iCHEM™ ROC 107 USER MANUAL
Contents
1. DU CR ad enews ER ECT RR AL 12 2 2 Loading ROC 107 14 2 3 Licensing iChem ROC 107 16 2 4 Saving and Loading Configuration 05 18 2 4 1 Saving Points and 5 5 18 2 4 2 Loading Previously Saved 5 5 19 3 Setup and 20 3 1 Mapping 1 0 20 3 1 1 Tank Level TLP S aci ah do deu oko aaa CE GE OR b E Ed e E C 21 OU PD Melor TLP S 22 3 1 3 ae tte te ety tere re re an rey yt a ees ee AC 23 3 1 4 Emergency Shutdown ESD 24 3 1 5 Pump Control DOUT 25 D LOFOWSWIC 26 3 2 Calibrating the Flow 27 3 2 1 Calibra ng the PD Molaf 27 3 2 2 Calibrating the Tank 2 3 2 3 Calibrating the Injection2. 28 3 3 Setting Up Cycles and Volume 28 3 3 1 Setting Daily 29 3 3 2 SUNG COMTACT 29 3 3 3 Setting Pump Cycle Interval 29 Table of Contents 2 ROC 107 User Manual 4 Controls and Features 30 4 1 Operation 5 30 4 1 1 AUTO hh aa 30 4 1 2 Manual 0 30 4 1 3 OFF and Calibrate 5 31 4 2 Pump Status Panel auaa 31 4 2 1 Pump Status Fields and Functions 31 4 2 2 Emergency Shut Down 32 4 2 3 ON OFF Buttons 32 4 2 4 Custom Batch 05 32 33 4 3 1 Alarm Messages Meanings 33 4 4 Pump Program 34 4 4 1 PD Meter 4 35 4 4 2 Tank
3. Automated Chemical Optimization ICHEM ROC 107 USER MANUAL INSTALLATION SETUP ano OPERATION FOR USE WITH THE FLOBOSS 107 AND ROCLINK 800 pcsFergusen iChem ROC 107 User Manual The iChem brand is trademarked by PCS Ferguson These documents and materials are copyrighted by PCS Ferguson 2014 All rights reserved The FloBoss and ROCLINK are licensed Emerson products For information contact PCS Ferguson 3771 Eureka Way Frederick CO 80516 Phone 720 407 3550 Fax 720 407 3540 Email information pcsferguson com Website www pcsferguson com iChem ROC 107 User Manual Table of Contents 1 5 1 1 Abbreviations 6 1 2 Safety Overview and Symbols 6 1 3 System i 1 3 1 FloBoss 4 1 3 2 ROCLINK 800 User UCT ACE 5 2 2 stn Ss esa st Sih en ll se an e e 9 1 3 3 ichem ROC 107 0 11 2 Software Installation 12 2 1 Installing ROCLINK 800 12 2 1 1 Logging IN the First TIM
4. Flags Low Reading ELI Comm Ports High Reading ELI System Variables EU Value FST Registers Alarm Mode Soft Point Parameters Scanning Mode Database Parameters Manual Module Information Physical Value Show All Point Types and Parameters Show Current Value 2 18 3 HINTS Cancel Figure 3 6 Pump Control DOUT Settings 25 Setup and Calibration iChem ROC 107 User Manual 3 1 6 Flow Switch TLP The Flow Switch point is a digital input Flow Switch TLP DIN Status Byte 0 0 0 select TLP Point Type Logical Number Parameter Undefined i Point T ag ID Configurable Filter Discrete Inputs Discrete Outputs Mode Analog Inputs Alarm Code Pulse Inputs Accumulated Value AGA Flow Parameters Counter History Parameters Counter AGA Flow Calculation values OF Pulse Width Clock 100 Pulse Width Flags Time Between Pulses Count Comm Ports Units System Variables Scan Period FST Registers Low Reading ELI Soft Point Parameters High Reading ELI Database Parameters Low Alarm EU Module Information High Alarm EU Show All Point Types and Parameters Show Current Value 1 21 2 HINTS Y 2 Cancel Figure 3 7 Flow Switch Settings Setup and Calibration 26 iChem ROC 107 User Manual 3 2 Calibrating the Flow Meter The calibration controls
5. Slot FIM BB FI 2 Slot FIM C5 Pl 1 Slots FIN PI 2 Slots Parameter Units Hate Flag Hate Pernod Filter Time Scan Period Conversion Low Alarm High Alarm ELI Low Low Alarm ELI HiHi Alarm ELI Hate Alarm ELI Alarm Deadband Rollover Maximum ELI Value Made Alarm Code Accumulated Value Current Rate Show Current Value yY OK Cancel Setup and Calibration 22 iChem ROC 107 User Manual 3 1 3 Injection Pressure TLP Injection Pressure is an analog input Point Logical Number Parameter Undefined RATE Paint T ag ID Configurable Al 1 Slat Units 12 Discrete Outputs AIM 2 Slot Scan Pernod Analog Inputs Al 1 Slot Filter Analog Outputs Al 2 Slots Adjusted 4 0 Pulse Inputs Lagic Adjusted 4 0 100 AGA Flow Parameters Battery Low Reading EU History Parameters Charge In High Reading EU AGA Flow Calculation values Unused Low Alarm Clock Brd Temp High Alarm ELI Flags Law Low Alarm ELI Comm Ports Hi Hi Alarm System Variables Hate Alarm FST Registers Alarm D eadband Soft Paint Parameters Filtered ELI Value Database Parameters Mode Module Information Alarm Code Show All Point Types and Parameters Show Current value 3 17 0 AC v UK Cancel JC CT oo Figu
6. 222 Pict ra gest x UOTA a 95 Figure 1 1 Example of Standard Junction Box Wiring 7 Introduction iChem ROC 107 User Manual CURREN 3 LIMIT E i amp CL ADJ 10 C LOOP 2 CL1 1 EXTANT SPD 2FLTLATCH 3 RAMP 4 RAMP 2 5 60 120 Figure 1 2 Example Junction Box Wiring with a Motor Control Board See example wiring diagrams in Appendix A Introduction 8 iChem ROC 107 User Manual 1 3 2 ROCLINK 800 User Interface ROCLINK 800 configuration software allows a remote user to monitor configure and calibrate the FB107 ROCLINK also enables off line management of gas meters I O and Proportional Integral Derivative Feedback Control Loops PIDs The ROCLINK user interface displays the modules installed in the FB107 backplane File Edit View ROC Configure Meter Utilities Tools Window Help SX E Top Menu History ARS User Program User Display SEREG ER SABE RS Configuration Tree Menu General Advanced Paints Meter Paints Diagnostic Installed Module Actual Module Description Application Firmware Revision Part Number Build Date Det 13 2011 08 33 Serial Humber 448083 0022 0838384 Boot Revision Boot Build Date Nov 17 2006 8 32 Integrity Uninstall Scan B Updat
7. 8 seconds after the pump stops Controls and Features 30 iChem ROC 107 User Manual 4 1 3 OFF and Calibrate Mode In OFF CAL mode the only function available is calibration The pump will not run ROC 107 switches to this mode when the Emergency Shut Down ESD button is activated 4 2 Pump Status Panel This area of the iChem ROC 107 interface displays live measurements and pump cycle timing data and contains the Emergency Shut Down and Batch functions 4 2 1 Pump Status Fields and Functions Connected to Pump efault Pump Mame Current Made OFF CAL Tank Level 0 0 Emergency Shut Down Cycle Timer Secs 422 Flow 0 0 Daily Volume 1 440 Injection Pressure 10 0 Custom Batch Start Cycle Frequency 1 Cycle Volume Batch Val 20 Curent Cycle 0 Todays Volume 0 0 Figure 4 2 Pump Status Panel Field Function Default Pump Name Allows the user to type a name for the pump Current Mode Shows which of the three operation modes OFF CAL Auto or Manual is currently set on the Pump Program Tab Cycle Timer Secs When the pump is OFF this field counts down the time until the next cycle starts When the pump is ON this field counts the amount of time that the pump has been running If the mode is switched from AUTO to another mode or Batch the count resumes when the next cycle begins Daily Volume Sets the total volume to be injected daily and displays the volume Cycl
8. MANUAL mode This button is disabled in other modes Pump State PUMPON or PUMPOFF shows the current state of the pump OFF Button Turns off pump in MANUAL or BATCH mode Disabled in other modes NOTE To turn off the pump in AUTO mode you must switch to MANUAL or OFF CAL 4 2 4 Custom Batch Fields Field Function Custom Batch Start Starts a custom Batch in AUTO or MANUAL mode Batch Vol Sets the volume for an instantaneous batch injection NOTE fa scheduled cycle occurs during batch mode the cycle is skipped Controls and Features 32 iChem ROC 107 User Manual 4 3 Alarms Panel This area of the iChem ROC 107 interface displays active Warnings and Alarms Current Alarms MANUAL ESD Clear Alarms Current Wy arririgs Figure 4 3 Alarms Panel 4 3 1 Alarm Messages and Meanings These alarms trigger Emergency Shut Down Message Abbreviation Meaning High Press HIPRES ESD The low pressure through the transducer is high Manual ESD MANUALESD The user has clicked the Emergency Shut Down buton 33 Controls and Features iChem ROC 107 User Manual 4 4 Pump Program Tab The Pump Program tab contains essential settings for operating and calibrating the system Fump Pragram Cycles Pump History LO Assignments Pump Operation AUTO PO Meter Units Quarts Tank Level Units Inches Pump Contract Hour Fump wv Flow Alarm E Enabled Tank Low warming O Disab
9. User Defined TLP Functions Users can set alarms and shut down the pump using any TLP point defined in the FloBoss 107 1 Select and map the User Defined TLP point 2 Match the TLP point to its data type 3 Setup the warning or alarm levels as required Common Tasks 42 iChem ROC 107 User Manual Appendix A Wiring Diagrams A 1 iChem for FloBoss107 Standard JB Wiring The following diagram shows an example wiring configuration iChem for FloBoss 107 Standard Junction Box ICHEM FB107 JB 1 1094749 em eee Example Wiring Diagram LooP E mows 3 10A 001 m 11A not shown 13 PH DI3 GND PI2 DI4 NC E 5 T 1 EG Ce MEE EG la e Jj a HEIN FIELD WIRING To ignal WR WR ignal WR WR ignal WR WR ignal WR Descrption PD Flow Meter 6 Tank Level Injection Pressure B Flow Switch 12 10 WR es I SE e gt oo 9 5 3 79 Figure A 1 Standard Junction Box Wiring Example 43 Wiring Diagrams iChem ROC 107 User Manual A 2 iChem for FloBoss107 Neptune JB Wiring The following diagram shows an example wiring configuration using the Neptune Pump iChem for FloBoss 107 Junction Box for Nept
10. are located on the Pump Program tab on the main iChem ROC 107 interface NOTE Click Apply in ROCLINK 800 when any field is changed 3 2 1 Calibrating the PD Meter PO Meter Calibration 1 Isolate the pump tank from the sight glass start Pump Test Calculate kF actor 2 Mark the top of the fluid point on your sight glass Test Time Secs 12 3 Click the Start Pump Test button to run the test Volume per Tick 0 006944 4 Record the low point of the fluid after the test runs HE and determine the difference KF actor 10959 73 5 in the Observed TickDrop with the ComputedTickDrop 243 difference in fluid level before and after the test 6 Click Apply Figure 3 8 PD Meter Calibration 7 Click the Calculate kfactor button 8 Click Update 3 2 2 Calibrating the Tank Level 1 Set the High and Low Voltage Points Low Level a HichLevel 150 Curent Level 0 0 Draw down the sight glass Enter the Low Level and click Set Calculate Scale and Offset Establish level to the sight glass m Tank Level Calibration Isolate the tank 729 5 p Enter the High Level and click Set Figure 3 9 Tank Level Calibration 2 Click Update 3 Calculate Scale and Offset 4 Click Update The ROC 107 calculates the current Tank Level 27 Setup and Calibration iChem ROC 107 User Manual 3 2 3 Calibrating the Injection Pressure r Inj Press Calibration 1 Setthe
11. field 3 3 2 setting Contract Hour The Pump Contract Hour determines the time of day that the pump cycle starts The clock uses a 24 hour format with a default value of 8 00 To change the default contract hour type a new value in the Pump Contract Hour field on the Pump Program tab 3 3 3 Setting Pump Cycle Interval The Cycle Frequency field in the Pump Status panel automatically updates based on the selected Cycle Interval set on the Pump Cycles tab Program Pump Cycles Purp History Assignments Hour Min Cycle Interval Daily Trigger Time 1 2 30 MEN T rex e e E O ES uua Monthly 4 Dl 5 D u pfi 0 13 14 Check All 18 20 19 29 2 DearAl D pj 2 p p z3 Figure 3 12 Cycle Interval the Pump Cycles Tab On the Pump Cycles tab select the desired time between each pump cycle in the Cycle Interval drop down list Figure 3 12 shows a pump configured to run every two hours oet the cycle interval to Daily when you want the pump to run once at the Daily Trigger Time each day Chapter 4 Controls and Features for descriptions of each data field 20 Setup and Calibration iChem ROC 107 User Manual 4 Controls and Features This section details the functions of all data fields in the iChem ROC 107 interface 4 1 Operation Modes The iChem ROC 107 features three operation modes AUTO Manual a
12. readings Clicking AutoScan updates all readings every second by default 11 Introduction iChem ROC 107 User Manual 2 Software Installation The ROCLINK 800 software must be installed and connected to a communication device NOTE Consult your FloBoss 107 ROCLINK 800 user documentation for additional information not included in this manual 2 1 Installing ROCLINK 800 To install ROCLINK from a CD ROM 1 2 Insert the disk into your PC and follow in the installation wizard instructions If any User Account Control messages appear click Yes to allow ROCLINK to install 3 Restart your PC when prompted to complete the installation To install ROCLINK 800 from a zip file 1 Extract all files in the zip folder and save the ROC folder in an appropriate location on your PC Open the ROC folder and ROCLINK sub folder Locate and open the setup file Follow the instructions in the Installation Wizard If any User Account Control messages appear click Yes to allow ROCLINK to install Restart your PC when prompted to complete the installation 2 1 1 Logging in the First Time ROCLINK automatically creates a shortcut on your desktop 1 To start ROCLINK double click the shortcut or locate the program in your Start menu Figure 2 1 ROCLINK 800 Shortcut For more information on the ROCLINK 800 application visit the following link htto www2 emersonprocess com en US bra
13. 12 03 458 2998 3 Figure 2 6 Download User Program File Software Installation iChem ROC 107 User Manual 6 Click Download to proceed After downloading ROC 107 appears in the User Program slot with the application s properties displayed 7 Click Close to download the application to the FloBoss 107 and automatically start running the program 2 3 Licensing iChem ROC 107 To correctly license a user program slot PCS Ferguson needs to know which slot will be running the application You can have multiple ROC 107 loads running simultaneously but each user program MUST have a license for each slot Utilities Tools Window Help Update Firmware License Key Administrator Transfer Between DEVICE and KEY Convert EFM File Transfer Between KEYS User Program Administrator ROCLINE 800 Security AI Calibration Values PLIMPOFF MVS Calibration Values MUN mergencu Shut Down FST Editor Custom Batch Start Custom Display Editor atch Vol 20 Custom EFM Report Editor Read File From Device Communications Monitor Figure 2 7 Menu Licensing Options PCS Ferguson needs two items to license a particular iChem ROC 107 firmware e FloBoss 107 serial number User Program slot or slots being activated In order to license the ROC 107 application PCS Ferguson needs the serial number of the LCD controller En
14. 33205 OF fOr 2014 12 05 48 HIPRESSSBN Alarm Clear 4000 0 OF OF 2014 12 05 47 PUMPOFF ALARM Alarm Set OF f O 2014 12 05 47 HIPRESSLMT Alarm Set 3000 0 OF fOr 2014 12 05 47 HIPRESSSBN Alarm Set 4001 533 Save Print Preview ON LINE 25 2 3 4 B g Figure 5 2 Sample Alarms Log Common Tasks 40 iChem ROC 107 User Manual 5 2 Clearing Alarms To clear alarms and restart the pump 1 Click the Clear Alarms button in the Current Alarms panel Current Alarms MANUAL ESD Clear Alarms Current V arinqgs Figure 5 3 Alarms Panel 2 Then click Update NOTE Alarms can also clear automatically For example the alarm will trigger if the injection pressure dips below the low alarm level If the injection pressure then rises above the low alarm level the alarm will automatically clear 5 3 Running Custom Batches 1 In AUTO or Manual mode enter the volume to be injected Emergency Shut Down immediately in the Batch Vol field DN PuMPOFF 2 Click the Custom Batch Start button to begin the batch injection Custom Batch Start The Pump Status panel updates as the batch runs Batch 0 1 Figure 5 4 Custom Batch Functions 41 Common Tasks iChem ROC 107 User Manual 5 4 Creating a User Defined TLP Extended soft points allow users to define data types User Defined 1 joo 0 User Defined 2 gt 00 D User Defined TLP FLAT Undefined Figure 5 5
15. High and Low Voltage Points LowLevel 00 Isolate the transducer High Level 30 0 Set Current Press 00 Bleed gas into the atmosphere Set the Low Level Calculate Scale and Offset Apply well pressure o 29 5 Set the High Level Figure 3 10 Injection Pressure Calibration 2 Click Update 3 Calculate Scale and Offset 4 Click Update The ROC 107 calculates the current Injection Pressure 3 3 Setting Up Cycles and Volume Once all data points are mapped the pump is ready for operation You can enter the necessary cycle and volume settings on the main ROC 107 screen in the Pump Status panel and Pump Program and Pump Cycles tabs NOTE Click Apply in ROCLINK 800 when any field is changed Connected ta Pump Default Pump Name Curent Tank Level 0 386535 Cycle Timer Secs 244 Flow Fate Do Daily Volume HO Injection Pressure 3500 Cycle Frequency 140000 Cycle Volume 0 0006944 Current Cycle nmm Todays Volume og Pump Prograrri Pump Cycles Pump History LO Assignments Pump Operation OFF and Calibrate PO Meter Units Quarts Tank Level Units Inches Purp Contract Hour E Figure 3 11 Pump Status Panel and Tabs on the ROC 107 Interface Setup and Calibration 28 iChem ROC 107 User Manual 3 3 1 Setting Daily Volume In the Pump Status panel enter the required injection volume per day in the Daily Volume
16. Level 36 4 4 3 INJ Pressure 36 4 5 Pump Cycles Tab 37 4 6 Pump History 38 4 7 VO Assignments Tab 39 5 COMMON 1 5 5 40 5 1 Viewing History and 40 5 2 Clearing lt 41 5 3 Running Custom 41 5 4 Creating a User Defined 42 Appendix A Wiring Diagrams 43 iChem for FloBoss107 Standard JB 43 2 iChem for FloBoss107 Neptune JB Wiring 44 Appendix B Troubleshooting and Known 55 65 45 iChem ROC 107 User Manual Revision History Date Description Version ita Release iChem ROC 107 User Manual 1 Introduction 5 Purpose This manual guides the user in installation setup calibration and operation of the iChem ROC 107 chemical well tending application Audience The iChem ROC 107 User Man
17. anual 4 6 Pump History Tab This tab displays statistics for chemical injection over time Today Vol Since Start 30 Day Volume 08 7 Yesterdays Volume 30DayTametVol Week Volume 30 Err Volume 08 27 Month Volurne 30 Day Batch 08 27 fear Volume 30 Manual sol 00 Forever Volume 30 Day Cycles 00 30 Day Skip Cycles 0 0 Batch Volume Today Batch Volume Day Clear History sl In Manual Volume Today 0 0 End OF D arce En ay Manual Volume 10 0 Figure 4 9 Pump History Tab Field Function Controls and Features 38 iChem ROC 107 User Manual 4 7 1 0 Assignments Tab The user must map the points on this tab prior to operation See 3 1 Mapping Points Prograr Pump Cycles Purp History Assignments Tank Level TLP FB Flow Meter Tank 3 1617 PEI Flow Rate 5 2017 Injection Pressure TLP ESD DIN TLF Ini Press 3 17 17 E DIN Status Byte Pump Control COUT TLF Flow Switch TLF DOUT Status asa DIN Status Byte 0 0 0 Figure 4 10 0 Assignments Tab Field Function Tank Lvl RawAD TLP point selected for the Tank Level transducer Injection Pressure point selected for the Inject
18. cer High Level 300 calibration for injection pressure Curent Press pg High Level Enables the user to set the high level entry during pressure transducer Calculate scale and Offset calibration for injection pressure 0 Displays the current injection pressure Figure 4 7 Injection Pressure Calibration Calculate Scale and Calculates the linear curve the Offset Button transducer will follow for a specific voltage based on the high and low levels Controls and Features 36 iChem ROC 107 User Manual 4 5 Pump Cycles Tab This tab enables the user to set the timing for pump cycles at a weekly monthly and daily level Pump Program Pump Cycles Pump History Assignments Cycle Interval 2 Daily Trigger Time 1 2 30 Check All Clear All weekly Monthly Check All Clear All Figure 4 8 Pump Cycles Tab Field Function Cycle Interval Defines the amount of time between the start of pump cycles in minutes hours or daily Daily Trigger Time Defines the time the pump starts if the Cycle Interval is once Daily Weekly Alows the user to select specific days of week to pump For every day click Check All Allows the user to select specific days of the month to pump During months shorther than 31 days the application skips the extra days For every day click Check All Indicates Disabled 37 Controls and Features iChem ROC 107 User M
19. e Apply 212 4 Figure 1 3 ROCLINK 800 User Interface Double click items or modules in the Configuration Tree Menu to manage types Use the Top Menu to set up your ROCLINK software for your system 9 Introduction iChem ROC 107 User Manual If necessary you can adjust the display of points from text to numerical the ROCLINK menu 1 Inthe Top Menu click Tools gt Options 2 Under Display TLP select As Number Display TLP As Test e a 6 1 ELI Scan Interval 1 000 Seconds TLP Selection Show All Point Types and Parameters ToolTip Popup Show source of data when the cursor hovers over object on a display OK Cancel Figure 1 4 ROCLINK 800 Options Dialog Box Introduction 10 iChem ROC 107 User Manual 1 3 3 iChem ROC 107 User Interface The ROC 107 application lets the user set chemical injection timing and volume Once in AUTO mode the application measures and monitors flow injection volumes and adjusts each cycle based on previous measurements iChem ROC 107 can be used with any pump However each ROC 107 version is custom built for the system and module slot ES rie Edit View ROC Configure Meter Utilities Tools Window Help D m E Pump Status Panel Connected to Pump Default Pump Curent Made DFF CAL Tank Level 0 29536 Emergency Shut Down C
20. e Configuration File 800 Figure 2 11 Save File Dialog Box 3 Click Close 2 4 2 Loading Previously Saved Settings 1 Click File gt Download 2 Locate and Open your configuration file The Download Configuration dialog box appears Download Configuration Select Points ta Download System Variables Clock Parameters Configuration Module Parameters Control Modbus Function Tables v PCS Ferg PumpPragram Comm Port Parameters FST Code Modbus History Table Analog Inputs FST Parameters Modbus Master Table Analog Outputs User List Parameters Modbus Master Modem Discrete Inputs Meter Calibration Sampler ECM Parameters Discrete Dutputs Meter Configuration User Displays Pulse Inputs History Configuration 5 Parameters Soft Points 05800 Parameters Extended Soft Paints 05800 Resources Opeode Tables User Program Status Status Point Paint Number ST Select All Deselect All Download Close Figure 2 12 Chem ROC 107 Download Configuration 3 Inthe Download Configuration dialog box select PCS Ferg Pump Status and PCS Ferg Pump Program See Figure 2 12 CAUTION You overwrite gas flow measurement settings by clicking the wrong check boxes when loading settings Use caution when selecting the check boxes 4 Click Download Your saved settings appea
21. e Frequency Displays the total number of pump cycles set to run on the current day This value is based on the Cycle Interval set in the Pump Program tab Current Cycle Displays the number of cycles that have occurred that day This count resets at the Contract Hour time defined in the Pump Program tab Tank Level Displays the Tank Level reading from the pressure transducer This entry requires calibration in the Pump Program tab and TLP definition in the I O TLP Assignments tab Flow Rate Displays the PD Meter reading This entry requires calibration in the Pump Program tab and TLP definition in the I O TLP Assignments tab Injection Pressure Displays the Injection Pressure reading from the Pressure Transducer This entry requires calibration in the Pump Program tab and TLP definition in the I O TLP Assignments tab 31 Controls and Features iChem ROC 107 User Manual Field Function Cycle Volume Displays the volume to be injected in the next cycle In AUTO and Batch modes this field counts down while pumping In Manual mode it counts up while pumping Todays Volume Displays the volume as measured by the PD meter for the current day starting at the Contract Hour time defined in the Pump Program tab 4 2 2 Emergency Shut Down Button Field Function Emergency Shut Down Turns off the pump and switches the application to the OFF CAL operation mode Button 4 2 3 ON OFF Buttons Field Function ON Button Turns ON Pump in
22. ed personnel Accidents can result in damage to equipment chemical spills loss of natural gas or other unintended consequences This manual contains Caution and Warning related text to alert the user to potential hazards CAUTION A Caution box indicates a potential for damage to equipment loss of data or interruption of essential processes WARNING A Warning box indicates likely damage to equipment or loss Introduction 6 iChem ROC 107 User Manual 1 3 System Overview The iChem ROC 107 application is designed to integrate with the Emerson ROCLINK 800 ROCLINK configuration software and the Emerson FloBoss 107 FB107 flow manager NOTE For more details regarding the FloBoss 107 or ROCLINK 800 refer to the appropriate Emerson documentation at http www 2 emersonprocess com en US brands roc software roclink800 Pages roclink800 aspx 1 3 1 FloBoss Hardware and iChem ROC 107 run with the FloBoss flow manager hardware The FloBoss 107 attaches to the outside of the pump and manages the injection volume and timing of the well The box has an LCD screen for basic operations The junction box wiring configuration determines the parameters for later mapping of the TLP points and other set up tasks The images shown in Figure 1 1 and Figure 1 2 are examples Your hardware setup may look different NP JN P ode ARTIS ac n AR D E p Lo c7 6 5 e Pa v XT P PPL MED
23. er Defined setup The user can enable the point for an Alarm or Warning flag User Defined 2 Defines a data point based on the User Defined setup The user can enable the point for an Alarm or Warning flag User Defined TLP Defines a TLP for dynamic definitions of alarms or warnings Enable Disable Buttons Allows the user to enable or disable any alarm or warning E enabled D Disabled Alarm Warning Buttons Lets the user set the Flow Switch and User Defined points as Alarms or Warnings 4 4 1 PD Meter Calibration Function PD Meter Calibration Test Time in Secs Defines the amount of time the pump Start Pump Test Calculate KF actor runs during a positive displacement PD Test Time in Secs meter calibration test 3 Volume Tick Volume per Tick Lets the user set the volume per tick ai 0 000694 used in pump calibration bsemedTickDrop 293 Observed Tick Drop During pump calibration the user enters kFactar 10959 73 how many ticks the fluid dropped in this ComputedTickDrop 243 field kFactor Displays the computed kFactor after Calculate kFactor clicked Figure 4 5 PD Meter Calibration Panel Computed Tick Drop Displays the computed fluid drop which should match the Observed Tick Drop This measurement is based off Test Time Volume per Tick and the kFactor Changing the Test Time in Secs and starting a pump test will compute a tick drop based on the calibrated facto
24. eter Units Scan Period Filter Adjusted 4 D Adjusted 4 0 100 Law Reading EU High Heading ELI Undefined 10 Configurable Al 1 Slot 2 Discrete Outputs Al 2 Slot a Analog Inputs Al 1 Slots Analog Outputs Al 2 Slots Pulse Inputs Lagic AGA Flow Parameters E Battery History Parameters Charge In Low Alarm ELI AGA Flow Calculation Values Unused High Alarm ELI Clock Brd Temp Law Low Alarm ELI Flags Hi Hi Alarm ELI Lamm Parts Hate Alarm System Variables Alarm Deadband FST Registers Filtered ELI Value Soft Paint Parameters Made Database Parameters Alarm Code Module Information Haw A D Input CT CT Fe co Figure 3 2 Tank Level Settings 21 Setup and Calibration 3 1 2 PD Flow Meter The PCI Flow Rate is always a pulse input iChem ROC 107 User Manual Select the correct Point Type Logical Number and Parameter for each point based on your system configuration select TLP Point Type Undefined Configurable Discrete Outputs Analog Inputs 0 AGA Flow Parameters History Parameters AGA Flow Calculation Values Clock Flags Comm Forts System Variables FST Registers 5nft Point Parameters Database Parameters Module Information Show All Point and Parameters 20 17 Figure 3 3 PD Meter Settings FIN BS
25. icense Source Expiration Time Created 1 00 0 1 Expiration 5 23 2014 02 51 31 PCS iChem 3 PCS 10228 0 02 4 1 File Expiration 0807 2014 01 34 51 1 00 0 Expiration 5 23 2014 02 51 37 PM Expiration 07 29 2014 11 14 31 AM PCS Chem 2 File Expiration 08713 2014 11 55 17 Connect to KEY Moye to Add License Remove Figure 2 9 Licensing Screenshot Licenses on Display The separate display file is not necessary to use the application The display is compiled into a single bin file for iChem ROC 107 in the FloBoss 107 and is included with the program load The display is under the User Program section of the tree 2 4 Saving and Loading Configuration Settings 107 s settings not saved automatically and can be overwritten when updating your software version Follow these procedures to save your settings before you update and then reload the settings when the update is complete 2 4 1 Saving TLP Points and Settings 1 Click File gt Save Configuration Edit View ROC Configure Meter New Ctrl O Download Close Save Configuration Print Configuration Print Ctrl P Print Setup Figure 2 10 Save Configuration Menu Path 2 Type aname for the file and click Save Software Installation 18 ROC 107 User Manual File name 107 AlG2 2014 07 08 Save as typ
26. ion Pressure transducer Pump Control DOUT TLP point for Digital Output control of the pump TLP PD Flow Meter TLP TLP point for Pulse Input for the positive displacement pump ESD DIN TLP TLP point for Digital Input for Emergency Shut Down Flow Switch TLP TLP point for Digital Input of Flow Switch 39 Controls and Features iChem ROC 107 User Manual 5 Common Tasks The following activities facilitate operation and maintenance of the EFM through iChem ROC 107 5 1 Viewing History and Events To view the Event Log 1 Click View gt Alarms 2 Select From Device or From File to view the History Alarms or Events log ES File Edit ROC Configure Meter Utilities Tools Window D ca Directory E We L HE EFM Report Calibration Report Connected to History a Default Alarms From Device Current Mode Events From File Cycle Timer Display Daily Volume VO Monitor 372 0 Cycle Freque 0 0006944 Toolbar Current Cycle Y 0 0 Figure 5 4 View Alarms Menu Path rice Edit View ROC Configure Meter Utilities Tools Window Help D c Bic iw hihi oe 4 Alam 162 FEO Uploaded 07 08 2014 14 54 40 Operator LOI Date Time Tag Set Clear Value Desorption 12 09 04 LOWPRESSDON Alarm Clear 1996 167 2014 12 09 04 CLEAR ALARM Alarm Clear OO 2014 120724 PUMPOFF_ALAR Fl Alarm Set 2014 12 07 24 LOWPRESLMT Alarm Set 500 0 OO 2014 12 07 24 LOWPRESSDH Alarm Set 1 5
27. led Tank Low Alarm Low Flow Alarm High Flow Alarm Low Pressure Alarm High Pressure Alarm ATIS Flow Switch User Defined 1 z User Defined 2 gt User Defined FLOAT gt 0 0 0 5 Figure 4 4 Pump Program Tab Field Function Pump Operation Defines the current mode of operation Select from AUTO Manual or OFF and Calibrate PD Meter Units Defines the units the ROC 107 uses to measure the flow Select from Quarts US Gallons or Liters Tank Level Units Defines the units the ROC 107 uses to measure the tank level Select from Inches or Centimeters Pump Contract Hour Defines the hour of the day when the pump restarts the Daily Volume measurement At the set hour Todays Volume clears to zero for the beginning of the new day This setting uses a 24 hour clock Pump Off W Flow Alarm Defines the flow rate af which the alarm will activate eight seconds after the pump is off Tank Low Warning Defines the level at which the tank low warning activates Tank Low Alarm Defines the level at which the tank low alarm activates and shuts off the pump Low Flow Alarm Defines the level at which the low flow alarm activates and shuts off the pump This function checks the flow pressure every 20 seconds after the pump starts and continuously while pumping Controls and Features 34 iChem ROC 107 User Manual Field Function User Defined 1 Defines a data point based on the Us
28. m ROC 107 application requires the bin file To install iChem ROC 107 1 If necessary extract the bin and save it in an appropriate location on your PC 2 Start ROCLINK80O and connect to the FloBoss 107 3 In the configuration tree expand User Program and click Administrator Modules 20 Control E Meter System ES History User Program Administrator B S B B Figure 2 4 User Program Administrator Path Software Installation 14 15 iChem ROC 107 User Manual User Program Administrator User Programe Installed Device IChemT ender V DID M No Fragram Pragram Program Version Library Version Program Created DAAM Used 0 Program FLASH Used 0 Program Entry Pt Displays All Option Status Empty Download User Program File isse Version Created Update Close Figure 2 5 User Program Administrator Dialog Box 4 Click the Browse button to locate and open the ROC 107 bin file on your PC 5 Ensure the Download User Program File path is correct and then click Download amp Start Download User Program File valutionsiChemT endersiChemT ender V bin Mame iChemTender ODIT Download amp Start Download Version Rev 0 00AT Created 7 23 2074 9 51
29. nd OFF and Calibrate The Operation Mode drop down menu is located on the Pump Program tab NOTE Click Apply in ROCLINK 800 when any field is changed Pump Operation AUTO PO Meter Units OFF and Calibrate Manual Tank Level Units AUTO Figure 4 1 Pump Operation Drop down Menu 4 1 1 AUTO Mode In Auto mode the ROC 107 manages the measured injection of well chemicals The electronic flow meter detects the amount of fluid to seven digits of precision that is pumped into the well after each injection cycle iChem ROC 107 then adjusts the next pump cycle amount to account for inaccuracies over or under the set volume per cycle The flow meter causes the pump to skip cycles or simply revise the volume of the next cycle The PUMP ON and OFF buttons are not available in Auto mode Any Alarms cause the pump to shut off and switch the application to OFF Calibrate mode Warnings appear in the Warning box but will disappear after an Update The user can define the Warning and Alarm parameters in the Pump Program tab All Warnings and Alarms are recorded in the event and history logs Custom batch injections can run in either Auto or Manual modes NOTE fa scheduled cycle occurs in manual mode or during a batch run the application skips that cycle 4 1 2 Manual Mode Manual mode allows the user to turn the pump ON or OFF and to run custom batches NOTE Manual mode the tank level will not update until eight
30. nds roc software roclink800 Pages roclink800 aspx Software Installation 12 ROC 107 User Manual 2 Open the ROCLINK application ROCLINK 800 Configuration Software Password A E Cancel M Process Manna MER Figure 2 2 ROCLINK 800 Login Screen 3 When the login screen appears type your User ID and Password and then click OK you do not have an individual user id and or password click the User ID text to automatically log in with the default credentials ID LOI and Password 1000 4 Locate the correct communication device for your FloBoss 107 configuration in the ROCLINK Device Directory 5 Right click on the device s corresponding PC port and click Properties od E Dee pe at 5 1 File Edit View ROC Configure Meter Utilities Tools Window Help 4 RS Eee PRO 2 Device Hoot Device Properties Connect Disconnect Rename 98 Delete Device ae Mew Groupi Figure 2 3 ROCLINK 800 Device Directory 13 Software Installation iChem ROC 107 User Manual 6 Define Communication Parameters as necessary for your system The green Online indicator will replace the red Offline field on the ROCLINK interface when you are successfully connected 2 2 Loading iChem ROC 107 The FloBoss 107 allows up to six 6 user program slots Loading the iChe
31. r Start Pump Test Button Starts the pump test Test Time and Volume per Tick must be entered before pressing this button The pump runs for time defined by the Test Time field Calculate kFactor Measures PD meter pulses during the Button pump test and calculates the kFactor for the injection system You must run the pump test before clicking this button to calculate When clicked this button computes the slope and offset of the calibration 35 Controls and Features iChem ROC 107 User Manual 4 4 2 Tank Level Calibration Field Function Tank Level Calibration Low Level Enables the user to set the low level LowLevel 00 Sel entry for tank calibration Click the Set High Level 15 0 Set button when the fluid is at the low level oo in tank High Level Enables the user to set the high level Calculate Scale and Offset entry for tank calibration Click the Set button when the fluid is at the high level Figure 4 6 Tank Level Calibration in tank Current Level Displays the current fluide level in the tank as measured eight 8 seconds after the pump stops Calculate Scale and Calculates the linear curve the Offset Button transducer will follow for a specific voltage based on the high and low levels 4 4 3 INJ Pressure Calibration Field Function Inj Press Calibration Low Level Enables the user to set the low level Low Lexel 0 0 Set entry during pressure transdu
32. r in your iChem ROC 107 user interface 19 Software Installation iChem ROC 107 User Manual 3 Setup and Calibration This section details the process for mapping and calibrating inputs and outputs for your system NOTE The same output slots can accommodate multiple output functions 3 1 Mapping 1 0 Points Before running your pump system with iChem ROC 107 you must properly map the TLP points based on your system configuration The user must define these TLP points For each TLP point 1 Click the button next to each TLP point to assign it to the corresponding slot based on your FloBoss setup Pump Program Pump Cycles Tank Level TLP FB Flow Meter Tank Lvl 3 8 17 E PCI Flow Rate 5 36 17 Injecton Pressure ESB DIN TLF Ini Press 39172 DIN Status Byte 0 0 0 Pump Control COUT Flow Switch DOUT Status 8 0 3 DIN Status Byte 0 0 0 Figure 3 1 0 Assignments Tab 2 Select the correct I O type the Point Type scrolling list 3 Select the corresponding Logical Number for the slot 4 Select the correct Parameter Setup and Calibration 20 iChem ROC 107 User Manual 3 1 1 Tank Level TLP The Tank Level point uses analog input 1 Select Analog Inputs in the Point Type scrolling list 2 Select the corresponding Logical Number for the slot 3 Select the correct Parameter select Point Type Param
33. re 3 4 nj Pressure Settings 23 Setup and Calibration iChem ROC 107 User Manual 3 1 4 Emergency Shutdown ESD DIN TLP The ESD is a discrete input Select Pont Type Logical Number Parameter ndefined Configurable O Discrete Inputs Discrete Outputs Analog Inputs Analog Outputs Pulse Inputs AGA Flow Parameters History Parameters D Pulse Width AGA Flow Calculation Values 100 Pulse Width Clock Max Time Between Pulses Count Flags Units Comm Ports Scan Pernod System Variables Law Reading ELI FST Registers High Reading EU Soft Paint Parameters Low Alarm EU Database Parameters High Alarm Show All Point Types and Parameters Show Current Value 1 21 Y OK Cancel Filter Status Mode Alarm Code Accumulated Counter OFF Counter OO JC 4X Gi Figure 3 5 ESD DIN Settings Setup and Calibration 24 iChem ROC 107 User Manual 3 1 5 Pump Control DOUT TLP The Pump Control point is a digital output Select TLP Point Type Logical Humber Parameter Undefined Point T ag ID Configurable maiU C3 Time On 2 Duzcrete Outputs DOU C4 3 Status Analog Inputs Analog Outputs 3 Alarm Code Pulse Input Accumulated Value AGA Flow Parameters L3 Units History Parameters Cycle Time 464 Flow Calculation Values 04 Count Clock 100 Court
34. sure that you send the LCD controller serial number and not the CPU serial number Software Installation 16 iChem ROC 107 User Manual Edit View ROC Configure Meter Utilities Tools Window Help D m ge 4 EI T 5 E E E On Line Ethemet FB107 FB107 E Modules B 6 Foint Mat Installed Mat Installed Mat Installed Hat Installed Mat Installed Mat Installed History ABS User Program EEE User Display General LED Advanced Installed Module LCD Controller Actual Module LED Controller 00 Description Led 00 Build Date Sep 17 2007 358 Boot Revision ee m Boot Build Date Sep 17 2007 98 Uninstall Figure 2 8 LCD Controller Serial Number PCS Ferguson will send you a 105 character string through email 1 Open ROCLINK 800 and click Utilities gt License Key Administrator gt Transfer Between DEVICE and KEY 2 Click Add License 3 Copy the 105 character string from your email and paste it into the text box Ensure you copy the entire string including the exclamation mark at the beginning 4 Click 17 Software Installation iChem ROC 107 User Manual Transfer Licenses Between a DEVICE and a KEY Licenses on DEVICE Application Vendor App Version Quantity L
35. ual is intended for knowledgeable professionals in the natural gas well industry with flow management software experience Scope Chapter 1 Introduction Provides an overview of the system described in this manual Chapter 2 Software Installation Provides step by step installation instructions for the ROCLINK 800 and ROC 107 software Chapter 3 Setup and Calibration Details the tasks required for customizing and testing your chemical injection system Chapter 4 Controls and Features Lists and describes each input field and function in the iChem ROC 107 application Chapter 5 Common Tasks Describes procedures for other useful options in the ROC 107 application Appendices Contains additional wiring diagrams and troubleshooting information Introduction iChem ROC 107 User Manual 1 1 Abbreviations and Acronyms DIN Digital Input DOUT Digital Output DP Differential Pressure EFM Electronic Flow Meter FB107 FloBoss 107 electronic flow computer iChem Intelligent Chemical Pump referring to the PCS Ferguson chemical injection system I O Input Output LOI Local Operator Interface PC Personal Computer PD Positive Displacement PID Proportional Integral Derivative PLC Programmable Logic Controller RTU Real Time Unit TLP Point Type Logical number and Parameter 1 2 Safety Overview and Symbols This product and other chemical injection systems and components should only be operated by trained and experienc
36. une Pump ICHEM FB107 JB 2 1094750 FloBoss 107 Connections Descrption From Example Wiring Diagram 1 LOOP AUDI GND AI DI2 XO XX A Pump Output_ run stor 002 GND oe X PU 4 E Y um BLACK lt WHITE GREEN BUE MOTOR RED PUMP BLACK RED YELLOW Descrption PD Flow Meter Tank Level HALL POWER HALLA HALLB HALL GND 4 Injection Pressure x Motor 7 PG OUT 12 Volt DIRECTION Controller FREEWHEEL Battery 5 lian Flow Switch FAULT OUT Q V CONTROL GND ESD Figure A 2 Example Junction Box Wiring for Neptune Pump Wiring Diagrams 44 iChem ROC 107 User Manual Appendix B Troubleshooting and Known Issues 45 Problem Solution Problem Solution Solution Problem Solution Solution Solution iChem will not license Refer to Section 2 3 Pump will not start Check wiring and refer to Section 3 1 Check operation and refer to Section 4 1 Pump starts but no or Low Flow Detected Check wiring and refer to Section 3 1 Check PD meter sensor is installed correctly lsolate the PD meter and examine inside the PD meter gears for blockage or flaws Troubleshooting and Known Issues iChem ROC 107 User Manual 46
37. ycle Timer 0 Flow Aate 00 Daily Volume 1 0 Injection Pressure 350 0 Cycle Frequency 440 10 0006944 Cycle Valume Curent Cycle 0 Todays volume nn Batch Val 20 Pump Program Tab Pump Program Pump Cycles Pump History 0 Assignments Clear l ear Alarms PO Meter Calibration Pump Operation DFF and Calibrate Start Pump T est Calculate kFactor Current warnings PO Meter Units Quarts Test Time in Secs 50 Tank Level Units Inches i Volume Tick 0 000694 Pump Contract Hour Observed TickDrop 30 Enabled 10893 91 ComputedTickDrop 34 66068 Tank Low Warming Tank Low Alarm Tank Level Calibration D D Low Level IE25 Gel High Flow Alarm E High Level 9 75 Set D D 2 Low Flow Alarm Current Level 1 0 38631 Calculate Scale and Offset Inj Press Calibration Low Level 0 0 Set User Defined 1 4 High Level 30 0 5 et User Defined 2 gt 10 0 D Current Press 360 0 User Defined FLOAT adefined Calculate Scale and Offset Print Save Auto Scan Update Close Apply 5 12 29 Ph Low Pressure Alarm High Pressure Alarm Alarm Warming Flow Switch C C D D D D D D Figure 1 5 ROC 107 User Interface Click the Apply button to save your changes and click Update to refresh the screen and meter
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