and 104 Instruction Manual Flow and Energy Accumulation The averages of the differential and static pressure temperature and sum of the IV are used with the flow time to compute the flow and energy over the calculation period The flow and energy are then accumulated and stored at the top of every hour At the configur
76. ion such as a flow calculation Points are defined by a collection of parameters Point Number The number of an I O point as installed in the FloBoss system PRI Primary PID control loop Protocol A set of standards that enables communication or file transfers between two computers Parameters include baud rate parity data bits stop bit and the type of duplex PSTN Public Switched Telephone Network PT Process Temperature PTC Positive Temperature Coefficient PTT Push to Talk signal Pulse Transient variation of a signal whose value is normally constant Pulse Interface Module Provides line pressure aux pressure and pulse counts to the FloBoss 104 R RAM Random Access Memory In a FloBoss it is used to store history data most user programs and additional configuration data RBX Report By Exception See SRBX RFI Radio frequency interference RI Ring Indicator modem communications signal Rev Aug 04 Glossary of Terms G 4 FloBoss 103 and 104 Instruction Manual ROC Remote Operations Controller is a microprocessor based unit that provides remote monitoring and control ROCLINK Software Configuration software used to configure FloBoss units ROM Read only memory Typically used to store firmware RTD Resistance Temperature Detector RTS Ready to Send modem communications signal RXD Received Data communications signal S SP Setpoin
77. ith the 5 point routine The built in inputs are assigned to the first three Analog Input points Differential pressure for AGA3 or Meter pressure for AGA7 located at AI Point A1 Static pressure for AGA3 or Auxiliary pressure for AGA7 located at AI Point A2 e RTD temperature located at AI Point A3 The optional Analog Inputs if configured as Analog Inputs on the termination board the can be calibrated with the 5 point routine 8 2 How to Perform a Calibration Perform the following steps 1 Launch ROCLINK 800 Configuration software and connect to the FloBoss 100 Series unit Rev Aug 04 Calibration 8 1 FloBoss 103 and 104 Instruction Manual 2 Select either Meter gt Calibration or Configure gt I O gt Analog Input gt AI Calibration tab If you are calibrating the Analog Input on the optional I O termination board you must select Configure gt I O gt Analog Input gt AI Calibration tab The current reading displays under each meter input as the Freeze Value The FloBoss uses these values in the flow calculations while calibrating the points 3 Click Freeze Meter Calibration 2 xi Meter ID fi Si Meter Tag Meter 1 P Freeze Values SSS eT Diff Pressure Low DP Stat Pressure Temperature 30 000000 En 4055 Lan 497 Manual Verify Verify Verify Calibrate Calibrate Calibrate x Cancel Figure 8 1 Meter Calibration FloBoss 103 Shown 4 Ifyou
78. jumper located on the LCD if installed or located at J1 on the Battery Charger Board in the ON position 3 Reattach the top end cap cover LCD end Screw the cover on until metal contacts metal Do not over tighten the cover After the FloBoss 100 Series completes start up diagnostics RAM and other internal checks the optional LCD displays the date and time to indicate that the FloBoss completed a valid reset sequence If the LCD does not come on refer to Section 9 for possible causes Rev Aug 04 Installation and Use 2 9 FloBoss 103 and 104 Instruction Manual 2 4 2 Operation Once startup is successful it is necessary to configure the FloBoss 100 Series Flow Manager to meet the requirements of the application ROCLINK SOU Software User Manual Form A6121 details the procedure for configuring the FloBoss and calibrating the I O Once the FloBoss is configured and calibrated it can be placed into operation When the enclosure end caps are unscrewed local configuration or monitoring of the FloBoss 100 Series through its LOI port must be performed only in an area known to be non hazardous Performance of these procedures in a hazardous area could result in personal injury or property damage During operation the FloBoss 100 Series can be monitored to view or retrieve current and historical data either locally or remotely Local monitoring is accomplished either by viewing the LCD panel or by using ROCLINK 800 software on a PC conn
79. le on page 6 3 displays the DVS ranges For information on calibration of a DVS sensor refer to Section 7 NOTE Consult your local sales representative for special ranges Rev Aug 04 Dual Variable Sensor 6 1 FloBoss 103 and 104 Instruction Manual 6 1 1 Process Connections Piping from the meter run connects to the Dual Variable Sensor DVS of the FloBoss Both the static and differential pressures pipe to female 14 18 NPT connections on the bottom of the DVS The FloBoss is an upstream device meaning that the static pressure line normally connects to the high pressure side labeled H on the sensor body NOTE The FloBoss 103 is intended to be used as an upstream device Open the by pass valve on the valve manifold prior to isolating the sensor from the process to protect the differential cell of the Dual Variable Sensor This keeps one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied This is required when calibrating either differential or static pressure Refer to Section 7 for the recommended sequence Do NOT close the by pass valve on the valve manifold until after process pressure has been reapplied to protect the differential cell of the Dual Variable Sensor This keeps one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied Refer to Section 7 for the recommended sequence 6 1 2 Configur
80. llowing information Section Page 7 1 Pulse Interface Module 7 7 3 7 2 Pulse Interface Module Specifications 7 1 Pulse Interface Module The primary function of the FloBoss 104 is to measure the flow of natural gas using turbine metering or rotary metering in accordance with the American Gas Association AGA and American Petroleum Institute API standards When performing AGA7 calculations the FloBoss unit uses 1992 AGA8 compressibility The Pulse Interface Module consists of two parts a pulse counter interface and a pressure transducer When used with a Rotary meter the Pulse Interface Module creates and measures electrical signals pulses from the rotary meter and raw pressure inputs from the pressure transducer The module automatically interprets the direction of rotation The module has a resolution of 1000 pulses per revolution When used with a Turbine input the pressure is measured by the pressure transducer and pulses from the turbine meter are measured by the Pulse Input on the optional I O board The Pulse Interface Module makes the readings available to the processor board The pressure inputs are read from an Analog Input while the pulse counts are read as a Pulse Input The primary inputs used for AGA7 flow measurement are Pulse Input PI counts static pressure and temperature The Pulse Input counts are acquired from a rotary meter or turbine meter the static pressure including auxiliary pressure i
81. lse Interface Module Data screen in ROCLINK 800 software and use the diagnostics provided on the screen Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 for more information on this screen No field repair or replacement parts are associated with the Pulse Interface Module Return the FloBoss to your local sales representative for repair or replacement NOTE The Pulse Interface Module should only be disconnected from the FloBoss 104 at the factory 9 2 8 RTD If you are experiencing troubles with the RTD Check to see how the RTD point is configured as Analog Input 3 Verify that the wiring to the RTD terminations is correct Refer to Section 5 Verify that the user supplied RTD probe is not faulty Refer to the instructions that accompanied the RTD probe No field repair or replacement parts are associated with the RTD input Return the FloBoss to your local sales representative for repair or replacement 9 3 Procedures 9 3 1 How to Preserve Configuration and Log Data Perform this backup procedure before removing power to the FloBoss unit for repairs troubleshooting removing or adding components or upgrades This procedure preserves the current flow computer configuration and log data held in RAM When installing equipment in a hazardous area ensure that all components are approved for use in such areas Check the product labels Change components only in an area known to be non hazardous Perform
82. multiple devices on a single bus The default values for the EI A 485 RS 485 communications are 9600 Baud Rate 8 Data Bits 1 Stop Bit No Parity 10 millisecond Key On Delay and 10 millisecond Key Off Delay The maximum baud rate is 19 200 bps The Comm 1 port may be enabled or disabled on the Configure gt Radio Power Control screen of ROCLINK 800 software enabled is default 1 3 4 3 Optional Communication Cards Comm 2 Two plug in communication cards and one communication module allow you to customize the FloBoss 100 Series unit installation for most communication requirements The communication cards and module provide an interface for the host communications Comm 2 port These cards permit serial communication protocols and dial up modem communications The Comm 2 port is capable of initiating a message in support of Spontaneous Report by Exception SRBX alarming Refer to Section 3 for additional information One of the following card types can be accommodated e EJA 232 RS 232 for asynchronous serial communications baud rate up to 19 200 e Dial up modem for communications over a telephone network default at 2400 baud Spread spectrum radio for wireless communications 1 3 5 RTD Input The FloBoss 100 Series supports a direct input from a Resistance Thermal Detector RTD sensor to measure flowing temperature The RTD has a measurement range of 40 to 240 C 40 to 464 F The terminals for the RTD wires are labele
83. n orifice or turbine or rotary meter in accordance with the 1992 American Petroleum Institute APD and American Gas Association AGA standards The primary inputs used for AGA3 flow measurement function are differential pressure static pressure and temperature The differential and static pressure inputs which are sampled once per second come from the Dual Variable Sensor The temperature input which is sampled and linearized once per second comes from an RTD probe The primary inputs used for AGA7 flow measurement are Pulse Input PI counts static pressure and temperature The Pulse Input counts are acquired from a rotary meter pulse interface module or turbine meter PI on termination board the static pressure including auxiliary pressure inputs come from the pressure transducers and the temperature input is read from an RTD probe 1 2 1 1 Flow Calculations for Orifice Metering The flow calculation is in accordance with ANSI API 2530 92 AGA Report No 3 1992 API Chapter 14 2 AGA Report No 8 1992 2nd printing 1994 and API Chapter 21 1 The flow calculation may be configured for either Metric or English units Flow Time The differential pressure stored for each second is compared to the configured low flow cutoff If the differential pressure is less than or equal to the low flow cutoff or the converted static pressure is less than or equal to zero flow is considered to be zero for that second Flow time for a recalculat
84. nd the FloBoss backplane do not remove the FloBoss unit from the Pulse Interface Module The Pulse Interface Module mounts between the bottom of the FloBoss unit and the top of the rotary meter or turbine meter Refer to Section 2 for Mounting instructions d NOTE The Pulse Interface Module is not equipped to provide a temperature input to the FloBoss for gas compensations in AGA7 calculations This input should come directly into the FloBoss by means of the RTD input on the termination board Rev Dec 10 Pulse Interface Module 7 2 FloBoss 103 and 104 Instruction Manual 7 1 1 How to Make Process Connections Piping from the meter run connects to the pressure transducers of the Pulse Interface Module Both the line and auxiliary pressures pipe to female 14 18 NPT connections on the sides of the Pulse Input Module CAUTION When loosening the connections between the piping and the pressure transducers use a wrench to hold the pressure transducers in place against the Pulse Input Module The wiring connections between the Pulse Input Module and the pressure transducers must be kept firmly in place to avoid internal damage 7 1 2 How to Configure the Pulse Interface Module Use ROCLINK 800 configuration software to configure the Pulse Interface Module Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 for instructions on configuring the meter the Analog Inputs the Pulse Inputs and any other parameters for your ap
85. neees 3 7 Termination Board ceccesceeseesseeeeeeeeeeseeereeeeeneees 1 5 Input Output Ponts 5 1 Tests ELE eeh d e seier diese deen 1 17 Troubleshooting cs eeesesccssecseeeecneeeeceseeeceseeaeeeenees 9 1 V Vibratii EE 2 2 Kid EE 3 3 W Watchdog Software and Hardware ssesseseeseeseeseeseeeseseeee 1 17 l 3 FloBoss 103 and 104 Instruction Manual Ke 3 1 Analog Inputs cece ierann rare i e 5 4 Analog Outputs esesseeseeeeeesrseeeresererrsrrereersreee 5 4 5 5 Communications s sseeseseseeeeeeeseeeseseeeeeersesrereerees 4 1 Communications Cards 4 4 4 5 Dial Up Modem Communications Cards 4 5 Discrete Inputs eiieeii aaan 5 6 Discrete Outputs csc ceeeecsseeeeeseeseeeeeeecneeeeeeeeees 5 7 EIA 485 Communications Cards 4 1 Generalinio iena se NE hes eesi acct 3 7 Gro nding aens h aiid ene Ae aE 3 7 Grounding Requirements s sseeseseeeeeeeeeerereeerereeee 3 2 VO Card Pulse Inputs eee eee eee cee ceeeereeeee 5 8 VO Wgd 5 3 eC De Se tito Ee ha E 4 2 POWER geed eg 3 8 RS 232 Communications Card 4 4 PRD sept ihe hte Bas hae a OS A a EEA 5 9 Wire Gall Ses eege aie RIA at ial aes 3 8 LeTO Shit EE 8 7 If you have comments or questions regarding this manual please direct them to your local sales representative or contact Emerson Process Management Flow Computer Division Marshalltown IA 50158 U S A Houston TX 77065 U S A Pickering North Yorkshire UK Y018 7JA Website w
86. nnas for radio and cellular communications must be located with an unobstructed signal path If possible locate antennas at the highest point on the site and avoid aiming antennas into storage tanks buildings or other tall structures Allow sufficient overhead clearance to raise the antenna Rev Aug 04 Installation and Use 2 2 FloBoss 103 and 104 Instruction Manual To minimize interference with radio or cellular communications locate the FloBoss 100 Series unit away from electrical noise sources such as engines large electric motors and utility line transformers Locate the FloBoss 100 Series unit away from heavy traffic areas to reduce the risk of being damaged by vehicles However provide adequate vehicle access to aid in monitoring and maintenance 2 2 3 Compliance with Hazardous Area Standards The FloBoss 100 Series without optional mast kit has hazardous location approval for Class I Division 1 Groups C to D exposures The FloBoss 100 Series unit also has a Class I Division 2 Groups A B C amp D approval The Class Division and Group terms are defined as follows Class defines the general nature of the hazardous material in the surrounding atmosphere Class I is for locations where flammable gases or vapors may be present in the air in quantities sufficient to produce explosive or ignitable mixtures Division defines the probability of hazardous material being present in an ignitable concentration in the surroun
87. nputs come from the pressure transducers and the temperature input is read from an RTD probe After the static pressure and auxiliary pressure values are read the flowing temperature is read The inputs are read by the FloBoss processor at the following rates Pulse counts are read from the Pulse Interface Module once per second Static pressure is sampled once per second Temperature is sampled and linearized once per second Rev Dec 10 Pulse Interface Module 7 1 FloBoss 103 and 104 Instruction Manual DOC0496A Figure 7 1 FloBoss 104 Assembly Standard PI and AI alarming are implemented along with sensor and flow alarms If the sensor fails to communicate either during initialization or run time the Failure bit in the Pulse Input and Analog Input alarm code is set If alarms are enabled an alarm is also entered in the Alarm Log The two Pulse Inputs in the Pulse Interface Module will be used for counting pulses acquired from a rotary meter PII is for clockwise CW rotation PI2 is for counter clockwise CCW rotation The optional Pulse Inputs on the termination board can be used for other pulse input devices The pressure transducers provide the measurement of the line pressure P1 and can optionally measure downstream pressure or station inlet pressure aux P2 The Pulse Interface Module will arrive from the factory already attached to the base of the FloBoss unit Due to cable connections between the interface a
88. nstallation and Use 2 5 FloBoss 103 and 104 Instruction Manual CRL E0911 Figure 2 3 Mounting Styles 2 3 2 Mounting the FloBoss 104 The Pulse Interface Module will arrive from the factory already attached to the base of the FloBoss 104 unit Due to cable connections between the interface and the FloBoss backplane do not remove the FloBoss unit from the Pulse Interface Module d NOTE The Pulse Interface Module should only be installed and removed from the FloBoss 104 unit at the factory The Pulse Interface Module cable plugs directly into the backplane board and should only be installed and removed at the factory NOTE The Pulse Interface Module is not equipped to provide a temperature input to the FloBoss for gas compensations in AGA7 calculations This input should come directly into the FloBoss 104 by means of the built in RTD input on the termination board If the FloBoss 104 has an optional LCD be careful to make sure the display will be visible after installation The Pulse Interface Module mounts between the bottom of the FloBoss unit and the top of the rotary meter or turbine meter To attach the FloBoss 104 and Pulse Interface Meter to a turbine meter attach the universal mounting plate on the base of the Pulse Interface Module to the meter flange Use 5 16 inch bolts user supplied Refer to Figure 2 6 Rev Aug 04 Installation and Use 2 6 FloBoss 103 and 104 Instruction Manual T
89. nual Dead Weight Tester Value f Live Reading ES 406 Difference 2559 406 Live Act Z Span H Log Veriy Vv Done Figure 8 12 Verify Calibration 6 To log the Tester Value and the Live Reading to the Event Log as a record of the verification click Log Verify 7 Click Done 8 Continue to verify all required pressures values 9 When the verification for a selected point is complete you have the choice to verify another input perform a calibration or close the calibration screen When complete read the following Caution and connect the Dual Variable Sensor back to the process CAUTION Do NOT close the by pass valve on the valve manifold until after process pressure has been reapplied to protect the differential cell of the Dual Variable Sensor This keeps one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied Refer to Figure 8 9 on page 8 6 10 Click OK to close the calibration window to cancel freeze values unfrozen and to enable live readings for use in the flow calculations The Event Log records all calibration settings that were changed Rev Aug 04 Calibration 8 9 FloBoss 103 and 104 Instruction Manual SECTION 9 TROUBLESHOOTING This section provides generalized guidelines for troubleshooting of the FloBoss 100 Series The procedures in this chapter should be performed before removing power for any reason a
90. number of solar panels can be determined using the following equation Number of Panels Iarray amps Ipanei amps panel panels NOTE The I pane value varies depending on the type of solar panel installed Refer to the vendor s specifications for the solar panel being used Ki NOTE The current accepted by the FloBoss 100 Series is limited by its charging circuit to around 1 Amp Therefore it is not practical to install a solar array that supplies significantly more than 1 Amp to the FloBoss The maximum input is 28 volts NOTE Do not allow the batteries to fully discharge If the batteries are fully discharged the battery charger board may enter thermal limiting 3 5 Batteries Batteries provide power for the FloBoss 100 Series unit when the solar panels are not generating sufficient output The batteries are three D size lead acid batteries providing 2 5 Amp hours of current at 6 2 volts The batteries are connected in series by the Battery Charger Board to achieve the required capacity The amount of battery capacity determines the number of days of reserve autonomy desired Rev Aug 04 Power Connections 3 5 FloBoss 103 and 104 Instruction Manual When the FloBoss 100 Series is configured as an API compliant Electric Flow Management EFM and requires an internal communications card a solar panel and the internal batteries the FloBoss should be able to communicate the API audit trail information once a day t
91. o a remote host using no additional battery source no additional solar panel and maintain a 13 day autonomy in the event that the solar panel is lost d NOTE The batteries and the charger board are matched to provide proper charging circuitry Use only batteries supplied by the Flow Computer Division of Emerson Process Management for use in a FloBoss 100 Series unit 3 5 1 How to Determine the Battery Requirements To determine the system capacity requirements multiply the system current load Isr on the batteries by the amount of reserve time required Compute Isr as described in Section 3 3 How to Determine Power Requirements The equation is as follows System Requirement Isr amps X Reserve hrs amp hrs 3 5 2 Howto Replace the Batteries The battery pack contains three D size lead acid batteries providing 2 5 Amp hours of current at 6 2 volts nominal When installing equipment in a hazardous area ensure that all components are approved for use in such areas Check the product labels Change components only in an area known to be non hazardous Performing these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working inside the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap To replace the battery pack 1 Unscrew the front end LCD end cap cover Place the power jumper located at J1 on the Battery Charger Bo
92. o attach the FloBoss 104 and Pulse Interface Meter to a rotary meter perform the following steps 1 Determine which threaded hex shaft adaptor to use The short adaptor has a 0 126 0 128 inch inner diameter at one end and a 0 110 0 112 inch inner diameter at the other end The short adaptor requires a rotary meter shaft length of 0 150 0 210 inch The long adaptor has a 187 189 inch inner diameter The long adaptor requires rotary meter shaft length of 0 150 0 260 inch 2 Ifthe short shaft adaptor is used determine which end of the adaptor fits tighter to the shaft The end that fits tighter is the end the set screw will be installed on 3 Loosely install the 5 40 set screw into the appropriate hole on the shaft adaptor The kit includes two set screws 0 125 inch and 0 188 inch long The 0 125 inch long set screw is for the long shaft adaptor The 0 188 inch long set screw is for the short shaft adaptor 4 Place the adaptor with the set screw inserted over the rotary meter shaft and tighten the set screw to lock the adaptor in place Magnet Magnet Set screw ll 1 90 in Max Shaft Adaptor _ 1 70 in Min Shaft Adaptor Set screw U Figure 2 4 Magnet Installed on Long Shaft Adaptor 0 66 in Max 0 46 in Min DUCOS45A Figure 2 5 Magnet Installed on Short Shaft Adaptor 5 Thread the magnet assembly on to t
93. odbus Slave or optional Modbus Host ASCII or RTU Radio Spread spectrum wireless radio when optional logic card and radio are installed POWER Internal Batteries Lead acid Rechargeable Nominal 6 2 V dc 2 5 Amp hour Battery life with no charging input and no communications 3 weeks External Power Charging Input 8 28 V dc Input Current 5 mA nominal 9 5 mA at 100 duty cycle battery charging not included ENCLOSURE Housing and Cap Die cast aluminum alloy with iridite plating and paint WEIGHT 6 58 kg 14 5 lbs SOLAR PANEL OPTIONAL 2 Watts Output 9 Volts nominal Size 114 mm by 159 mm 4 5 in by 6 25 in 5 Watts Output 9 Volts nominal Size 222 mm by 229 mm 8 75 in by 9 in RTD INPUT Quantity Type Single input for a 2 or 3 wire RTD element with alpha of 0 00385 Terminals RTD current source RTD signal positive input and RTD RET signal negative input Sensing Range 40 to 240 C 40 to 464 F Accuracy 0 2 C 0 64F over sensing range includes linearity hysteresis repeatability Ambient Temperature Effects per 28 C 50 F 0 50 C 0 90 F for process temperatures from 40 to 240 C 40 to 464 F Filter Band pass hardware filter Resolution 16 bits Sample Period 1 sec minimum ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F LCD Display 20 to 75 C 4 to 167 F Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity
94. onnection Battery 8 0 to 28 volts power and CHG for negative power connection Battery Common on a label on the termination board Refer to Figure 3 3 NOTE The terminal block for power CHG has changed location and orientation on all terminal boards The CHG terminations are now at the bottom of the right hand column This change only affects the FloBoss 103 as the change took effect before the FloBoss 104 was released NOTE Check the label for the pin location of the CHG and CHG terminals carefully If the positive and negative connections are reversed the internal batteries will not charge GGG Gil KA it itt lit N OS e o kl N raran Sg Ou Al 2 Al 1 Jl DO 1 AO 1 ES So vosos H COM1 gt IF MODEM INSTALLED US FSRMRO6B103 REN 0 6 GCYOC KV VSP GHG VCVog RTD D m 4 CHG I CHG Termination DOC0492A Figure 3 3 Termination Board It is important that good wiring practice be used when sizing routing and connecting power wiring All wiring must conform to state local and NEC codes The CHG CHG terminal can accommodate up to 16 AWG wire Rev Aug 04 Power Connections 3 8 FloBoss 103 and 104 Instruction Manual
95. ons climate and site accessibility as well as the suitability of the FloBoss application while planning an installation Rev Aug 04 Installation and Use 2 1 FloBoss 103 and 104 Instruction Manual The versatility of the FloBoss allows it to be used in many types of installations For additional information concerning a specific installation contact your local sales representative NOTE The FloBoss 100 Series has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits provide reasonable protection against harmful interference when the equipment operates in a commercial environment This equipment generates uses and can radiate radio frequency energy If not installed and used in accordance with this instruction manual the FloBoss 100 Series may cause harmful interference to radio communications Operation of the equipment in a residential area is likely to cause harmful interference in which case you will be required to correct the interference at your own expense 2 2 1 Environmental Requirements The FloBoss enclosure is classified as a NEMA 4 equivalent enclosure This provides the level of protection required to keep the units operating under a variety of weather conditions The FloBoss 100 Series unit is designed to operate over a wide range of temperatures However in extreme climates it may be necessary to moderate the temperature in which the unit mu
96. ou to access the FloBoss 100 Series unit using ROCLINK 800 software for configuration and transfer of stored data The LOI port is capable of initiating a message in support of Spontaneous Report by Exception SRBX alarming The LOI terminal on the Termination Board provides wiring access to a built in E A 232 RS 232 serial interface which is capable of up to 19 2K bps operation The operator interface port supports ROC or Modbus protocol communications The LOI also supports the log on security feature of the FloBoss 100 Series if the Security on LOI is Enabled in ROCLINK 800 software Rev Aug 04 General Information 1 15 FloBoss 103 and 104 Instruction Manual 1 3 4 2 EIA 485 RS 485 Serial Communications Comm 1 Use Comm 1 to monitor or alter the FloBoss unit from a remote site using a host or ROCLINK 800 software Comm supports baud rates up to 19 200 bps Comm 1 also supports the log on security feature of the FloBoss unit if the security on Comm 1 is enabled in ROCLINK 800 software Comm 1 sends and receives messages using the ROC or Modbus protocol Comm is capable of initiating a message in support of Spontaneous Report by Exception SRBX alarming Comm 1 permits EIA 485 RS 485 serial communication protocols that meet E A 485 RS 485 specifications for differential asynchronous transmission of data over distances of up to 1220 m 4000 ft The EIA 485 RS 485 drivers are designed for true multi point applications with
97. ou to view the current and past gas volumes on site without requiring a PC The LCD provides you a visual indication of the status of the meter run by displaying the historical performance data to help ensure the health and integrity of your installation The LCD panel remains on at all times when the power is applied in the valid operating range The panel cycles its display through a configured list of up to 16 parameter values with the first seven being pre configured The first three displays show values for time date and battery condition and cannot be configured The next five displays show certain flow parameters and are factory configured but you may change their configuration To configure the list of values for the LCD panel refer to the LCD User List Setup procedure in the ROCLINK SOU Configuration Software User Manual Form A6121 1 3 4 Communications Ports The FloBoss provides two standard and one optional communication ports Standard Operator interface port EIA 232 RS 232 LOI Standard EIA 485 RS 485 Communications Comm 1 Optional EIA 232 RS 232 Spread spectrum Wireless Radio or Dial up Modem Communications Comm 2 1 3 4 1 Local Operator Interface Port LOI The Local Operator Interface LOI port provides direct communications between the FloBoss unit and the serial port of an operator interface device such as an IBM compatible computer using an EIA 232 RS 232 link The interface allows y
98. ough ROCLINK 800 software 1 2 5 PID Control PID Control is available when the optional I O termination points are installed PID Proportional Integral and Derivative functionality calculates both the Primary Control and Override Control change in output PID Control then selects which Control is to be used based upon whether the High Override Type Select or Low Override Type Select is chosen and adjusts the Output control as necessary The Output of the PID functions can be implemented through an Analog Output or the two Discrete Outputs 1 2 6 Spontaneous Report By Exception SRBX Alarming The SRBX functionality allows a communications port to be set up to enable the FloBoss to contact the host computer when specified alarm conditions exist To configure SRBX alarming each comm port must have the SRBX parameter enabled each point must have the alarming parameter enabled and points must have the SRBX Set on Clear parameter set 1 2 7 Pass Through Communications Pass Through Communications allow the user to configure a FloBoss 100 Series unit to send Pass Through messages when using a FloBoss 100 Series By using any of the FloBoss 100 Series communications ports Pass Through Mode allows data to be received by one unit and then passed through to other devices connected on any other communications port For example the host communicates via a radio on the FloBoss 100 Series Comm 2 port Other FloBoss 100 Series units can then be conne
99. plication The defaults contained within the sensor are the initial pressures read You can re range each sensor through the calibration routines 7 2 Positive Displacement Interface Specifications For detailed specifications refer to Technical Specifications FB104 Rev Dec 10 Pulse Interface Module 7 3 FloBoss 103 and 104 Instruction Manual SECTION 8 CALIBRATION This section describes the calibration procedures for the Analog Input RTD Input and Dual Variable Sensor Inputs For information on wiring and process connections refer to Sections 5 and 6 This section contains the following information Section Page 8 1 Calibration AI RTD amp DVS 8 2 How to Perform a Calibration 8 3 How to Verify a Calibration 8 1 Calibration Al RTD amp DVS Use ROCLINK 800 software to perform initial calibration or re calibration such as after a change in an orifice plate in the meter run handled by the FloBoss unit The calibration routines support 5 point calibration with the three mid points calibrated in any order The low end or zero reading is calibrated first followed by the high end or full scale reading The three mid points can be calibrated next if desired The diagnostic analog inputs for logic voltage E1 battery voltage E2 and board battery temperature E5 are not designed to be calibrated The diagnostic analog input for charge input can be resealed and calibrated The built in inputs may be calibrated w
100. porate the safety factor multiply the total power consumption P by 1 25 Psp P x 1 25 Watts To convert Psr to current consumption in amps Isr divide Psr by the system voltage V of 12 volts Isp Psp 12V Amps Rev Aug 04 Power Connections 3 3 FloBoss 103 and 104 Instruction Manual 3 4 Solar Powered Installations Solar power allows installation of the FloBoss 100 Series in locations where a DC voltage source is not available Size solar panels properly for the application and geographic location to ensure continuous reliable operation A 2 Watt or 5 Watt solar panel can be ordered and installed to provide charging power for the backup batteries An external solar panel typically mounts to the same 2 inch pipe that supports the FloBoss 100 Series The panel wiring terminates at the charge CHG CHG power terminals on the termination board The panel must face due South not magnetic South in the Northern Hemisphere and due North not magnetic North in the Southern Hemisphere The panel must also be tilted at an angle from horizontal dependent on latitude to maximize the energy output The angles for different latitudes are normally included in the solar panel documentation At most latitudes the performance can be improved by less of an angle during the summer and more of an angle during the winter As a site may have additional power requirements for repeaters and other monitoring devices power supply and converte
101. r accessories may be used to minimize the number of separate power sources required for an installation Solar arrays generate electrical power for the FloBoss 100 Series from solar radiation The size of solar panels required for a particular installation depends on several factors including the power consumption of all devices connected to the solar array and the geographic location of the installation The optional solar panel is adequate for support of API Chapter 21 1 compliant measurement and the retrieval of the historical logs once a day using the internal communication methods 3 4 1 1 How to Size the Solar Panel To determine solar panel output requirements first determine the solar insolation for your geographic area The map in Figure 3 2 shows solar insolation in hours for the United States during winter months Call your local sales representative for a map detailing your specific geographic area Insolation from map hours Next calculate the amount of current required from the solar array per day using the following equation Isp is the system current requirement Refer to Section 3 3 on page 3 3 Lan Isr amps x 24 hrs Insolation hrs amps Rev Aug 04 Power Connections 3 4 FloBoss 103 and 104 Instruction Manual Figure 3 2 Solar Insolation in Hours for the United States gt do NOTE Refer to http www solar4power com solar power global maps html for global solar insolation maps Finally the
102. ries unit This section contains the following information Section Page 2 1 2 2 Installation Requirements 2 1 2 1 Installation Overview 2 3 Mounting 2 3 2 4 Startup and Operation 2 9 2 Configuration 2 10 2 1 Installation Overview The following steps must be taken to install a FloBoss 103 to a pipestand or orifice plate or a FloBoss 104 to a turbine or rotary meter Refer to the Table of Contents to find an explanation of each step in the appropriate sections of this manual If pipestand mounting install the pipestand per the directions include with the pipestand Remove the orifice meter run from service Mount the FloBoss assembly according to the procedures in Section 2 3 1 or 2 3 2 Connect the impulse lines Connect the FloBoss 100 Series unit to the operator interface ROCLINK 800 software Power the FloBoss unit If powered externally wire the unit to the external power source Calibrate the input s from the Dual Variable Sensor or Pulse Interface Module 1 2 3 4 5 Install the RTD and connect it to the termination board 6 7 8 9 Calibrate the RTD input 10 Connect the FloBoss 100 Series unit to any other external communication devices or networks Place the meter run in service and monitor with ROCLINK 800 software for proper operation 2 2 Installation Requirements Planning helps to ensure a smooth installation Be sure to consider location ground conditi
103. ries units EIA 232 RS 232 transmission that connects to the field device s receive Rev Aug 04 Communications 4 4 FloBoss 103 and 104 Instruction Manual 4 4 Dial up Modem Communications Card The dial up modem communications card supports V 22 bis 2400 baud communications with auto answer auto dial features The modem card is FCC part 68 approved for use with public switched telephone networks PSTNs A label on the termination board and Section 4 6 2 provide the FCC registration number and the ringer equivalent The optional modem communications logic card for the host port activates Comm 2 The defaults for the dial up modem communications card are 2400 baud rate 8 data bits 1 stop bit no parity 10 millisecond Key On Delay and 10 millisecond Key Off Delay On power up the modem must be set up for Auto Answer Periodic checks are made to ensure that the modem is still in Auto Answer or that it is not left off the hook after a certain period of non communication The modem card interfaces to two wire full duplex telephone lines using asynchronous operation at data baud rates of 1200 and 2400 The modem can be controlled using industry standard AT command software A 40 character command line provides AT command set which is compatible with EJA document TR302 2 88 08006 The initialization Config Command modem strings are 1200 Dial up Modem ATS 1S 7 2 e 2400 Dial up Modem ATS 1
104. s Dead Weight Tester Value W Live Reading jeooo Difference bam x Live Act Span SetSpan Xl Cancel Figure 8 5 Set Span Apply the desired high value to the input the top end of the expected operating range To maintain rated accuracy be sure to observe the turndown limits listed in the Specifications table in Sections 5 and 6 Enter the applied value in the Dead Weight Tester Value field of the Set Span dialog For static pressure on an absolute pressure device add the actual atmospheric pressure such as 300 14 73 When the Live Reading is stable click Set Span to calibrate the high reading The window advances to the Set Midpoint 1 window as in Figure 8 6 Rev Aug 04 Calibration 8 4 FloBoss 103 and 104 Instruction Manual 14 If you are performing a two point calibration click Done Calibration for this input is complete Set Mid 1 ES Point Line Press Dead Weight T ester Value fo Live Reading 2543406 Difference jeza x Live Act Span H Set Mid 1 X Cancel yY Done Figure 8 6 Set Midpoint 1 15 To calibrate Midpoints apply the desired pressure or temperature and enter the applied value in the Dead Weight Tester Value field Note that you can calibrate the midpoints in any order 16 When the Live Reading is stable click Set Mid 1 to calibrate this reading The display advances to the
105. s Card Signals TE RR The request to send signals that the modem is ready to transmit RX The RXD receive data The RXD receive data signals that data is being received at the communications card that data is being received at the communications card RRE The TXD transmit data signals that data is being transmitted from the communications card Rev Aug 04 Communications 4 3 FloBoss 103 and 104 Instruction Manual 4 3 1 How to Wire EIA 232 RS 232 Communications Signal wiring connections to the communications card are made through the terminal block located on the termination board A nine terminal removable connector is used for the wiring of external device communications A EJA 232 RS 232 communications card in the Comm 2 port provides a means to switch power to external communication devices such as a radio to conserve power A label on the termination board denotes the usage of each pin on the connector Table 4 4 displays connector signals and their functions Table 4 4 EIA 232 RS 232 Communications Card Wiring Pin Signal Label 9 Ring Transmit data TX 8 Tip Receive data RX 7 Request to Send RTS 3 Ground COM 2 Switched Power B 1 Signal Common Negative COM 1 COM at Pin 1 and COM at Pin 3 are identical They are only separated for ease of wiring 2 Switched power is for use with an internal radio or cell phone and not for power to external devices 3 Transmit is the FloBoss 100 Se
106. s complete you have the choice to calibrate another input to verify the calibration or to close the calibration screen When the calibration is complete and you calibrated pressure inputs read the following Caution and return the Dual Variable Sensor to service Do NOT close the by pass valve on the valve manifold until after process pressure has been reapplied to protect the differential cell of the Dual Variable Sensor This keeps one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied Refer to Figure 8 9 Pre Startup start3 Startup Sequence Figure 8 9 Returning the DVS to Service NOTE If you calibrated the Differential Pressure input refer to Section 8 2 1 Zero Shift before completing the last step 4 Click OK to close the calibration window cancel freeze values unfrozen and enable live readings for use in the flow calculations The Event Log records all calibration settings that were changed Rev Aug 04 Calibration 8 6 FloBoss 103 and 104 Instruction Manual 8 2 1 Zero Shift If desired use the Zero Shift procedure after calibrating the Differential pressure input The Differential Pressure is calibrated without line pressure being applied to the sensor When the sensor is connected back to the process after calibration a shift in the differential pressure can occur due to the influence of the line pressure This effect can be canceled out with
107. s section describes the FloBoss 100 Series electronics For Communication Cards refer to Section 4 For I O Termination Points refer to Section 5 For the Dual Variable Sensor refer to Section 6 For the Pulse Interface Module refer to Section 7 1 3 1 Termination Board Overview The Termination Board Figure 1 4 components support the functionality of the FloBoss 100 Series and includes e Local operator interface LOI EIA 232 RS 232 terminations EIA 485 RS 485 communications Comm 1 terminations RTD input terminations Optional I O and terminations Remote charge terminations eff gt Optional Comm 2 terminations 1 3 2 Processor and Memory The FloBoss derives processing power from a 32 bit microprocessor The 32 bit CMOS micro processor features dual 32 bit internal data buses and a single 8 bit external data bus The unit can address up to 4 MB of memory including high speed direct memory access The FloBoss has 512 KB of static random access memory SRAM for storing interrupt vectors Proportional Integral and Derivative alarms events and history data Rev Aug 04 General Information 1 14 FloBoss 103 and 104 Instruction Manual The FloBoss also has a 2 MB flash memory chip for storing the operating system factory code configuration parameters and user C programs 1 3 3 Liquid Crystal Display An optional two line Liquid Crystal Display LCD panel mounts on the Battery Charger Board The LCD allows y
108. sancaetesss 3 2 Grounding Earth Ground iieis eters NEEN EES 3 2 Ground WINE EENS 3 7 Wiring Requirements 0 0 0 0 cesseeesecseeeecneeeeeeseeees 3 2 H Hardware Watchdog AA 1 17 Hazardous Locations 00 ceescsseeceesecreesecnerereneseeeees 2 3 Rev Aug 04 History LOG i e eaen rei ii e 1 11 History Ponts innne neen i n eaa 1 10 Hourly Historical Log 1 11 T O Ram o a E RA A R R 1 6 V O Wiring Requirements eseseeeeeeeereeeererererrereeeees 5 3 Impedance Grid isla ea eae 3 2 Input and Extension Calculation eee eeeeeeeeeeeee 1 9 Input Output Termination Ponts 5 1 Installation Guidelines r n aie 2 1 SLAMUP ee ath vases 2 9 WIDE ee 3 7 Instantaneous Rate Calculations 0 0 0 0 ee eeeeeeneeeee 1 9 Integral Multiplier Value LKE 1 9 Jot eralkNalge eeeteeegeeg REESEN 1 11 I DA E 1 9 Bolat O ege 3 2 J Jumper Keget anrai airneo an S EEE S 9 5 L E GE EE 1 15 Liquid Crystal Display eee eceeseereesecneeeeeneenees 1 7 See LED va enti eee 1 15 Local Operator Interface LOT tee ee Bike esis 1 6 1 7 1 15 TOT Waitin ee EEN Ee 4 2 LOG data sios enere Ee 9 4 LOD eegene 1 15 Low Power Mode 1 17 M MEMOTLY inrano tn deviate ge E acess 1 14 e EE 6 2 MICFOPLOCESSOT sienos unate iiia etae 1 5 1 14 Min Max Historical Log 1 11 Minute Historical Log 1 11 MOnitoring EE 1 17 Mounting cava cas A Eed haved 2 3 N National Electrical Code NEG et Satis ee BS 2 3 3 1 3 7 NEMA 53 2058 Rosette ei AAS
109. st operate The FloBoss 100 Series is designed to operate over a 40 to 75 C 40 to 167 F temperature range The LCD temperature range is 25 to 70 C 13 to 158 F When mounting the unit be aware of external devices that could have an effect on the operating temperature Operation beyond the recommended temperature range could cause errors and erratic performance Prolonged operation under extreme conditions could also result in failure of the unit Check the installation for mechanical vibration The FloBoss 100 Series unit should not be exposed to levels of vibration that exceed 2g for 15 to 150 Hz and 1g for 150 to 2000 Hz 2 2 2 Site Requirements Careful consideration in locating the FloBoss 100 Series unit on the site can help prevent future operational problems The following items should be considered when choosing a location e Local state and federal codes often place restrictions on monitoring locations and dictate site requirements Examples of these restrictions are fall distance from a meter run distance from pipe flanges and hazardous area classifications Locate the FloBoss 100 Series unit to minimize the length of signal and power wiring When using solar powered FloBoss 100 Series units orient solar panels to face due South not magnetic South in the Northern Hemisphere and due North not magnetic North in the Southern Hemisphere Make sure nothing blocks the sunlight from 9 00 AM to 4 00 PM Ante
110. t or Static Pressure SRAM Static Random Access Memory Stores data as long as power is applied typically backed up by a lithium battery or supercapacitor SRBX Spontaneous Report By Exception FloBoss function to initiate reports of alarm conditions to the host Sometimes referred to as RBX System Variables Parameters configured that describe the FloBoss unit These parameters are set in the Device Information screen of ROCLINK software T Z Tf Flowing temperature TLP Type of point Logical or point number and Parameter number TXD Transmitted Data communications signal Upload Send data a file or a program from the FloBoss unit to a configuration PC or the Host Rev Aug 04 Glossary of Terms G 5 FloBoss 103 and 104 Instruction Manual INDEX A EE 1 7 EE Ee Ee eer 1 9 Flow Calculations ccccccccccccsssceceesseeeeessseeeens 1 9 AGAT Flow Calculations ssseesoeneoooeneoeeeessesesseee0e0e 1 10 EE 1 10 Alarm BE 1 12 Analog Inputs MIDD bid buat hanes does 5 4 Analog Output issin 5 4 5 5 ATILCTINAS ee EEN 2 2 FN od EE 1 9 APL Chapter 21 1 WE 3 4 APPLOVAlS nocions a o EES aE Se 2 3 Archive Type isre a o ea 1 10 AT Command KEE 4 5 Automatic Self Tests 1 17 B Backplane Board sic c ssscesstssecvsssscsesestbessbessocsonestebaveases 1 5 E rr 9 4 Backup Battery cisccsssssccssecsseestesshesstyscchssbescsoseosebaveasss 1 5 Battery s isscsesscsssestsdesbessacseessedssshscssvect
111. t strap 3 6 1 How to Make Wiring Connections The FloBoss Termination Board connectors use compression terminals The input power termination CHG CHG uses a removable connector and accommodates wiring up to 16 AWG in size In all cases make connections by baring the end inch maximum of the wire inserting the bared end into the clamp beneath the termination screw and then tightening the screw to 0 25 N m 2 2 lb in NOTE Take Caution Do not over torque the connector screws The inserted wires should have a minimum of bare wire exposed to prevent short circuits Allow some slack when making connections to prevent strain 3 6 2 How to Connect Enclosure Ground Wiring The FloBoss 100 Series unit and related components use the National Electrical Code NEC that governs the ground wiring requirements Two ground screws are located inside the back of the enclosure It is recommended that a minimum of 14 AWG wire be used for the ground wiring Rev Aug 04 Power Connections 3 7 FloBoss 103 and 104 Instruction Manual 3 6 3 How to Connect Main Power Wiring The FloBoss 100 Series accepts input voltages from 8 0 volts to 28 volts at the charge terminals CHG CHG with no external current limiting internal current limit is 200 mA The maximum power for DC voltage sources is 130 mWatts for the FloBoss 103 and 300 mWatts for the FloBoss 104 not including battery charging The terminals are labeled CHG for positive power c
112. ted to the I O channels The I O channels have a removable plug in terminal block for field wiring I O includes Analog Input AI Analog Output AO Discrete Input DI Discrete Output DO Pulse Input PI et gt Five of the six points of I O are selectable The Analog Output may be switched to a Discrete Output switch on termination board The Analog Inputs and Pulse Inputs may be selected as Discrete Inputs on the I O Setup screen in ROCLINK 800 Configuration Software Rev Aug 04 Input Output amp RTD Input 5 1 FloBoss 103 and 104 Instruction Manual Table 5 1 I O Terminations Termination Number UO Type 10 Al1 DI1 COMMON Al2 Dl2 AO DO1 AO DO1 DO2 DO2 Pl1 DI3 COMMON Pl2 Dl4 Oo Mh Jo A aIo N oo 5 1 1 How to Select the Type of I O To select the type of output for the Analog Output Discrete Output 1 channel flip the AO DO switch on the termination board to the desired position Refer to Figure 5 1 for the switch location Then select the desired output type on the Configure gt I O gt Setup screen in ROCLINK 800 configuration software Analog Output is the default position for this channel To select the type of input for the Analog Input Discrete Input and Pulse Input Discrete Input channels use the Configure gt I O gt Setup screen in ROCLINK 800 configuration software The defaults are Analog Input and Pulse Input NOTE Make sure
113. the field wiring and is located in the terminal side of the explosion proof housing Refer to Figure 1 4 Connections include the power supply Local Operator Interface LOI communications Comm 1 for EI A 485 RS 485 communications optional Comm 2 for EIA 232 RS 232 wireless spread spectrum radio or dial up modem communications RTD wiring and the I O field wiring The termination board provides surge and static discharge protection for the field wiring Electronics include the RTD circuits and the final I O drivers receivers The radio interface board mounts to the termination board The termination board also serves as an interface to the backplane board in the electronics portion of the enclosure The 32 bit processor board contains the processor memory static RAM Flash EEPROM and boot ROM Local Operator Interface LOI EIA 232 RS 232 communications driver Comm 1 EIA 485 RS 485 communications driver the reset controller and the real time clock The processor board also called the central processor unit CPU provides the Serial Peripheral Interface SPI bus the Liquid Crystal Display LCD drivers the Dual Variable Sensor DVS control the Pulse Interface Module control and the optional I O termination points control The microprocessor has low power operating modes including inactivity and low battery condition The FloBoss comes standard with 512 KB of built in static random access memory SRAM for storing data and
114. tional I O termination points Rev Aug 04 General Information 1 6 FloBoss 103 and 104 Instruction Manual Communications based on the ROC protocol or Modbus slave or optional host ASCII or RTU protocol for use with EFM applications Alarm call in to host for Spontaneous Report By Exception SRBX User level security 1 1 3 Options and Accessories The FloBoss 100 Series supports the following options and accessories Communication cards for either E A 232 RS 232 dial up modem or spread spectrum radio communications 6 Input Output I O termination points Local Operator Interface LOI cable Liquid Crystal Display LCD with two line alpha numeric viewing Solar panel mast assembly ft gt gt Blank plate for the FloBoss 103 for use when no DVS is required Plug in communication cards allow you to customize the FloBoss installation for most communication requirements Optional communication cards provide the ability to send and receive data One of the following card types can be accommodated e EIA 232 RS 232 for asynchronous serial communications e Dial up modem for communications over a telephone network Spread Spectrum wireless radio communications The local operator interface LOI port provides for a direct local link using a Local Operator Interface Cable between the FloBoss and a personal computer With the personal computer running ROCLINK 800 software you can configure t
115. tput Current Control Voltage Signal In AO 1 5V output y Control Externally powered Common device IC Figure 5 5 1 5 Volts Analog Output Voltage Control Rev Aug 04 Input Output amp RTD Input 5 5 FloBoss 103 and 104 Instruction Manual 5 5 Discrete Input The Discrete Input DI monitors the status of relays solid state switches or open collector devices DI functions support discrete latched inputs and discrete status inputs When a field device such as a relay contact or open collector is connected across and the closing of the contacts completes the circuit which causes a flow of current between Vs and ground at terminal This current flow activates and is sensed in the DI circuitry that in turn signals the FloBoss electronics indicating that the relay contacts have closed When the contacts open current flow is interrupted and the DI circuit signals to the FloBoss electronics that the relay contacts have opened The selectable Pulse Inputs Discrete Inputs are configured as Pulse Inputs through ROCLINK 800 software Refer to Section 5 1 1 NOTE The selectable Analog Inputs Discrete Input channels should have the 250 ohm resistor switched off when configured for use as Discrete Inputs 5 5 1 How to Wire the Discrete Input The terminals for connecting the DI wiring are shown in Figure 5 1 The terminal is the positive signal input
116. ts NOTE No field repair or replacement parts are associated with the I O termination points 9 2 4 Software Issues If you are experiencing problems with the FloBoss 100 Series that appear to be software related try resetting the FloBoss 100 Series unit Use a Warm Start to restart without losing configuration or log data To perform a Warm Start open ROCLINK 800 software connect to the FloBoss unit and select ROC gt Flags Refer to ROCLINK 800 Configuration Software User Manual Form A6121 Use a Cold Start to restart without a portion of the configuration log data or programming that may be the trouble To perform a Cold Start open ROCLINK 800 software connect to the FloBoss unit and select ROC gt Flags Refer to ROCLINK 800 Configuration Software User Manual Form A6121 Rev Aug 04 Troubleshooting 9 2 FloBoss 103 and 104 Instruction Manual Ifa warm start and a cold start do not allow you to connect and you can not connect to the FloBoss 100 Series unit via the LOI port use the RESET jumper on the FloBoss unit and cycle power to restore the LOI Communications parameters to factory defaults Refer to Section 9 3 2 NOTE If these methods do not solve the problem contact your local sales representative 9 2 5 Power Issues If you are experiencing trouble with powering up the FloBoss 100 Series e Check the ON OFF jumper the wiring connections at CHG and CHG and the wiring at the power source e Check th
117. udes linearity hysteresis repeatability Ambient Temperature Effects per 28 C 50 F 0 50 C 0 90 F for process temperatures from 40 to 240 C 40 to 464 F Filter Band pass hardware filter Resolution 16 bits Sample Period 1 sec minimum ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F LCD Display 20 to 75 C 4 to 167 F Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity 5 to 95 non condensing Vibration Meets SAMA PMC 31 1 Radiated Conducted Transmissions Meets requirements of IEC 61326 Electrical Equipment for Measurement Control and Laboratory Use Radiated Emissions Meets FCC Part 15 Class A DIMENSIONS 160 mm H by 150 mm W by 135 mm D 6 3 in H by 5 9 in W by 5 3 in D excludes mounting flange and interface APPROVALS Designed to meet the following North American standards CSA C22 2 No 30 CSA C22 2 No 213 UL 1203 UL 1604 Meets CSA standards for hazardous locations as Model W40106 with enclosure plug Type 4 enclosure Class I Division 1 Groups C amp D Class I Division 2 Groups A B C amp D Temp T3 Model W40112 with optional solar panel mast assembly Type 4 enclosure Class I Division 2 Groups A B C amp D Temp T3 General Information 1 20 FloBoss 103 and 104 Instruction Manual SECTION 2 INSTALLATION AND USE This section provides generalized guidelines for successful installation and operation of the FloBoss 100 Se
118. vide additional inputs and outputs for expanded monitoring and control applications I O includes analog input AI analog output AO discrete input DI discrete output DO and pulse input PI The DO circuitry is optically coupled to help isolate the processor board from the output device I O can be used to drive a sampler or odorizer open a valve or monitor an additional analog input 1 1 4 FCC Information This equipment complies with Part 68 of the FCC rules On the termination board is a label that contains among other information the FCC certification number and Ringer Equivalence Number REN for this equipment If requested this information must be provided to the telephone company The REN is used to determine the quantity of devices that may be connected to the telephone line Excessive RENs on the telephone line may result in the devices not ringing in response to an incoming call Typically the sum of the RENs should not exceed five 5 0 To be certain of the number of devices that may be connected to a line as determined by the total RENs contact the local telephone company If this equipment dial up modem causes harm to the telephone network the telephone company will notify you in advance that temporary discontinuance of service may be required But if advance notice isn t practical the telephone company will notify the customer as soon as possible Also you will be advised of your right to file a complaint with
119. wireless radios are available for use in the FloBoss 100 Series The optional radio communications interface cards provide radio communications through Comm 2 Radio power control accessed with ROCLINK 800 configuration software is used to turn power on to the spread spectrum radio and provides a low power mode when the radio is not communicating Although the radio communications interface cards are intended for host communications they may also be employed for operator access at the FloBoss Alternatively the LOI connection on the LOI port may be used for operator access while the radio communication card is mounted and functioning in the FloBoss housing DOCO479A Figure 4 2 Radio and Interface Card FreeWave shown 4 5 1 How to Install a Radio Communications Card If you have ordered the FloBoss 100 Series unit with a radio the installation is already complete To install a radio communications card to an existing FloBoss 100 Series unit perform the following steps Both models of radio communication cards are mounted within the enclosure in the same manner Rev Aug 04 Communications 4 6 FloBoss 103 and 104 Instruction Manual SS o gt oo T 9 9 Ts b On p AA HH AA z t i tlt ett O O O OOOO sr 1 U Tuck LOI Cable here Plastic Standoffs Al 2 Al 1 e eg
120. ww EmersonProcess com flow Rev Aug 04 Index
121. y and internal voltages internal temperature COMMUNICATIONS Local Operator Interface ElA 232 RS 232C format Software configurable 1200 to 19 200 bps rate selectable EIA 485 RS 485 Software configurable 1200 to 19 200 bps rate selectable Host EIA 232 RS 232 Modem or Radio interface when optional communications card is installed Protocols ROC or Modbus Slave or optional Modbus Host ASCII or RTU Radio Spread spectrum wireless radio when optional logic card and radio are installed POWER Internal Batteries Lead acid Rechargeable Nominal 6 2 V dc 2 5Amp hour Battery life with no charging input and no communications 1 week External Power Charging Input 8 28 V dc Input Current 5 mA nominal 9 5 mA at 100 duty cycle battery charging not included ENCLOSURE Housing and Cap Die cast aluminum alloy with iridite plating and paint WEIGHT 4 3 kg 9 5 lbs approximate with Pulse Interface Module SOLAR PANEL OPTIONAL 2 Watts Output 9 V nominal Size 114 mm by 159 mm 4 5 in by 6 25 in 5 Watts Output 9 V nominal Size 222 mm by 229 mm 8 75 in by 9 in Rev Aug 04 RTD INPUT Quantity Type Single input for a 2 or 3 wire RTD element with alpha of 0 00385 Terminals RTD current source RTD signal positive input and RTD RET signal negative input Sensing Range 40 to 240 C 40 to 464 F Accuracy 0 2 C 0 64 F over sensing range incl
122. you select the I O types before you configure the I O in ROCLINK 800 software NOTE When an Analog Input Discrete Input channel is selected to Analog Input be sure the 250 Ohm Resistor Active switch is set to the resistor active position Refer to Figure 5 1 for the switch location Rev Aug 04 Input Output amp RTD Input 5 2 FloBoss 103 and 104 Instruction Manual GE A E 8 pee leg fet 3 S ojl cou fg job 2 SE CG g DAlzl Gre lee 250 Ohm Resistor A ST 18 SE Active Switches S el z A d Kee 2 2 S AO DO i 3 8 8 Switch a EU E S e RET o DOC0503A Figure 5 1 Termination Board with Optional I O 5 2 UO Wiring Requirements VO wiring requirements are site and application dependent Local state or NEC requirements determine the I O wiring installation methods Direct burial cable conduit and cable or overhead cables are options for I O wiring installations 5 3 Analog Input The diagnostic Analog Inputs logic voltage battery voltage and board battery temperature are not designed to be configured or wired The pressure and temperature inputs are configured as the first three Analog Input points in ROCLINK 800 Configuration Software Differenti

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