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FloBoss 103 Instruction Manual

1. eee 2 18 Ria 2 4 ROC FloBoss Accessories Instruction Manual 1 2 ROCLINK 800 Configuration Software User Manual 1 1 ROM BU ASH ii en e re EE ER OTI EE 1 5 RS 232 Communication Card AKT ed 3 2 lUS uen aen 1 5 1 6 1 9 1 16 4 3 DIET 2 12 S SeC rity iiis ete ier te netten 1 6 1 12 1 15 Site Requirements sess 2 2 Sleep Mode dre eet ee 1 17 Software Watchdog sse 1 17 Solar Panels nece erre 1 7 2 2 ld omm c 2 8 SIND nugae eee 2 9 Specifications Communications Cards 3 4 Rev 10 02 Dual Variable Sensor 4 12 O Termination Board sess 5 6 Maat ie 1 18 SRAM Sins eme a eene 1 5 SRBX situant bien 1 13 Start p oec eoim 2 15 Startup and Operation 2 14 Static Pressure 1 9 1 10 4 2 Static Random Access Memory SRAM nua Ate ee 1 14 Surge Protection id e pete 2 4 System Voltage 2 8 T Table 2 1 CHG and CHG eese 2 11 Table 2 2 RTD Signal Routing 2 12 Table 2 3 EIA 485 RS 485 Communications Wiring Sinus E IE ptit i eeu Er 2 13 Table 2 4 Local Operator Interface Port Wiring 2 13 Table 2 5 PC Comm Port Wiring 2 14 Table 3 1 Communications Card 3 1 Table 3 2 EIA 232 RS 232 Communications Card WEBS niuis is 3 2 Table
2. 9 9 Support for a three wire 100 ohm Resistance Thermal Detector RTD input Internal lead acid batteries optional Local Operator Interface LOI port EIA 232 RS 232 EIA 485 RS 485 Comm 1 port Communications card using EIA 232 RS 232 or dial up modem on Comm 2 port optional 9 Extensive applications firmware Physically the FloBoss 103 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 or to an orifice plate via a three or five valve manifold The aluminum enclosure protects the electronics from physical damage and harsh environments Refer to Figure Figure and Figure 1 2 General Information Rev 10 02 FloBoss 103 Instruction Manual 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 inch pipe threaded holes for field conduit wiring and communications The DVS flange also has bracket holes that allow the enclosure and DVS to be mounted on a pipestand or mounting bracket Optional Solar Panel mo
3. Shutdown Sequence Operating Shutdn2 Figure 4 5 Removing the DVS from Service 8 Apply the low zero value For a pressure input this would typically be open to atmosphere 9 Enter the applied value in the Dead Weight Tester Value field of the Set Zero dialog Refer to Figure For static pressure on an absolute pressure device remember to enter the actual current atmospheric pressure such as 14 73 psi 4 6 Dual Variable Sensor Rev 10 02 10 11 12 13 14 15 16 FloBoss 103 Instruction Manual When the displayed Live Reading is stable click Set Zero to calibrate the zero reading The Set Span window then appears as in Figure 4 Sat Span Pork Line Press Dead weghtT aer Value ERES Live leading 1 006006 X Difference 12 00 x Lips At Span L 5e Span x Cancel Figure 4 6 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 on page 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 ENE Pont Line Pess Dead Wwede T ede Value
4. 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 103 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 2 5 4 RTD Wiring 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 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 wires connect to the three screw terminals designated RTD on the Termination Board The FloBoss 103 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 103 should be shielded wire with the shield grounded only at one end to prevent ground loops Ground loops cause RTD input signal errors Table b 3 displays the connections at the RTD terminals for the various RTD probes Table 2 2 RTD Signal Routing Terminal Designation 3 Wire RTD 2 Wire RTD RTD Signal positive input RTD RTD RTD Signal positive input RTD Jumper to RTD RTD RET Return reference RT
5. Sustained discrete outputs Momentary discrete outputs Slow pulse train outputs The I O termination board provides a Discrete Output channel located at Point Number B4 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 Vdc at 0 2 A maximum The Discrete Output on the I O termination board can be used in Toggle mode Latched mode Timed discrete output TDO mode Induction load solenoid or DO T i relay using a snuber diode ontro is highly recommended pt External power aa cas x i LA FET Switch Figure 5 6 Solid State Relays Discrete Outputs 5 5 Troubleshooting To troubleshoot an I O channel first check to see how the channel is configured using ROCLINK software If the configuration looks correct then simulate an input within the range of the input or force an output to be produced using ROCLINK software 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 results No field repair or replacement parts are associated with the I O Rev 10 02 Input Output 5 5 FloBoss 103 Instruction
6. 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 2 8 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual 2 4 1 1 System Solar Panel Sizing To determine solar panel output requirements first determine the solar insolation for your geographic area The map in Figure 2 3 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 Isr is the system current requirement Refer to Section pA on page 2 8 Larray Isr amps x 24 hrs Insolation hrs amps San A M ER NE Texas Oklahoma Arkansas annesseg lt A n ES Figure 2 3 Solar Insolation in Hours for the United States Nebragka TT Colorado NI 4 0 NOTE Refer to http www solar4power com solar power global maps html for global solar insolation maps Finally the number of solar panels can be determined using the following equation Number of Panels Iaray amps Ipane amps panel panels NOTE The I panei value varies depending on the type of solar panel installed Refer to the vendor s specifications for the solar panel being used Rev 10 02 Using the FloB
7. idend eie eked aides 1 9 Flowing Minutes 1 10 Function Sequence Tables 1 12 Sas Te eee eye A Ae e d 1 8 G Grid Impedance eee 2 4 Ground Rod ated eaves oh 2 4 Grounding Earth Ground eee 2 4 Ground Wiring eese 2 11 Wiring Requirements sese eee ee eee eee 2 4 H Hardware Watchdog esee 1 17 Hazardous Locations eeeeeeeeeee 2 3 History LOB ues egalement A 1 10 History POIntS 1i iit trt 1 10 Hourly Historical Log 1 11 1 2 I I O Bilbo 1 6 VO Wiring Requirements eene 2 5 Impedance Gid M 2 4 Input and Extension Calculation 1 9 Input Output Termination Points ee 5 1 Installation Cn delmes dat e tein 2 1 iei 1 2 15 MEI sese p ed ih iere 2 10 Instantaneous Rate Calculations 1 9 Integral Multiplier Value IIMA ose 1 9 Integral Value etre 1 10 DWV is cista tiU D EEUU RE 1 9 Isolation LE dont rp ERE TE 2 4 J Jumper Reset nete oe e pe SE EE 2 19 L LG aa hee 1 14 Liquid Crystal Display 1 7 SeclEDi edocet 1 14 Local Operator Interface LOL ere ideni 1 6 1 7 1 15 LOL Wig endete ni eade es 2 13 M My Yen M 1 14 Met Coosa cete Rhen E E 4 2 Microprocessor citar 1 5 1 14 Min Max Historical Log eese 1 11 Minute Histori
8. uH ET SIGNAL 4 TO 20 mA Figure 5 1 Current Signal on Analog Input NOTE When connecting the analog input channel to a voltage device be sure to remove the 250 ohm resistor from the analog input terminal block Al External powered device Low Power Voltage Output Sensor 4SIGNAL 1 TO 5 VDC m LT Figure 5 2 Voltage Signal on Analog Input 5 2 Input Output Rev 10 02 FloBoss 103 Instruction Manual 5 2 Analog Output The Analog Output AO 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 The Analog Output provided on the I O termination board connects as follows AO Positive IC Current control AO Common Figure shows wiring for the Analog Output AO 1 5V output Control 4 20mA current device External power Figure 5 3 4 20 mA Analog Output Current Control Voltage Signal In j 1 5V output Contre Externally powered Common id device Figure 5 4 1 5 Volts Analog Output Voltage Control Rev 10 02 Input Output 5 3 FloBoss 103 Instruction Manual 5 3 Discrete Input The Discrete Input DI monitors the status of relays solid state switches or open collector devices DI functions support discrete latched in
9. 2 Select the File gt Quick Setup gt Meter Calibration tab or select Meter gt Calibration 3 Click Freeze This opens the Meter Calibration window Refer to Figure 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 NOTE The Freeze Value function occurs automatically when using Quick Setup Mele Labhair Meter ID Meli Tag Meter El Freeze Values Dif Pressure Ska Fretnae Temperatuse IE REOT pams Fear Manual Mey v rape cost Figure 4 1 Meter Calibration Window Rev 10 02 Dual Variable Sensor 4 3 FloBoss 103 Instruction Manual 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 4 3 on page 4 6 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 Pont Line Pess Dead Wwedge T ede Value us a Live Facing cag X Diflerence zag x Lie 665 Span L Laden Y Dom Figure 4 2 Verify Calibration To log the Tester V
10. H HistoryLink Utility HistoryLink utility allows you to access and retrieve the 10 Minute History from the FloBoss 103 The HistoryLink utility supplements ROCLINK for Windows Software G 2 Glossary of Terms Rev 10 02 FloBoss 103 Instruction Manual hw Differential pressure I J UO 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 established 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 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 Rev 10 02 G
11. Inputs nec eite 2 16 Inputs a 1 16 Dial Up Modem Communications Cards 3 3 Will iei e ep e a WR e torte 3 3 Differential Pressure 1 9 4 2 Discrete Inputs etc ana 5 4 Win s cie ei o RE eti terr ees 5 4 Discrete Outputs eec erect teet ed 1 6 MATINS o ic oi beoe Dp e agree ere URS 5 5 DIVISION 2 5 concederet de hu ied 2 3 Doze Mode nere nderit rat s 1 17 Dual Variable Sensor sse 1 5 Configuration ei e eb Rt pet 4 2 Description iege cte tee qr tne reet tienne 4 1 DSi 4 1 Upstream Usage 4 2 E ET E2 and E5 siete deae rs 1 16 EIA 232 Communications Cards 3 1 Electrical Isolation 2 4 Electromagnetic Interference 2 4 Electronics Board see 1 7 2 1 EML xa costa mieten uti e hte deeds 2 4 Enclosure e etr ao eie ee 1 2 Energy iii edites ones a ene ees 1 10 Energy Accumulation seen 1 9 Environmental Requirements essere 2 2 Event LOB santa n ire dent 1 12 Expansion VO Poms sci hare a iiie 5 1 Extension Calculation sees ee eee 1 9 l 1 FloBoss 103 Instruction Manual F Figure 1 1 FloBoss 103 Flow Manager LCD 1 3 Figure 1 3 Wiring Terminals sess 1 4 Figure 2 1 Outline and Mounting Dimensions without Solar Patel L a nee ene 2 6 Figure 2 2 Outline and Mounting Dimensions with Sola
12. 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 103 should not be exposed to levels of vibration that exceed 2g for 15 to 150 Hz and 1g for 150 to 2000 Hz 2 1 2 Site Requirements Careful consideration in locating the FloBoss 103 on the site can help prevent future operational problems The following items should be considered when choosing a location 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 103 to minimize the length of signal and power wiring When using solar powered FloBoss 103 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 Antennas 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 To minimize interference with
13. The twisted pair and the shielding minimize signal errors caused by EMI electromagnetic interference RFI radio frequency interference and transients 2 4 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual 2 1 6 1 0 Wiring Requirements I O 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 2 2 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 antennas when using cellular phones or radios The FloBoss enclosure assembly can mount directly to an orifice plate via 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 for additional information The optional Blank plate is available when the FloBoss 103 is ordered without a DVS The
14. Transmit 6 TX 1 Do not use the LOI to power external devices 2 Transmit is the FloBoss 103 unit s EIA 232 RS 232 transmission that connects to the field device s receive To screw terminals Connection at PC COM Port Figure 2 4 Operator Interface Wiring Rev 10 02 Using the FloBoss 103 2 13 FloBoss 103 Instruction Manual Table 2 5 PC Comm Port Wiring Signal Pin Label Transmit 2 TX Receive 3 RX Ground 5 GND 1 Transmit TX connects to the FloBoss 103 unit s receive Receive RX connects to the FloBoss 103 unit s transmit 2 5 5 3 Optional Comm 2 Port Wiring The Comm 2 port provides communications access to the FloBoss 103 through an optional communications card Section B details the types of communications cards available for the FloBoss and how to make wiring connections to each one 2 6 Startup and Operation Before starting the FloBoss 103 perform the following checks to ensure the unit is properly installed Check the field wiring for proper installation Refer to Section b Make sure the input power has the correct polarity NOTE It is important to check the input power polarity before turning on the power 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 a
15. us Live Reading 2621406 X Dfierence 2ZIB2 E x Le ot A Spar 4 Se Mid K Cancel Y Done Figure 4 7 Set Midpoint 1 To perform a two point calibration click Done Calibration for this input is complete 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 When the Live Reading is stable click Set Mid 1 to calibrate this reading The display advances to the Set Midpoint 2 window as in Figure H Rev 10 02 Dual Variable Sensor 4 7 FloBoss 103 Instruction Manual 17 18 19 20 21 22 23 4 8 Pork Line Press Dead wesght T eie waka conn NN Live Pleading Feat X Difference 2157838 d Lig A Spa t sanz X pee y Dom Figure 4 8 Set Midpoint 2 To perform a three point calibration click Done Calibration for this input is complete To calibrate additional midpoints apply the desired pressure or temperature and enter the applied value in the Dead Weight Tester Value field 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 4 Pork Line Pess Dead Vwede T eie Vale ES Live Hendra Feat qifen HE x Lreg cx Epa r Se Hi K Cancel Y Done Figure 4 9 Set Midpoint 5 To perform a four point calibration click Done Calibration
16. 2 3 FloBoss 103 Instruction Manual 2 1 5 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 disconnect All equipment grounding conductors must provide an uninterrupted electrical path to the service disconnect The National Electrical Code Article 250 83 1993 paragraph c defines the material and installation requirements for grounding electrodes The National Electrical Code Article 250 91 1993 paragraph a defines the material requirements for grounding electrode conductors 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 The FloBoss 103 has two grounding screws inside the enclosure Proper grounding of the FloBoss 103 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 optio
17. 3 3 Dial Up Modem Communications Card WIEIDg unite e eU IR 3 3 Table 4 1 DVS Ranges eee 4 2 Ter perature ern certet tenere reete s 1 9 1 10 2 2 Terminal Connections sees ee eee eee eee eee 2 11 Termination Board sss 1 5 1 13 Input Output Points 5 1 Tests Avtomat aoee a is 1 16 Troubleshooting 2 17 no P C 2 18 Turbine Interface Module sss 4 10 V lor 2 2 Voltage ii ii arias iii 2 8 W Warm Stait T 2 19 Watchdog Software and Hardware sss 1 17 WATLING oc siot ete e eee ip e eoe epe ts 2 1 Analog Inputs eme 5 1 Analog Outputs essere 5 3 Communications essere 2 13 Communications Cards 3 2 3 3 Dial Up Modem Communications Cards 3 3 Discrete Inputs ieri eee 5 4 Discrete Outputs essere 5 5 EIA 485 Communications Cards 2 13 G n ral aaeoa gerse Oaeei ou 2 11 Grounding ien ee pee Rte eraa ias 2 11 1 3 FloBoss 103 Instruction Manual Grounding Requirements esses 2 4 LON onneen eiae iere EN 2 5 LOL ecd aces 2 13 POWE oi hk Raid es eee EE 2 12 RS 232 Communications Card sss 3 2 REED iaceo pod de tad ase uM n 3 2 12 Wire Gauge acetate teet 2 12 Z Zero Shift If you have comments or questions regarding this manual please direct them to your local sales representative or contact Eme
18. 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 2 2 4 Mounting the FloBoss 103 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 refer to Section 4 Dual Variable Sensor Refer to Figure and Figure Rev 10 02 Using the FloBoss 103 2 5 FloBoss 103 Instruction Manual 2 6 IVNIA3 L SCIL s IE DOC0417A Figure 2 1 Outline and Mounting Dimensions without Solar Panel Le 7 50 si IS 8 50 Max w all l D MN 15 50 Max I R
19. Manual 5 6 1 0 Termination Point Specifications 1 0 Termination Point Specifications ANALOG INPUT A Quantity Type Single ended voltage sense analog inputs current loop if scaling resistor is used Signal 1 to 5 Vdc software configurable 4 to 20 mA with 250 resistor installed across and terminals Accuracy 0 5 over 40 to 65 C 40 to 149 F range Isolation None Input Impedance 1 MQ Filter Single pole Resolution 10 bits Conversion Time 200 us Sample Period 1 0 second minimum NALOG OUTPUT Quantity Type 1 5 Vdc output or 4 20 mA current control Terminals positive voltage output and common or IC positive current point and common Resolution 8 bits Accuracy 0 1 of full scale output Reset Action Output goes to last value software configurable on power up warm start or on watchdog time out 5 6 Input Output DISCRETE INPUT Quantity Type Contact sense discrete input Terminals positive input COM negative input common Current Rating 35 uA in the active on state O uA in the inactive off state Isolation None Frequency 0 5 Hz maximum Sample Period 1 0 second minimum DISCRETE OUTPUT Quantity Type Solid state switch Terminals common Switch Rating 50 Vdc 0 2 A maximum Isolation 3000 volts ENVIRONMENTAL Meets the Environmental specifications of the FloBoss units in
20. Save The Save As dialog box appears Type the desired File name for the backup file or use the default puo Op M e Click Save The file is saved in the default directory C Program Files ROCLINK 800 Data unless you changed the directory 2 9 2 Replacing 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 cap cover 2 Place the power jumper located at J1 on the Battery Charger Board in the OFF position 3 Remove the four screws from the Battery Charger Board Remove the ribbon cable from the Battery Charger Board to the Backplane Board Remove the Battery Charger Board Replace the Battery Charger Board Replace the ribbon cable from the Backplane Board to the Battery Charger Board 9 NAR Replace the four screws from the Battery Charger Board 10 Place the power jumper located at J1 on the Battery Charger Board in the ON position 11 Replace the front
21. 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 The FCC label on the card provides the FCC registration number and the ringer equivalent This optional modem communications 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 EIA document TR302 2 88 08006 The initialization Config Command modem strings are 1200 Dial up Modem ATS 1S 7 2 2400 Dial up Modem ATS 1 3 2 1 Dial Up Modem Communications Card Wiring 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 de
22. 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 103 enters Sleep mode after one minute of inactivity on the communication ports Wake up from Sleep occurs when the FloBoss 103 receives a Timed interrupt from the Real Time Clock Signal from one of the communication ports Rev 10 02 General Information 1 17 FloBoss 103 Instruction Manual 1 7 FloBoss 103 Specifications Main Specifications PROCESSOR INFORMATION 32 bit running at 3 68 MHz Program Memory 2MB x 8 flash EPROM program mable 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 DIAGNOSTICS These conditions are monitored and alarmed sensor and RTD point fail battery and internal voltages internal temperature COMMUNICATIONS Local Operator Interface EIA 232 RS 232C format Software configured 1200 to 19200 bps baud rate selectable RS 485 Software configured 1200 to 19200 bps baud rate selectable Host RS 232 or Modem interface when optional communications card is installed Protocols ROC or Modbus Slave or optional Host ASCII or RTU POWER Internal Batteries Lead acid Rechargeable Nominal 6 2 Vdc 2 5 Amp hour Chargin
23. flow metering history and cannot be changed They are as follows 1 Flowing Minutes Today Accumulate archive type Differential Pressure Average Static or Line Pressure Average Flowing Temperature Average IMV Integral Multiplier Value or C Prime Average Pressure Extension or IV Integral Value Average Instantaneous Flow Accumulate NAA WD Instantaneous Energy Accumulate History Point 2 History Point 3 History Point 4 and History Point 6 are all set up as an Average Archive Type that employs one of the following techniques Flow dependent time weighted linear averaging default Flow dependent time weighted formulaic averaging Flow weighted linear averaging Flow weighted formulaic averaging The Averaging Technique is selected by using ROCLINK software In the Meter menu Setup screen click Inputs In the Inputs screen that appears select the desired Averaging Technique The selected Averaging Technique is applied to the meter inputs The seven user configurable history points 9 15 may be configured using ROCLINK software History point archival includes Archival of minute data from the last 60 minutes for 15 points Archival of 60 days of 10 minute data for 4 points Archival of 35 days of hourly data for 15 points Archival of 35 days of daily data for 15 points 9 Archival of minimum maximum historical data for today and yesterday 1 5 2 1 Minute Historical Log The F
24. input output I O termination points provide additional inputs and outputs for expanded monitoring and control applications I O includes an analog input AJ an analog output AO discrete input DI and discrete output DO 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 The AO permits current or voltage control Refer to Section 5 Input Output Termination Points Rev 10 02 General Information 1 7 FloBoss 103 Instruction Manual 1 4 4 FCC Information This equipment complies with Part 68 of the FCC rules On the modem assembly 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 servi
25. 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 G 4 Glossary of Terms Rev 10 02 FloBoss 103 Instruction Manual RTS Ready to Send modem communications signal RXD Received Data communications signal S Script An uncompiled text file such as keystrokes for a macro that is interpreted by a program to perform certain functions Typically scripts can be easily created or edited by the end user to customize the software SP Setpoint or Static Pressure SPK Speaker SRAM Static Random Access Memory Stores data as long as power is applied typically backed up by a lithium battery or supercapacitor T Z Tf Flowing temperature TLP Type of point Logical or point number and Parameter number TXD Transmitted Data communications signal Rev 10 02 Glossary of Terms G 5 FloBoss 103 Instruction Manual G 6 Glossary of Terms Rev 10 02 FloBoss 103 Instruction Manual INDEX 1 10 Minute History Log 1 11 1992 AGA Flow Calculations eene 1 9 3 32 bit CMOS Microprocessor eeeeeenn 1 5 A ACCeSSOFIeS za eite ta Autti havin ia he REED de 1 7 After Installing Component eese 2 20 S sorte tte ie 1 8 Alarm Lg secet ioi te teet be t eden 1 11 Analog Inputs Vol
26. which the board is installed including Temperature and Voltage Surge specifications CLASSIFICATION FCC Class A and CISPR 22 computing device normally open contact Rev 10 02 FloBoss 103 Instruction Manual GLOSSARY OF TERMS A AGA American Gas Association 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 Built 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 DP Differential Pressure DSR Data Set Ready modem communications signal Rev 10 02 Glossary of Terms G 1 FloBoss 103 Instruction Manual DTR Data T
27. 00 software must match one of the IDs stored in the FloBoss The Local Operator Interface port Security on LOI 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 5 4 Function Sequence Tables FST The FloBoss supports FST user programmability One FST program can be developed with 300 lines of code depending upon the requirements of the FST The FST code resides in static RAM and is backed up to flash memory when the Save Configuration function is issued through ROCLINK 800 software 1 5 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 the FloBoss 103 does not have two Discrete Outputs 1 12 General Information Rev 10 02 FloBoss 103 Instruction Manual 1 5 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
28. 3 provides information concerning the use of the FloBoss including installation requirements mounting the FloBoss 103 power requirements the termination board backplane board battery charger board Local Operating Interface LOI EIA 485 RS 485 communications wiring processes and troubleshooting Section B Communication Cards provide information and specifications for the optional EIA 232 RS 232 and dial up modem communication cards Section 4 Dual Variable Sensor describes the Dual Variable Sensor DVS included with the FloBoss 103 for sensing static pressure and differential pressure Section 5 VO Termination Points describes the optional input output termination points that provide additional inputs and outputs for implementing expanded monitoring and control applications lossary of Terms defines terms used in documentation opical Index alphabetically lists the items contained in this manual along with their page numbers 1 3 Additional Information The following manuals include additional information not found in this manual ROCLINK 800 Configuration Software User Manual Form A6121 Part Number D301159X12 Rev 10 02 General Information 1 1 FloBoss 103 Instruction Manual ROC FloBoss Accessories Instruction Manual Form A4637 Part Number D301061X012 1 4 Product Overview The FloBoss 103 is a 32 bit microprocessor based Electronic Flow Computer The FloBoss 103 Flow Manager elec
29. Boss 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 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 changes The Event Log is stored separately to prevent recurring alarms from overwriting configuration audit data 1 5 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 8
30. Communication Cards 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 the 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 A solar panel can be installed to recharge the backup batteries it connects to the CHG CHG inputs on the termination board 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 Refer to Section b Using the FloBoss 103 The expansion
31. D RET RTD RET 2 5 5 Connecting Communications Wiring The FloBoss communicates to external devices through its operator interface port LOD the EIA 485 RS 485 port Comm 1 the optional EIA 232 RS 232 Comm 2 port or the optional dial up modem Comm 2 port 2 12 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual 2 5 5 1 ElA 485 RS 485 Communications Wiring The EIA 485 communications provides for RS 485 signals on the Comm 1 port Wiring should be twisted pair cable The terminals and their functions are as follows Table 2 3 EIA 485 RS 485 Communications Wiring Pin Function Label 1 RS 485 B 2 RS 485 A 2 5 5 2 Local Operator Interface Port Wiring The Local Operator Interface LOI port provides connections for a built in EIA 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 The LOI port is intended for use with a PC running ROCLINK software This LOI port is compatible with EIA 232 RS 232 levels The Table b 4 shows the signal routing of the Termination Board connections Table 2 4 Local Operator Interface Port Wiring Signal Pin Label Common 1 GND LOI Power 2 PWR Common 3 GND Ready to Send 4 RTS Receive 5 RX
32. Form A6114 Part Number D301153X012 October 2002 FLOBOSS 103 FLOW MANAGER Instruction Manual Flow Computer Division EMERSON occ 1 lamas m ocess Managem C Website www EmersonProcess com flow FloBoss 103 Instruction Manual Revision Tracking Sheet October 2002 This manual is periodically to incorporate new or updated information The date revision level of each page is indicated at the bottom of the page opposite the page number A major change in the content of the manual also changes the date of the manual which appears on the front cover Listed below is the date revision level of each page Page Revision All Pages 10 02 applies to version 1 10 All Pages 04 02 applies to version 1 0 FloBoss and ROCLINK are marks of one of the Emerson Process Management companies The Emerson logo is a trademark and service mark of Emerson Electric Co All other marks are the property of their respective owners Fisher Controls International Inc 2002 All rights reserved Printed in the U S A While this information is presented in good faith and believed to be accurate Fisher Controls does not guarantee satisfactory results from reliance upon such information Nothing contained herein is to be construed as a warranty or guarantee express or implied regarding the performance merchantability fitness or any other matter with respect to the products nor as a recommendation to use any product or process in conflict w
33. NOTE The Freeze Value function occurs automatically when using Quick Setup 3 Click Freeze CES Caibi aliii HE Meter TD Meter Tag Mae Hi Freeze Vahe Col Fwzzum Lex DP Sis Pene Terpasiue Manual vel ves vn Cabasse renas Celtae yok x cues Figure 4 3 Meter Calibration 4 If you are calibrating a pressure input read the following Caution and then isolate the Dual Variable Sensor from the process If you are calibrating a temperature input proceed to Step 6 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 4 5 for the recommended sequence 5 If you are calibrating a pressure input set up the pressure calibrator and make the necessary connections to the DVS Rev 10 02 Dual Variable Sensor 4 5 FloBoss 103 Instruction Manual 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 Pressure Remains _ _
34. SIONS 0 7 in H by 2 0 in W by 2 75 in L 18 by 51 by 70 mm 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 3 4 Communication Cards ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity To 95 relative non condensing APPROVALS Meets CSA standards for hazardous locations as Model W40106 with enclosure plug Type 4 enclosure Class Division 1 Groups C 8 D Class Division 2 Groups A B C amp D Temp T3 Model W40112 with optional solar panel mast assembly Type 4 enclosure Class Division 1 Groups A B C amp D Temp T3 Rev 10 02 FloBoss 103 Instruction Manual 3 3 2 Dial up Modem Card Specifications Dial up Modem Card Specifications OPERATION Mode Full duplex 2 wire for dial up PSTN 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 0 196 Answer 2400 Hz 0 1 Receive Carrier Frequencies Originate 2400 Hz 7 Hz Answer 1200 Hz 7 Hz Telepho
35. SRBX parameter enabled each point must have the alarming parameter enabled and points must have the SRBX Set on Clear parameter set 1 5 7 Pass Through Communications Pass Through communications allow the user to configure a FloBoss 103 to pass communications from one communication port to another port if the message is not intended for that ROC For example a FloBoss 103 can be configured to have a radio connected to the LOI port and pass communication to other field devices with addresses that are connected to the ELA 485 RS 485 comm port In another example the communications would pass from a Dial up modem in COM2 out the radio connected on LOI Many combinations are possible of Pass Through communications utilizing the LOL COMI and COMZ ports NOTE COM2 may only use a Dial up modem if it is receiving Pass Through messages It cannot initiate phone calls to other field devices via Dial up modem 1 5 8 Protocol Automatic Switching The FloBoss 103 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 contact your local sales representative 1 5 9 User C Capability The FloBoss 103 has User C capability that allows special features to be written which can be loaded into the FloBoss 103 unit to enhance the function of the FloBoss 103 One example of User C program is Modbus Host program If this user program is loaded into th
36. a TOT e BOIL ges LORS DOC0418A Figure 2 2 Outline and Mounting Dimensions with Solar Panel and LCD Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual 2 2 2 Installing the FloBoss 103 on a Pipestand The following steps must be taken to install the FloBoss 103 on a 2 inch pipestand Install the pipestand per the directions included with the pipestand Remove the orifice meter run from service Install the FloBoss 103 on the pipestand using clamps or mounting brackets Connect the impulse lines Install the RTD and connect it to the termination board Connect the FloBoss 103 to the operator interface ROCLINK 800 software Power the FloBoss 103 unit If powered externally wire the unit to the external power source Calibrate the Dual Variable Sensor Calibrate the RTD O s SOT On E AI m mb e Connect the FloBoss 103 unit to any other external communication devices or networks mb mb Place the meter run in service and monitor with ROCLINK software for proper operation 2 2 3 Installing the FloBoss 103 on an Orifice Plate The following steps must be taken to install the FloBoss 103 on an orifice plate 1 Remove the orifice meter run from service N Install the FloBoss 103 on the meter run using a manifold and hardware to secure the FloBoss 103 to the orifice flanges Connect the impulse lines Install the RTD and connect it to the termination board Connect the FloBoss 103 to
37. alue 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 or 10 4 4 calibrate another input or to complete the verification or calibration When complete connect the Dual Variable Sensor back to the process 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 4 10 on page 4 9 Click Done to close the calibration window to cancel the freeze values and to begin using live readings for the flow calculations Dual Variable Sensor Rev 10 02 FloBoss 103 Instruction Manual 4 4 2 Calibrating the FloBoss Use ROCLINK 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 Perform the following steps 1 Launch ROCLINK software and connect to the FloBoss 2 Select the Quick Setup Meter Calibration tab or select Meter Calibration 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
38. ation concerning a specific installation contact your local sales representative NOTE The FloBoss 103 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 103 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 Rev 10 02 Using the FloBoss 103 2 1 FloBoss 103 Instruction Manual 2 1 4 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 103 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 must operate The FloBoss 103 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
39. bar or 0 to 3626 psi 250 bar depending upon the sensor installed You can re range each sensor through the calibration routines The turndown on the range should not be greater than the values in the Specifications table on page 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 software 1 Select ROC Information 2 Onthe ROC Information display under Units enable the Metric radio button 3 Click Apply The FloBoss automatically adjusts the units of the differential pressure static pressure RTD and enclosure battery temperature to the Metric mode To return to US imperial units enable the US field and save this change to the FloBoss NOTE The FloBoss adjusts the Units only You must manually change all values to the proper unit of measurement 4 2 Dual Variable Sensor Rev 10 02 FloBoss 103 Instruction Manual 4 4 Calibration Use ROCLINK software to perform calibration The procedure allows you to perform a 5 point minimum maximum and up to three intermediate points calibration of the DVS The Resistance Thermal Detector RTD is configured at Analog Input Point Number A3 4 4 1 Verifying Calibration ROCLINK software can verify the calibration to check if the DVS requires re calibration To verify perform the following steps 1 Launch ROCLINK software and connect to the FloBoss
40. cal Log 1 10 MONO iii 1 16 Mouliting tit ea 2 5 N National Electrical Code NEG sede neat eh eiie n 2 3 2 11 NEMA endet ss tetera ane as nes ES 2 2 O Operation eeen iii des 2 15 Operator Interface Port esee 1 15 LOL Es ori exe 1 7 Wi Sy eer n SEE 2 13 ODtODS sicot epe TT 1 7 ONCE i reote peni ie 4 1 OVERVIEW iioi e tremite pesti eee ee 1 2 Rev 10 02 FloBoss 103 Instruction Manual P Periodic Log See Hourly Historical Log 1 11 PID Controles 1 12 PUP UD otras 2 5 4 2 Polanty ss s ted ette bts 1 16 Ports COMME o eiecti ete n alias 2 13 Com Zee i eiee Ea E EEA aE AEN R Ea ET 3 1 Power Before Removing 2 17 ODeratilig 5o iiie iret E RA 1 16 R quiteiments o etie tie tes 2 3 2 8 Sleep Mode sitos ii 1 17 Solar POWER tna de ts 2 8 Surge A TS 2 4 WAIT a oen FG n es 2 12 Pressure Connections 4 2 Process Connections 2 5 4 2 PrOCeSSOt 5 etr RERO ERRARE 1 5 Processor STT etes 1 5 Product Overview 1 2 Public Switched Telephone Networks PSIN Sitios es mA ist 3 3 R Radio Frequency Interference sss 2 4 RAM onte mnt nn eta UO 1 5 RBX PUNCH OM vise eite tec PERO NER 1 13 Real Time Clock sse 1 16 Rebooting See Resetting the FloBoss ees 2 18 R palt anar nma oo ero RORIS OR 2 17 Reset Jumper ss n 2n e neri eres 2 19 Resetting the FloBoss
41. ce 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 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 5 Product Functions This section describes the functions of the FloBoss 103 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 Flow calculations for an orifice meter 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 9 9 Spontaneous Report by Exception SRBX capability 1 5 1 Flow Measurement The primary function of the FloBo
42. change eo 2 9 3 3 Jumper Reset The Reset jumper located on the LCD if installed or on the Battery Charger Board 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 2 18 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual This cold start does not include any of the clearing options available in a Cold Start performed using ROCLINK software Refer to Section 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 Refer to Section and perform the Backup Procedure 2 Unscrew the front end cap cover LCD end e om gt 7 Place the reset jumper located on the LCD if installed or on the Battery Charger Board at J2 in the RST position Cycle the power Remove the reset RST jumper and install it in the normal NORM position Replace the front end cap cover LCD end Refer to Section and perform the After Installing Components procedure This reset action loads the factory default values into the communication ports 2 9 4 After Installing Components After removing power to the FloBoss 103 and installing components as needed perform the following steps to s
43. containing ethylene gases or vapors of equivalent hazards Group D Atmosphere containing propane gases or vapors of equivalent hazards For the FloBoss 103 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 1 4 Power Installation Requirements Typical sources of primary power for FloBoss 103 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 103 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 mW 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 10 02 Using the FloBoss 103
44. e FloBoss 103 unit the FloBoss 103 can be configured to poll other Modbus slave devices 1 6 Product Electronics This section describes the FloBoss 103 Termination Board For Communication Cards refer to Section BJ For the Dual variable Sensor refer to Section H For I O Termination Points refer to Section 1 6 1 Termination Board Overview The Termination Board Figure components support the functionality of the FloBoss 103 and includes Local operator interface LOI EIA 232 RS 232 terminations EIA 485 RS 485 communications Comm 1 terminations Rev 10 02 General Information 1 13 FloBoss 103 Instruction Manual RTD input terminations Optional I O and terminations Remote charge terminations 9 Optional Comm 2 terminations 1 6 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 four 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 The FloBoss also has a 2 MB flash memory chip for storing the operating system factory code configuration parameters and user C programs 1 6 3 Liquid Crystal Display An optional two line Liquid Crystal Display LCD panel mo
45. end cap cover Rev 10 02 Using the FloBoss 103 2 17 FloBoss 103 Instruction Manual 2 9 3 Resetting the FloBoss 103 If you are experiencing problems with the FloBoss 103 that appear to be software related try resetting the FloBoss with a Warm Start Cold Start or Jumper Reset If these methods do not solve the problem contact your local sales representative 2 9 3 1 Warm Start This re initialization is performed by setting a parameter in the ROC Flags The re initialization includes the Tasks Database Communication Ports DVS and I O This does not change the current configuration of any parameters 1 Launch ROCLINK software Connect to the FloBoss 103 Select ROC Flags Select the Start Options Warm Start flag mee obo Apply to save the change 2 9 3 2 Cold Start This re initialization is performed by setting a parameter in the ROC Flags called Cold Start Options The re initialization includes the Tasks Database Communication Ports Sensor I O and restoring the saved configuration if there is one It also includes other items based upon the selection made in the Options screen 1 Launch ROCLINK software Connect to the FloBoss 103 Perform the Backup Procedure in Section Select ROC Flags Select the Cold Start flag Click the Cold Start Options button NOP H Select a type of Cold Start Select Restore Config and Clear All of above to reset all options Click OK 9 Apply to save the
46. erminal 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 E ESD Electronic Static Discharge EIA 232 Serial Communications Protocol using three or more signal lines intended for short distances 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
47. ese procedures in a hazardous area could result in personal injury or property damage During operation the FloBoss 103 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 detailed in Section b or by using ROCLINK software on a PC connected through the LOI port Remote monitoring is performed through Comm 1 or Comm 2 of the FloBoss using ROCLINK software or host system 2 7 Configuration The FloBoss 103 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 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 103 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 itis At a minimum the following items should be checked and configured as required Meter Setup and Gas Quality Quick Setup in ROCLINK File menu Clock Quick Setup History points check Averaging Technique on History Points 2 3 4 and 6 Analog Input points 1 to 3 for Dual Variable Sensor and RTD High Low Readi
48. for this input is complete To calibrate a third midpoint apply the desired pressure or temperature and enter the applied value in the Dead Weight Tester Value field When the Live Reading is stable click Set Mid 3 to calibrate this reading The display returns to the Meter Calibration window When the calibration for a selected point is complete you have the choice to calibrate another input or to complete the calibration If calibration is complete and you calibrated pressure inputs then read the following Caution and return the Dual Variable Sensor to service Dual Variable Sensor Rev 10 02 FloBoss 103 Instruction Manual 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 Pre Startup Startup Sequence start3 Figure 4 10 Returning the DVS to Service NOTE If you calibrated the Differential Pressure input refer to Section Zero Shift before completing the last step 24 Finally click Done to cause the calibration window to close cancel freeze values unfrozen and enable live readings for use in the flow calculations The Event Log records all calibration settings that were changed 4 4 3 Zero Shift If desired use the Zero Shift procedure after calibrat
49. g Input from optional Solar Panel 8 10 Vdc nominal External Power Charging Input 8 28 Vdc 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 SOLAR PANEL OPTIONAL Output 2 Watts 9 Volts nominal Size 114 mm by 159 mm 4 5 in by 6 25 in RTD INPUT Quantity Type Single input for a 2 or 3 wire RTD element Terminals RTD current source RTD signal positive input and RTD RET signal negative input Sensing Range 40 to 100 C 40 to 212 P Accuracy 0 56 C 1 0 F over sensing range includes linearity hysteresis repeatability Ambient Temperature Effects per 28 C 50 F 0 50 0 90 F for process temperatures from 40 to 100 C 40 to 212 F Filter Band pass hardware filter Resolution 10 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 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 flan
50. ge and sensor Pipestand Mounting Mounts on a 2 inch pipe with U bolt mounting kit optional WEIGHT 6 58 kg 14 5 lbs APPROVALS Meets CSA standards for hazardous locations as Model W40106 with enclosure plug Type 4 enclosure Class l Division 1 Groups C amp D Class l Division 2 Groups A B C amp D Temp T3 Model W40112 with optional solar panel mast assembly Type 4 enclosure Class Division 2 Groups A B C amp D Temp T3 1 18 General Information Rev 10 02 FloBoss 103 Instruction Manual SECTION 2 USING THE FLOBOSS 103 This section describes the FloBoss 103 Flow Manager focusing on function and wiring This section contains the following information Section Page 2 1 Installation Requirements 2 1 2 2 Mounting 2 5 2 3 Power Requirements 2 4 Solar Powered Installations 2 5 Connecting the FloBoss 103 to Wiring D C 2 6 Startup and Operation FO UN un 2 7 Configuration 2 8 Calibration 2 9 Troubleshooting and Repair N l2 Q Q 2 1 Installation Requirements This section provides generalized guidelines for successful installation and operation of the FloBoss Planning helps to ensure a smooth installation Be sure to consider location ground conditions climate and site accessibility as well as the suitability of the FloBoss application while planning an installation The versatility of the FloBoss allows it to be used in many types of installations For additional inform
51. igure Click Done to close the calibration window cancel the freeze values and cause the FloBoss to begin using live readings for the flow calculations 4 5 Troubleshooting No field repair or replacement parts are associated with the DVS Return the FloBoss to your local sales representative for repair or replacement NOTE The DVS should only be installed and removed at the factory If your DVS is not responding Launch ROCLINK software Select Configure gt I O gt AI Points Select Analog Inputs 1 Point Number A1 pe we D oS Ensure that the DVS is not in manual mode by setting the Scanning field to Enabled Refer to Figure 4 10 Dual Variable Sensor Rev 10 02 FloBoss 103 Instruction Manual Analog Input ME General Advanced Al Calibration Analog Inputs fi y B o IN H20 Scan Period 1 00 Low Reading EU o High Reading EL o Active Alarms f Copy Paste 2 Update v e X Cancel Apply Figure 4 12 Analog Input Scanning Enabled Point Number Tag Dit Pres Value Units Scanning Enabled C Disabled Alarming C Enabled HE Secs 5 Ifthe DVS is still not responding reset the DVS to factory defaults to clear invalid calibration data 4 6 Specifications Dual Variable Sensor DVS Specifications DIFFERENTIAL PRESSURE INPUT Range 0 250 in H O 0 62 2 kPa Reference Accuracy 0 075 of span with 10 1 turndown
52. includes linearity hysteresis and repeatability effects STATIC PRESSURE INPUT Range Either Absolute or Gauge 0 800 psia psig 0 5516 kPa 0 3626 psia psig 0 25 000 kPa Reference Accuracy 0 075 of span with 5 1 turndown includes linearity hysteresis and repeatability effects Stability 0 1 of upper range limit for 12 months PROCESS CONNECTIONS 1 4 18 NPT on 2 1 8 in centers located on bottom of Coplanar flange CONSTRUCTION 316 SST Wetted O rings are glass filled TFE Coupler is cast aluminum ENVIRONMENTAL AND OTHER SPECS Meets specifications described in the Main Specifications table Consult factory for special ranges and materials that may be available Rev 10 02 Dual Variable Sensor FloBoss 103 Instruction Manual 4 12 Dual Variable Sensor Rev 10 02 FloBoss 103 Instruction Manual SECTION 5 INPUT OUTPUT TERMINATION POINTS 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 The I O uses the microprocessor for monitoring control and acquisition of data from external devices connected to the I O channels The I O channels have removable plug in terminal blocks for field wiring I O includes Analog Input AI Analog Output AO Discrete Input DI Discrete Out
53. ing the pressure inputs 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 a Zero Shift adjustment 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 software is connected to the FloBoss 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 Rev 10 02 Dual Variable Sensor 4 9 FloBoss 103 Instruction Manual 3 Under the Diff Press input click Zero Shift to open the Set Zero Shift window shown in Figure Port l Dela an Figure 4 11 Set Zero Shift 4 Check the Reading to determine if you need to perform a Zero Shift correction 5 If the 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 F
54. ints Archival of 35 days of daily data for 15 points Archival of Min Max historical data for today and yesterday Power control wake up on ring on optional internal modem Logic and sequencing control using a user defined Function Sequence Table FST Closed loop PID control capabilities requires optional I O termination points 9 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 6 General Information Rev 10 02 FloBoss 103 Instruction Manual 1 4 3 Options and Accessories The FloBoss 103 supports the following options and accessories Communication cards for either EIA 232 RS 232 or dial up modem communications 4 point Input Output I O termination points Local Operator Interface LOI cable Liquid Crystal Display LCD with two line alphanumeric viewing Solar panel mast assembly 9 Blank plate 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 FIA 232 RS 232 for asynchronous serial communications Dial up modem for communications over a telephone network Refer to Section B
55. it data signals that data is being transmitted from the communications card Rev 10 02 Communication Cards 3 1 FloBoss 103 Instruction Manual 3 1 1 EIA 232 RS 232 Communications Card Wiring 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 EIA 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 displays connector signals and their functions Table 3 2 EIA 232 RS 232 Communications Card Wiring Pin Signal Label 1 Signal Common Negative GND 2 Switched Power PWR 3 Ground GND 7 Request to Send RTS 8 Tip Receive data RX 9 Ring Transmit data TX 1 GND at Pin 1 and GND 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 103 unit s EIA 232 RS 232 transmission that connects to the field device s receive 3 2 Communication Cards Rev 10 02 FloBoss 103 Instruction Manual 3 2 Dial up Modem Communications Card The dial up modem communications card supports
56. ith any patent Fisher Controls reserves the right without notice to alter or improve the designs or specifications of the products described herein i Rev 10 02 FloBoss 103 Instruction Manual Table of Contents SECTION 1 GENERAL INFORMATION eese ee eee eene sns sn setas sens sensn Lil Section a lt 71 1 PR een 1 2 Manual OVetrvIe Wicca died tee nitide aie te d dee drain 1 3 Additional b ree Te aee aai aeaiaioe 14 Product Over vie Weir caia 1 5 Product FunctiONS occcccncnnnnononononononenonenoninonononononenonononononenonononononenonenonanonononenonenonanonanonananinenanons 1 6 Product BIecttOll6S eee teet e ett ios 1 13 1 7 FOB oss 103 Spec cata A das SECTION 2 USING THE FLOBOSS 103 4 eere eese eese eene eene n enun 2 l Installation Requirements uie utes nue is 22 NI 2 3 P wer QUISO T ient 2 Solar Powered Installation 23 Connecting the FloBoss 103 to Wiring osasuna S Startup AO D TOUR a it 2 17 Configuration TT O H Ee loci M 20 TOURS DONS and Ih GMail ou pee vo EPIO one nine SECTION 3 COMMUNICATION CARDS eee eee eves esse resse resse ad Seral Communications CAS querentes DN pad de de ne 3 2 Dial up Modem Communications Card 3 2 Communication Cards Specifications eo reine tob ei ttr t GE INN o ap
57. loBoss 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 10 General Information Rev 10 02 FloBoss 103 Instruction Manual 1 5 2 2 10 Minute Historical Log The FloBoss has a 10 minute historical log for up to four 4 history points that stores 60 days of 10 minute data The four 4 10 Minute history points include differential pressure static pressure flowing temperature and an auxiliary Analog Input 1 5 2 3 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 5 2 4 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 configured for FST contr
58. lossary of Terms G 3 FloBoss 103 Instruction Manual 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 Pf Flowing pressure PC Personal computer Point Software oriented term for an I O channel or some other function 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 R RAM Random Access Memory In a FloBoss it is used to store history data most user programs and additional configuration data RFI Radio frequency interference RI Ring Indicator modem communications signal ROC Remote Operations Controller is a microprocessor based unit that
59. m current load Isr on the batteries ba System Requirement Isr amps x Reserve hrs amp hrs 2 5 Connecting the FloBoss 103 to Wiring The following paragraphs describe how to connect the FloBoss 103 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 2 10 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual 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 wrist strap 2 5 1 Making 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 44 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 Ib in NOTE Take Caution Do not over torque the connector scre
60. n Manual Standard Operator interface port EIA 232 RS 232 LOI Standard EIA 485 RS 485 Communications Comm 1 Optional EIA 232 RS 232 or Dial up Modem Communications Comm 2 1 6 4 1 Local Operator Interface Port LOI The Local Operator Interface LOI port provides direct communications between the FloBoss 103 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 you to access the FloBoss 103 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 EIA 232 RS 232 serial interface which is capable of up to 19 200 bps operation The operator interface port supports ROC or Modbus protocol communications The LOI also supports the log on security feature of the FloBoss 103 if the Security on LOI is Enabled in ROCLINK software 1 6 4 2 EIA 485 RS 485 Serial Communications Comm 1 Use Comm 1 to monitor or alter the FloBoss 103 from a remote site using a host or ROCLINK software Comm 1 supports baud rates up to 19 2K bps Comm 1 also supports the log on security feature of the FloBoss 103 if the Security on Comm 1 is Enabled in ROCLINK software Comm 1 sends and receives messages using the ROC or Modbus protocol Comm 1 is ca
61. n 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 8 volt 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 103 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 converter accessories may be used to minimize the number of separate power sources required for an installation Solar arrays generate electrical power for the FloBoss 103 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 Refer to Section
62. nal 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 The grounding installation method for the FloBoss 103 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 103 could be flange mounted or saddle clamp mounted directly on the meter run and grounded with a ground rod or grid system On pipelines without cathodic protection the pipeline itself may provide an adequate earth ground and the FloBoss 103 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 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 The recommended cable for I O signal wiring is an insulated shielded twisted pair
63. nd a 2 or 3 wire 100 ohm Resistance Thermal Detector RTD input interface Three diagnostic analog inputs AI monitor the battery voltage logical voltage and enclosure battery temperature Refer to Section Y for more information The Local Operator Interface LOI 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 the PC running ROCLINK 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 EIA 232 RS 232 or dial up modem communication card activates Comm 2 Refer to Section 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 ROCLINK 800 User Manual Form A6121 for details concerning software capabilities 1 4 2 Firmware The firmware contained in flash ROM on the termination board determines the functionality of the FloBoss and includes 1992 AGA 3 flow calculations with user selectable AGA8 compressibility Detail Gross I or Gross II for a single meter run Memory logging of 240 alarms and 240 events Archival of minute data from the last 60 minutes for 15 points Archival of 60 days of 10 minute data for 4 points Archival of 35 days of hourly data for 15 po
64. ne 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 DIMENSIONS See Serial Card Specifications Rev 10 02 OPERATION CONTINUED 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 ENVIRONMENTAL See Serial Card Specifications POWER REQUIREMENTS 3 3 Vdc 0 25 W maximum supplied by processor board APPROVALS Meets CSA standards for hazardous locations as Model W40106 with enclosure plug Type 4 enclosure Class Division 1 Groups C amp D Class Division 2 Groups A B C amp D Temp T3 Model W40112 with optional solar panel mast assembly Type 4 enclosure Class Division 2 Groups A B C amp D Temp T3 FCC registered modem chip Registration Number US FSTMTOOBIOO REN 0 0B Registration Holder XECOM INC Communication Cards 3 5 FloBoss 103 Instruction Manual 3 6 Communication Cards Rev 10 02 FloBoss 103 Instruction Manual SECTION 4 DUAL VARIABLE SENSOR This section describes the orifice metering sensor called a 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 p
65. ng EU Scanning Enabled alarm setup and such 9 Communication Comm Ports Security 9 SRBX if alarm call in is required LCD User List for local display of additional values Rev 10 02 Using the FloBoss 103 2 15 FloBoss 103 Instruction Manual 2 8 Calibration 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 logic voltage El battery voltage E2 and board battery temperature E5 are not designed to be calibrated With the optional I O termination points installed the Analog Input can be calibrated using ROCLINK software The built in inputs that are supported with the 5 point calibration are Differential pressure located at AI Point Al Static pressure located at AI Point A2 RTD temperature located at AI Point A3 These inputs are assigned to the first three Analog Input points The calibration procedure for these inputs is described in Section H Dual Variable Sensor 2 9 Troubleshooting and Repair Troubleshooting and repair procedures help you replace the batteries and reset the FloBoss 103 unit Return faulty boards to your local sales representative for repair or replacement To troubleshoot communications cards refer to Section The follo
66. notes 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 displays the connector signals and their functions Table 3 3 Dial Up Modem Communications Card Wiring Pin Signal Label 8 Tip Transmit data TX 9 Ring Receive data RX NOTE Tip and Ring are the telephone interface signals Rev 10 02 Communication Cards 3 3 FloBoss 103 Instruction Manual 3 3 Communication Cards Specifications The following subsections list the specifications for each communications card 3 3 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 DIMEN
67. od ed pr dori dandas SECTION 4 DUAL VARIABLE SENSOR e eere eee eee eene eene tnn tnnano SHEER urit m 2 Process Connections dans rond nn ain RR M qat MEI NDS nU AO 4A Calbration 4 5 Trouble h nn Deuda Esa den EE SEE AS SOS CMICANIONG PEOR SECTION 5 INPUT OUTPUT TERMINATION POINTS SENE eds der NP a resoa E aaa aa eainiie 5 2 Analog BI E 3 3 Discrete MPUl EE Tp KE Discrete OUD tcI TS 5 5 Troubleshooting eR 5 6 10 Termination Point SpectficBllODs necne Reese caca Rev 10 02 Table of Contents iii FloBoss 103 Instruction Manual GLOSSARY OF TERMS seems INDEX dq I 1 iv Table of Contents Rev 10 02 FloBoss 103 Instruction Manual SECTION 1 GENERAL INFORMATION 1 1 Section Contents This section contains the following information Section Page 1 2 Manual Overview 1 1 1 3 Additional Information 1 1 1 4 Product Overview 1 2 1 5 Product Functions 1 8 1 6 Product Electronics 1 13 1 7 FloBoss 103 Specifications 1 18 1 2 Manual Overview This manual describes the FloBoss 103 Flow Manager part of the family of FloBoss flow computers manufactured by Emerson Process Management This manual includes the following sections Section 2 Using the FloBoss 10
68. ogical voltage E2 battery voltage E5 board battery temperature 1 6 8 Automatic Self Tests The FloBoss 103 performs the following self tests on a periodic basis Battery low and battery high Software and hardware watchdog RTD automatic temperature compensation Sensor operation 9 Memory validity The FloBoss 103 will operate with its internal batteries down to 5 4 VDC 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 103 is operating in the optimum mode 1 16 General Information Rev 10 02 FloBoss 103 Instruction Manual 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 6 seconds then the watchdog timer forces the FloBoss 103 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 103 automatically shuts down The FloBoss 103 monitors its orifice metering Dual Variable Sensor for accurate and continuous operation 1 6 9 Low Power Mode Sleep mode is used to place the CPU in a low power mode The
69. olled logging 1 5 2 5 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 1 5 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 the oldest entry when the buffer is full The Alarm Log provides an audit history trail of past alarms The Alarm Log is stored separately to prevent recurring alarms from overwriting configuration audit data Rev 10 02 General Information 1 11 FloBoss 103 Instruction Manual 1 5 2 7 Event Log The Event Log contains changes to any parameter within the Flo
70. on 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 Table displays the DVS ranges Rev 10 02 Dual Variable Sensor 4 1 FloBoss 103 Instruction Manual Table 4 1 DVS Ranges Range Differential Pressure P1 Pressure Rating Rating psia Range 1 250 in H2O 800 psi Range 2 250 in H2O 3000 psi NOTE Consult your local sales representative for special ranges 4 2 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 4 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 4 3 Configuration Use ROCLINK configuration software to configure the DVS The differential pressure is configured at Analog Input Point Number Al The static pressure gauge or absolute is configured at Analog Input Point Number A2 The defaults contained within the DVS are the initial pressures read The initial range of the differential pressure is 0 to 250 inches 0 to 6350 mm of water and the static pressure is either 0 to 800 psi 55 15
71. oss 103 2 9 FloBoss 103 Instruction Manual NOTE The current accepted by the FloBoss 103 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 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 2 1 2 Batteries Batteries provide power for the FloBoss 103 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 When the FloBoss 103 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 to 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 by the amount of reserve time required Compute Isr as described in Section Power Requirements The equation is as follows To determine the system capacity requirements multiply the syste
72. pable 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 EIA 485 RS 485 specifications for differential asynchronous transmission of data over distances of up to 1220 m 4000 feet The EIA 485 RS 485 drivers are designed for true multi point applications with multiple devices on a single bus The default values for the EIA 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 2K To enable or disable the Comm 1 port select Configure Radio Power Control and select the Enable Disable radio button under Radio Power Control enable is default 1 6 4 3 Optional Communication Cards Comm 2 Two plug in communication cards allow you to customize the FloBoss 103 installation for most communication requirements The communication cards 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 B for additional information One of the following card types can be accommodated EIA 232 RS 232 for asynchronous serial communications baud rate up to 19 2K Dial up modem for communications over a tele
73. perature and calculates the IV 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 Averages of the inputs are recorded to allow monitoring during no flow periods Instantaneous Rate Calculations The instantaneous value of the 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 Integral Value IV The instantaneous flow rate is used with the volumetric heating value to compute the instantaneous energy rate 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 configured 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 Rev 10 02 General Information 1 9 FloBoss 103 Instruction Manual 1 5 2 History Points A total of fifteen history points may be logged and accessed in the FloBoss 103 The first eight history points are pre configured for
74. phone network default at 2400 baud Rev 10 02 General Information 1 15 FloBoss 103 Instruction Manual 1 6 5 RTD Input The FloBoss 103 supports a direct input from a Resistance Thermal Detector RTD sensor to measure flowing temperature The RTD has a measurement range of 40 to 100 C 40 to 212 F The terminals for the RTD wires are labeled 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 1 6 6 Real Time Clock The real time clock provides the FloBoss 103 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 6 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 software The three values are available as the following Analog Input AI points El l
75. put DO This section contains the following information Section 5 1 Analog Input 5 2 Analog Output 5 3 Discrete Input 5 4 Discrete Output 5 5 Troubleshooting Oy Ln WIL ga 5 6 VO Termination Point Specifications 5 1 Analog Input The Analog Input AI monitors current loop and voltage input devices The A D signal input range is 1 to 5 volts with 10 bit resolution The AI is located at Point Number B1 in ROCLINK software The terminals for connecting analog input wiring include AH Positive Input Al Negative Input Common The Analog Input has two field terminals per channel A 250 ohm scaling resistor is required for use between the and analog input terminals when 4 to 20 mA is implemented The terminal is the positive signal input and the terminal is the signal common These terminals accept a voltage signal in the 1 to 5 volt range Because the terminal is internally connected to common the analog input channels function as single ended inputs only Rev 10 02 Input Output 5 1 FloBoss 103 Instruction Manual Current inputs of 4 20 mA can be used with the addition of a 250 ohm resistor across the input terminals When wiring a 4 20 mA current signal leave the 250 ohm resistor installed between the and terminals Refer to Figure Al 4 20mA transmitter External power 250 OHM
76. puts and discrete status inputs The discrete input provided on the I O termination board is located at Point Number B3 and connects as follows DI Positive DI Common The Discrete Input operates by providing a closed contact across terminals and Refer to Figure 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 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 5 Discrete Input Wiring 5 4 Input Output Rev 10 02 FloBoss 103 Instruction Manual 5 4 Discrete Output The Discrete Output DO provides a solid state switch to control relays and power small electrical loads The DO circuitry is optically coupled to help isolate the processor board from the input signal Refer to Figure DO functions include
77. r Panel and LCD esses 2 6 Figure 2 3 Solar Insolation in Hours for the United iri M 2 9 Figure 2 4 Operator Interface Wiring 2 14 Figure 4 1 Meter Calibration Window 4 3 Figure 4 10 Returning the DVS to Service 4 0 Figure 4 11 Set Zero Shift 4 10 Figure 4 12 Analog Input Scanning Enabled 4 11 Figure 4 2 Verify Calibration esses 4 4 Figure 4 3 Meter Calibration esses 4 5 Figure 4 4 Set Zero Calibration 4 6 Figure 4 5 Removing the DVS from Service 4 6 Figure 4 6 Set Span sseni einne anii 4 7 Figure 4 7 Set Midpoint 1 esses 4 7 Figure 4 8 Set Midpoint 2 4 8 Figure 4 9 Set Midpoint 3 4 8 Figure 5 1 Current Signal on Analog Input 5 2 Figure 5 2 Voltage Signal on Analog Input 5 2 Figure 5 3 4 20 mA Analog Output 5 3 Figure 5 4 1 5 Volts Analog Output Voltage Control 5 3 Figure 5 5 Discrete Input Wiring sess 5 4 Figure 5 6 Solid State Relays Discrete Outputs 5 5 Piri Ware sc sciet ia 1 6 1 8 Flash Memory 1 14 Flash ROM utes eteo id 1 5 FloBoss Flow Manager 1 1 ElowWos sas nine neu es Re SRE A 1 10 Flow and Energy Accumulation 1 9 Flow Measurement essent 1 8 Flow Time
78. radio or cellular communications locate the FloBoss 103 away from electrical noise sources such as engines large electric motors and utility line transformers Locate the FloBoss 103 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 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual 2 1 3 Compliance with Hazardous Area Standards The FloBoss 103 without optional mast kit has hazardous location approval for Class I Division 1 Groups C to D exposures The FloBoss 103 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 surrounding 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 amp B Atmosphere containing hydrogen gases or vapors of equivalent hazards Group C Atmosphere
79. reas 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 6 4 Startup The FloBoss 103 ships with the reset jumper in the OFF positions to prevent unnecessary battery drainage To apply power to the FloBoss 103 1 Unscrew the front end cap cover LCD end 2 Place the power jumper located on the LCD if installed or located at J1 on the Battery Charger Board in the ON position 3 Screw the top end cap cover LCD end 2 14 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual After the FloBoss 103 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 the Troubleshooting and Repair on page 2 16 for possible causes 2 6 2 Operation Once startup is successful it is necessary to configure the FloBoss 103 to meet the requirements of the application ROCLINK 800 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 103 through its LOI port must be performed only in an area known to be non hazardous Performance of th
80. rovide a temperature input to the FloBoss this input comes directly into the FloBoss by means of the built in RTD input Refer to Section 2 Using the FloBoss This section contains the following information Section Page 4 1 Description A 1 4 2 Process Connections m 4 3 Configuration m 4 4 X Calibration 4 3 od 4 5 Troubleshooting 1 Ra Ea 4 6 Specifications 4 1 Description 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 this in turn mounts with four bolts to the bottom of the FloBoss enclosure The DVS cable plugs directly into the backplane board 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 initializati
81. rson Process Management Flow Computer Division Marshalltown IA 50158 U S A Houston TX 77065 U S A Pickering North Yorkshire UK YO18 7JA Website www EmersonProcess com flow 4 Index Rev 10 02
82. s install directly onto the backplane board and activate the host port Comm 2 when installed You may use either the EIA 232 RS 232 Serial Communications Card or the Dial up Modem Communications Card but not both This section contains the following information Section 3 1 Serial Communications Card 3 2 Dial up Modem Communications Card DEE 3 3 Communication Cards Specifications NOTE To enable disable the Comm 2 port select Configure gt Radio Power Control and select the Enabled Disabled radio button under Radio Power Control 3 4 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 feet The EIA 232 RS 232 communications card provides transmit receive and modem control signals The EIA 232 RS 232 communication card activates Comm 2 The EIA 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 19200 bps The EIA 232 RS 232 communications card signals include RX TX and RTS signal control lines Refer to Table Table 3 1 Communications Card Signals Signals Action The request to send signals that the modem is ready to transmit The RXD receive data signals that data is being received at the communications card RTS The TXD transm
83. ss 103 is to measure the flow of natural gas through an orifice in accordance with the 1992 American Petroleum Institute APT and American Gas Association AGA standards 1 8 General Information Rev 10 02 FloBoss 103 Instruction Manual The primary inputs used for the orifice metering 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 1 5 1 1 1992 Flow Calculations for Orifice Metering The 1992 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 1992 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 recalculation 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 tem
84. tage Signal nce Het eerte 5 2 Wiring I O Termination Board 5 1 Analog 61T ette 5 3 Antennas c eec nn 2 2 S Rs De iecit peti ient cic 1 8 APL Chapter 21 T ae sine eee 2 8 APPIOVALS cite e pter nee tonis 2 3 Archive PY pe ie mine ert e OR 1 10 AT Command 5 metere 3 3 Automatic Self Tests 1 16 B Backplane Board vicio tees 1 5 Backup Battery scsi ia esce teet dede 1 5 Backup Procedures After Installing Components 2 20 Battery ARR essere seeren estesi ks tsip iE oi aeea 2 10 ONE A LT SR TO 1 7 C Calculations 1992 BlOW 5 c oet rit RE pem es 1 9 Input and Extension 1 9 Instantaneous Rate 1 9 Cahbr ti n 3 3 d dra etnia 2 16 VO Channels ss 2 15 Cathodic Protection sese 2 4 Charger Board ep RED UR OESTE oo ies 1 5 Class Lisette te 2 3 Clock RealcTime uote 1 16 Cold R eot epeis 2 19 Comm T sinon EE 1 6 1 15 bist 2 13 Rev 10 02 Comm lex 1 6 1 15 3 1 Comm Port Operator Interface 1 15 Communication Ports sss 1 14 Communications ETT UR Een 2 13 Communications Cards sss esse 1 7 1 15 Descriptions ii Yar 79520 eter 3 1 Dial Up Modern sentent 3 3 BIA 232 iss eotetnomb eo eR 3 1 Specific ti ns 15 er ome ers 3 4 WarIDg ieee lise a Ra lie poe 3 2 3 3 Configuration 2 16 Dual Variable Sensor 4 2 D Daily Historical Logs sese 1 11 Diagnostic 35a peo ED Red PS 1 6 Analog
85. tart your FloBoss 103 and reconfigure your data The procedure assumes you are using ROCLINK software Ensure all input devices output devices and processes 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 103 by inserting the CHG CHG power terminal 2 Launch ROCLINK software log in and connect to the FloBoss 103 o A Ug m os 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 Download From the Open dialog box select the backup configuration file has extension FCF Select the portions of the configuration you want to download restore Click Download to restore the configuration Rev 10 02 Using the FloBoss 103 2 19 FloBoss 103 Instruction Manual 2 20 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual SECTION 3 COMMUNICATION CARDS The communications cards provide communications between the FloBoss and a host system or external devices The communications card
86. 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 the excess of five years The orifice metering Dual Variable Sensor DVS measures static pressure and differential pressure 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 Dual Variable Sensor An RTD temperature probe typically mounts in a thermowell on the meter run The RTD measures the flowing temperatures under a constant current drive 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 Rev 10 02 General Information 1 5 FloBoss 103 Instruction Manual The built in inputs and outputs I O on the FloBoss consist of a port for a Dual Variable Sensor DVS a
87. the operator interface ROCLINK 800 software Power the FloBoss 103 unit If powered externally wire the unit to the external power source Calibrate the Dual Variable Sensor Calibrate the RTD SAUS c oT ed o Connect the FloBoss 103 unit to any other external communication devices or networks 10 Place the meter run in service and monitor with ROCLINK software for proper operation Rev 10 02 Using the FloBoss 103 2 7 FloBoss 103 Instruction Manual 2 3 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 mW 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 incorporate 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 Isp divide Psp by the system voltage V of 12 volts Isp Psp 12V Amps 2 4 Solar Powered Installations Solar power allows installation of the FloBoss 103 i
88. tronically measures monitors and manages gas flow for a single meter run using orifice plate differential pressure 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 103 performs minute 10 minute hourly periodic daily and minimum maximum historical data archrivals The FloBoss 103 is the perfect solution to electronically replace traditional paper charting The FloBoss records the corrected gas flow across an orifice plate stores the data and has the ability to send the data to a remote host The FloBoss 103 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 103 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 512K of battery backed up RAM Random Access Memory storage Integral Dual Variable Sensor DVS for static pressure and differential pressure measurement using orifice metering
89. unts here Field Conduit Entry Liquid Crystal Display LCD Field Conduit Entry Dual Variable Sensor DVS Figure 1 1 FloBoss 103 Flow Manager LCD gt NOTE Your FloBoss may be positioned in a different direction Rev 10 02 General Information 1 3 FloBoss 103 Instruction Manual Battery Pack If Ordered Battery Charger Board Optional Liquid Crystal Display LCD 1 4 gt mm El 8 Z mai o 2 29 Z Qt EM S E 55 2 FSRMROOBIOO IF MODEM INSTALLED REN 0 0B RTD RET CHG gt 1 S SIIS SIIS OV COM1 2 Figure 1 3 Wiring Terminals General Information Termination Board Connectors Processor Board Backplane Optional Communications Card RAM Backup Rev 10 02 FloBoss 103 Instruction Manual 1 4 4 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 and the battery charger board Refer to Figure The termination board provides connections to the field wiring and is located in the terminal side of the explosion proof housing Refer to Figure Connections include the power s
90. unts on the Battery Charger Board The LCD allows you to view the current and past gas volumes on site without requiring a computer 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 cannot be configured and show values for time date and battery condition The next five displays are factory configured to show certain flow parameters but you may change their configuration Refer to Section History Points on page 1 10 To configure the list of values for the LCD panel 1 Connect the FloBoss to a computer running ROCLINK software 2 Select Configure LCD User List Setup from the menu 3 Select a Data Point and click the Point Definition lee button 4 Select the Point Type Logical Number and Parameter for the value you desire to display on the LCD Click OK 5 Enter a 5 character alphanumeric Description 6 Click Apply 7 Continue adding values as necessary When finished adding values click OK 1 6 4 Communications Ports The FloBoss provides two standard and one optional communication ports 1 14 General Information Rev 10 02 FloBoss 103 Instructio
91. upply Local Operator Interface LOI communications Comm 1 EIA 485 RS 485 communications optional Comm 2 EIA 232 RS 232 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 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 functions for the I O of analog conversion originate on the processor board The processor board also called the central processor unit CPU provides the Serial Peripheral Interface SPI buss Liquid Crystal Display LCD drivers the Dual Variable Sensor DVS 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 512K of built in static random access memory SRAM for storing data and 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
92. wing tools are required for troubleshooting IBM compatible personal computer ROCLINK 800 software 2 9 1 Backup Procedure Before Removing Power Perform this backup procedure before removing power to the FloBoss 103 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 2 16 Using the FloBoss 103 Rev 10 02 FloBoss 103 Instruction Manual 2 Ensure that the configuration is saved in flash memory by performing a Write to Internal Config Memory ROC Flags This saves all configuration settings including the current states of the ROC Flags and calibration values 3 Select ROC Collect Data and select the All checkbox Click OK This action saves event logs evt alarm logs alm report data det hourly logs pdb and daily day logs You can specify your own file name and path if desired Backup the 10 minute history file Select File gt
93. ws The inserted wires should have a minimum of bare wire exposed to prevent short circuits Allow some slack when making connections to prevent strain 2 5 2 Connecting Enclosure Ground Wiring The FloBoss 103 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 2 5 3 Connecting Main Power Wiring The FloBoss 103 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 mW not including battery charging NOTE It is important to check the input power polarity before turning on the power The terminals are labeled CHG for positive power connection and CHG for negative power connection on a label on the termination board Table 2 1 CHG and CHG Pin Signal Description 1 CHG Battery 8 0 to 28 V Power 2 CHG Battery Common Rev 10 02 Using the FloBoss 103 2 11 FloBoss 103 Instruction Manual 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 Make sure the hook up polarity is correct

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