Home

FloBoss 503 and 504 Instruction Manual

1. U2 U2 Hi 8 o s C4 t RIRER3 EU eu L Z soy CR2 FB3 ds FB4 C6 CRA gt mo CRE FB3 FB4 c G noQ O CR3 aS RI O E i il o N O OF ed PTR1 PTR2 Je PTRI Je PTRE DOC0415A DUC0415B Figure 4 4 Dial up Modem Communications Card Model W28146X0012 on left Model W28146X0022 on right Note The communications modem module was upgraded in September of 2011 with a new modem component U2 available in model W28146X0022 The new modem component is smaller and shows a portion of the printed circuit board PCB see Figure 4 4 The modem card interfaces to 2 wire full duplex telephone lines using asynchronous operation at data baud rates of 1200 and 2400 The card interfaces to a PSTN through an RJ11 jack located at the bottom of the communications card Control the modem using industry standard AT command software A 40 character command line is provided for the AT command set Note Set the modem initialization strings with the appropriate AT command Config Command in the Modem screen within ROCLINK configuration software The Config Command for the FloBoss 503 and 504 is ATEOHOVOXIQO amp CI
2. Q a ON 828 BE BE P Canta TB2 f OUOU0E OCUOUCE TB3 ower Contro PA ost Part Terminal Terminals FOI O O OO OG J DPF POR AREN DOC0274A Figure 4 2 EIA 232 RS 232 Serial Communications Card Rev 04 04 Communications Installation and Wiring 4 3 FloBoss 503 and 504 Instruction Manual Table 4 2 Communications Cards LED Indicators Status and Activity DCD The data carrier detect LED lights when a valid carrier tone is detected DTR The data terminal ready LED lights when a signal from the processor indicates the modem is ready to answer an incoming call When the DTR is triggered a connected modem disconnects RTS The ready to send LED lights when a signal from the processor specifies the modem is ready to transmit RXD The receive data LED blinks when the receive signal is being received from the communications card The LED is on for a space and off for a mark TXD The transmit data LED blinks when transmit signal data is being received from the processor The LED is on for a space and off for a mark The ring indicator LED blinks when the modem rings and it glows when Power is on 4 2 2 EIA 485 RS 485 Serial Communications Card The EIA 485 RS 485 communications cards meet EIA 485 specifications for differential ELA 485 RS 485 asynchronous transmission of data over distances of up to 1220 meters 4000 feet The EIA 485 RS 485
3. DO 4 5V SELF POWERED id pe DISCRETE DEVICE CONTROL B11 C2 DOC0428A Figure 5 15 Selectable Circuit Discrete Outputs 5 3 4 1 Built In Discrete Output Wiring A built in Discrete Output is provided on the FloBoss Main Electronics Board in the P10 terminal block Refer to Figure The typical application for this output is a sampler or odorizer control although it may be used for other purposes such as a standard DO This includes toggle mode latched mode and timed DO mode The Discrete Output is accessed by the ROCLINK for Windows software as DO Point Number A4 When the Sampler function is enabled the FloBoss unit provides a Time Duration Output TDO based on the volume A control volume and a pulse duration must be specified with the Sampler function After each flow calculation an internal volume accumulator is compared to the control volume If the accumulator exceeds the control volume a pulse is output and the accumulator is reduced by the control volume This output may be used to drive an external totalizer odorizer gas sampler or similar device The DO uses a P channel Metal Oxide Semiconductor Field Effect Transistor MOSFET to switch current limited 300 mAmp battery power to the positive terminal The negative terminal is internally connected to battery negative A blocking diode a 22 volt transorb and a back EMF diode protect the FloBoss electronics Refer to Table
4. The input terminal wiring is arranged on the lower edge of the Main Electronics Board The terminal designations are printed along the bottom of the circuit board 3 8 Power Connections Rev 04 04 FloBoss 503 and 504 Instruction Manual 3 2 2 Connecting Ground Wiring The FloBoss unit and related components must be connected to an earth ground The National Electrical Code NEC governs the ground wiring requirements for all line powered devices A ground bar is located inside the enclosure at the top right hand side This ground bus bar is electrically bonded to the enclosure and provides screw compression terminals to connect shields from I O wiring line power earth ground and other device earth grounds as required An external lug on the bottom outside of the enclosure refer to Figure provides a place to connect an earth ground to the enclosure Although this ground lug is electrically connected to the ground bar through the enclosure it is recommended that a ground wire also be connected between the ground lug and the ground bar It is recommended that 14 AWG wire be used for the ground wiring Make sure the installation has only one ground point to prevent creation of a ground loop circuit A ground loop circuit could cause erratic operation of the system The Main Electronics Board is electrically isolated from the enclosure no earth ground connections to the board should be made However the drain shields of I O sig
5. 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 Current inputs of 4 20 milliAmps can be used with the addition of a 250 ohm resistor across the input terminals When wiring a 4 20 milliAmp current signal on the 10 channel I O Card leave the 250 ohm resistor installed between the and terminals The 24 channel I O Card has 250 ohm resistors in the sockets on the back of the card Remove any resistors that will not be required For both I O Cards wire the current loop device lead to the T terminal and the device lead to the AI terminal Figure 5 7 shows the wiring for a typical current signal NOTE FloBoss powered means power is received from the Input Output or Module shown External or self powered means power is received from the device a battery the FloBoss Main Electronics Board or another source Al T CURRENT LIMIT O Vs FLOBOSS POWERED CURRENT LOOP DEVICE We 250 OHM I l T 12 24 VDC 22mA MAX SIGNAL 4 TO 20 mA Docoo98C 7 Figure 5 7 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
6. I Active Flow Alarms C Disabled C Disabled IE Enabled Enabled Active Sensor Alarms None 7 Update v x x Cancel Figure 7 5 Turbine Meter Setup for FloBoss 504 ISO 9951 shown 7 4 2 Configuring Inputs To configure parameters for the individual inputs associated with the SM and the flow calculation use the ROCLINK for Windows Configure I O menu as described in the ROCLINK for Windows Configuration Software User Manual Form A6091 The inputs and their Point Numbers are displayed in Table Table 7 5 Configuration Inputs Input Type Sue Reading Analog Input Al Auxiliary Pressure Analog Input A2 Static Line Pressure RTS A3 Temperature on the FloBoss Main Electronics Board Pulse Input 1 Channel A A5 Pulse Count Pulse Input 2 Channel B A6 Auxiliary Pulse Input Pseudo Pulse Input A7 Corrected Pulse Count created by the firmware for Level A metering NOTE When configuring parameters for the Pulse Input identified in the Meter gt Setup be sure to setup the Conversion factor and Advanced parameters to match the flow calculation results MCF Day or 1000 m Day For example if your turbine meter produces 100 pulses ft then enter 100 000 in the Conversion field of the Pulse Input screen and select Rate Period EU day and Conversion Pulses EU in the Pulse Input Advanced parameters dialog Otherwise the calculation of Instantaneous Flow and Ins
7. The following tools are required for troubleshooting IBM compatible personal computer ROCLINK for Windows software Flat head and Philips screwdrivers This section contains the following information Section 9 1 Troubleshooting Guidelines 1 522 00 9 2 Troubleshooting Checklists 2 8 0 anne attieses 9 2 0 3 Procedures senec rere ete e eei eee 9 1 Troubleshooting Guidelines When you are attempting to diagnose a problem with a FloBoss 503 or FloBoss 504 unit Remember to write down what steps you have taken 9 Note the order in which you remove components Note the orientation of the components before you alter or remove them Save the configuration and log data Section How to Preserve Configuration and Log Data on page 9 6 Read and follow all Cautions in this manual When you are done troubleshooting perform the restart procedure in Section How to Restart and Reconfigure on page 9 7 Rev 04 04 Troubleshooting 9 1 FloBoss 503 and 504 Instruction Manual 9 2 Troubleshooting Checklists 9 2 1 Dial up Modem If you are experiencing troubles with an internal dial up modem Check to make sure power is applied to the FloBoss unit at terminal block P8 Check the wiring to the modem Refer to Section 4J Communications Installation and Wiring Check the communication port settings in ROCLINK for Windows software Select ROC gt Comm Ports Check the modem INIT string refer to sec
8. 2 Unplug the Power terminal block at P8 on the Main Electronics Board to remove power 5 4 Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual 3 Disconnect the ribbon cable connected at P11 and any wiring that would restrict the panel from opening Press down on the detent and open the swing out panel Refer to Figure and Figure 4 Mate the 20 pin connector J2 on the I O Card with connector P5 on the Main Electronics Board 5 After mating the connectors press firmly to seat the board For earlier versions of the I O Card also ensure that the card seats on the two compression standoffs 6 For earlier versions of the I O Card install three 6 32 screws For the current version install five 6 32 screws 7 When using a 24 channel I O Card select the necessary DI DO selector switches and verify AI scaling resistors are installed as required Refer to Section I O Wiring on page 5 8 8 Close the swing out panel and reconnect the ribbon cable and any other wiring removed in Step 3 9 Affix I O label to swing out panel The 24 channel card also has a label to be placed on the inside of the enclosure door The two labels for the 24 channel card are shown in Figure 10 Apply power Plug in the Power terminal block at P8 on the Main Electronics Board to restore power to the FloBoss When using a 24 volt optional transformer plug it into P10 on the I O board 11 Refer to Section b How to Restar
9. Table 5 14 Discrete Output Function Output Output Voltage during ON state Battery voltage minus 0 7 volts Output Voltage during OFF state 0 volts Maximum Output Current 0 3 Amp Maximum Voltage 22 volts clamping occurs at this voltage Because the output is not isolated care must be used to ensure that the operation of the load does not affect the operation of the FloBoss unit This may include installation of back EMF diodes and MOVs on the load The load should be connected as in Table 5 16 Inputs and Outputs Rev 04 04 DOC0358A Rev 04 04 FloBoss 503 and 504 Instruction Manual Table 5 15 Built in Discrete Outputs Terminals Terminal Function Positive load Negative load SN Figure 5 16 Built in Discrete Output Terminal Wiring Inputs and Outputs 5 17 FloBoss 503 and 504 Instruction Manual 5 3 5 Pulse Inputs Pulse Inputs PIs count pulses from pulse generating devices The I O Card Pulse Input circuits are physically the same as the Discrete Inputs The Pulse Input after the isolation routes to a pulse accumulator where the pulses are counted and accumulated Table and Table display the Pulse Input s number the Point Number to which the AO is assigned in ROCLINK for Windows software and the number printed on the I O Card In the case of the 24 channel card the number in the software and on the label are the same Ta
10. The I O parameters sensor inputs flow calculations power control security and FST programm ability are configured and accessed using the ROCLINK for Windows software Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 for details concerning software capabilities 1 3 2 Options and Accessories The FloBoss supports the following options and accessories Communications Card for host communications Comm1 Bracket for internally mounted radio T O Card 10 channel or 24 channel Internal AC Power Supply Intrusion Switch Local Operator Interface LOI cable Batteries Solar Panels A variety of plug in communication cards are available that allow you to customize the FloBoss installation for most communications requirements The communication cards provide an interface for the host communications port Comml These cards permit serial communication protocols as well as dial up modem communications Refer to Section 4 Communications Installation and wiring for more information A radio with an integral modem can also be mounted inside the FloBoss enclosure using the optional radio bracket Refer to Section b Installation and Use The radio bracket allows a radio up to 57 15 mm 2 25 inches high to be mounted securely in the battery compartment inside the FloBoss enclosure Power for the radio can be controlled through the EIA 232 RS 232 communications card Clearance is provided
11. eee 3 8 Intrusion Switch 5 13 Local Port LOL 5 sti nn en 4 1 PL ON SM nt hub aan a be aids nai 7 6 POWER rss rites 3 10 Power Connections c ccscceeseeeeeeeeeeeeeseeneeeeeees 3 1 PulseInputs ue ER ee SUR Fo iret 5 18 Radi ceto re 3 15 4 9 RID ze esame 5 22 sensor Module iret RES 7 5 Solar Panel Charge Connections 3 12 Wire Gaul tis eue pep ie eite 3 10 Write to Internal Config Memory 9 6 Z Zero SMES weil aves ne evertere RR near 8 7 If you have comments or questions regarding this manual please direct them to your local sales representative or contact Emerson Process Management Flow Computer Division Marshalltown lowa 50158 U S A Houston TX 77065 U S A Pickering North Yorkshire UK YO18 7JA Website www EmersonProcess com flow l 6 Rev 04 04
12. z PT E c EH NS R37 cu oo mioo 9 R4 Eos o oo Hoo cra RS D crs9 S S 9 9 T JO O PI cR42 S de CRAB n pp cr44 e Se EC DER D pcr47 a e ee z 4 R6 m i 7 D bords 9 9 o p lo E Dhs o o ce M R7 4 D pcrss o Al Scali AE wir 8e zoo x 7p rss o o Sca ing ES ia Resistor R8 2o cw e e 9 s P 2 use m wi we Ren 997 Ke Isolation O 0 O Jumpers DOCO0407A Figure 5 3 Input Output Card 24 Channel Back 5 2 How to Install an I O Card The I O Card installs on the back of the swing out mounting panel in the FloBoss enclosure The I O Card electrically connects to the Main Electronics Board with a mating connector Earlier versions of the I O Card prior to January 2000 physically mount on two compression standoffs and secure with three 6 32 screws Current versions mount and secure with five 6 32 screws Refer to Figure and Figure 5 To avoid circuit damage when working with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap Always turn the power to the FloBoss off before you attempt any type of wiring Wiring of powered equipment could result in personal injury or property damage 1 Asa precaution save the current configuration and historical data to Config Memory Write to Internal Config Memory on the ROC Flags screen of ROCLINK for Windows software
13. CHE RER Res tee iis anne 3 11 Class T asma hi aea M ns AE 2 2 Clock Real TIME x asa scd ande t Rae S 1 18 Cold Start zis hoe atate te oe aet 9 3 9 6 Collect Data a iari nai WERE ER ates Ee 9 6 Comm Port Host Port Comm 1 16 Local Port EOD nem eie 1 16 Wiring Host Port Comm 4 9 Wiring Local Port LOT 4 1 Comml nine annees 1 16 Troubleshooting isis 3 5e eter Het 9 2 WAEIBE eiie ttem pin ertet Meese ween 4 9 Communication Ports 1 16 Communications Cards Descriptions rte n ire P etti 4 2 Dial Up Modem 4 5 ETA 232 RS 232 d iret teer ge tees 4 3 EIA 485 RS 485 sse 4 4 Installation rect RR eH ar RE 4 7 LED Indicators nones aa 4 4 Replacing sioe mte e ur tet 4 11 SP CIFICATIONS cp pad en 4 13 Troubleshooting the Dial up Modem 9 2 Troubleshooting the Serial Communications 9 2 Wiring Auxiliary Power eene 4 0 Wiring Dial Up Modem eee 4 11 Wiring EIA 232 RS 232 sss 4 9 Wiring EIA 485 RS 485 sss 4 10 Wiring Host Port Comm 4 9 Configuration reap a n eris 2 7 Dual Variable Sensor sess 6 2 Sensor Module 7 7 Connect a Communications Card Wiring 4 9 D Daily Historical Logs eere 1 11 DC Power Source sss 3 11 FloBoss 503 and 504 Instruction Manual DCD
14. Common RX TX ms WE Red TX White RX Black Common Connections at PC Serial Port DOCO0356A Figure 4 1 Local Port LOI Interface Wiring 4 2 Communications Cards Product Descriptions The optional communications cards provide communications between the FloBoss and a host system or external devices The communications cards install directly onto the Main Electronics Board at P3 and activate the Host Port Comm1 when installed The following cards are available EIA 232 RS 232 Serial Communications Card EIA 485 RS 485 Serial Communications Card Dial up Modem Communications Card 4 2 Communications Installation and Wiring Rev 04 04 FloBoss 503 and 504 Instruction Manual 4 2 1 EIA 232 RS 232 Serial Communications Card The EIA 232 RS 232 communications card meets all EIA 232 specifications for single ended EIA 232 RS 232 asynchronous data transmission over distances of up to 15 meters 50 feet Refer to Figure The EJA 232 RS 232 communications card provides transmit receive and modem control signals Normally not all of the control signals are used for any single application The EIA 232 RS 232 card is one of the optional interface cards for the Host Port of the FloBoss 500 series products The EIA 232 RS 232 communication card s P1 connector plugs into the Main Electronics Board at P3 and activates Comml The RTS and DTR control lines are supported The EIA 232 RS 232 c
15. R67 BE ggg Sue m d P mg mca amp a pumuga EL o D i BB 5 R63 us m m ad presreo Main Board Be PES C 3 D R64 R65 q D Mes yan CRIE R69 1 15 m d D cem D ag D oe il Screw Connector aa ut med m oe F87 R73q D R758 j E LL R76 Be Ue Qa d D mp7 R78 QI B f 2 E R DE d h q D 0 80 5 CRY C23 R81 R82 d oo m g pb iio A 10 ore I c m uu c D BE wd P is ve rage EU s 9 2 iO TAM usa FB cD UP7 I resa Do JE ces rez res H D FB8 soe c38 oY p res ma D res 689 oo TD c II ces E q R93 Q Da o f NR ce4 2 EI roe R h a o MEE 3 qd om ud Dp RM En ORI 5 q EE TR D m NA CRe17 CO Sosa E D FB9 d mgm Des U rue mos de lt o O ceg gg c E R97 co om m 2 R98 TII u26 Ei Ce q R99 2100 d D m m his 3 TRE agg 9 Q H R104 Cee E ORM Rom I R90 u28 g cRee i Q a RA lal S Rio tm ceo p EY R107 D Foose JE iE a el el LE COS em JE oe e ila I O Power y 8 les Rizo E mim Z H Hoo Hoo p R117 C35 7 C LL Pe B05 m 8 8 Screw DOCO407A Figure 5 2 Input Output Card 24 Channel Front A 24 channel I O Card has sockets for AI scaling resistors provided on the back of the I O Card along with switches for the selectable DI DO channels The DI DO Point Numbers are configured using ROCLINK for Windows software The 24 channel I O Card receives its power from the main processor card The processor is isolated from noisy I O circuits by o
16. Rev 04 04 Sensor for FloBoss 503 6 1 FloBoss 503 and 504 Instruction Manual 6 2 Process Connections Piping from the meter run connects to the DVS Sensor of the FloBoss 503 unit Both the static and differential pressures pipe to female 4 18 NPT connections on the bottom of the Sensor The FloBoss 503 is an upstream device meaning that the static pressure line normally connects to the high pressure side labeled H on the sensor body and the upstream values are normally calculated If you need to use the FloBoss 503 as a downstream device refer to the ROC FloBoss Accessories Instruction Manual Form A4637 6 3 Sensor Wiring The FloBoss 503 and the Sensor ship from the factory with the wiring connected between them This wiring consists solely of a ribbon cable from the Sensor which plugs into the P DP connector on the Main Electronics Board at P11 This ribbon cable fits into the P11 connector in only one direction Always turn off power to the FloBoss 503 before you connect or disconnect wiring Wiring of powered equipment could result in personal injury or property damage 6 4 Configuration Use the ROCLINK for Windows configuration software to configure the DVS Sensor meter run and I O For more information refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 6 4 4 Meter Run To configure the meter run select the Meter Setup This displays a screen that allows you to configure a flow calcul
17. comm card one should connect to comm card two and comm card two should connect to comm card three 4 10 Communications Installation and Wiring Rev 04 04 FloBoss 503 and 504 Instruction Manual 4 4 3 Dial Up Modem Communications Card Wiring The dial up modem card interfaces to a PSTN line through the RJ11 jack located at J2 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 500 series enclosure LEDs are provided for diagnostic functions The dial up modem card provides a modular phone RJ11 jack that directly interfaces to phone line connections The RJ11 connector signals and their functions are diplayed in Table Table 4 5 Dial up Modem Host Port Terminations RJ11 Signal 1 2 3 Tip 4 Ring 5 6 4 5 How to Replace a Communications Card If you are installing a communications card for the first time refer to Section Communications Card Installation and Setup To remove and replace a communications card on an in service FloBoss 500 series perform the fo
18. telephone company If this equipment dial up modem causes harm to the telephone network the telephone company will notify you in advance that temporary discontinuance of service may be required But if advance notice isn t practical the telephone company will notify the customer as soon as possible Also you will be advised of your right to file a complaint with 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 2 2 Mounting When choosing an installation site be sure to check all clearances Provide adequate clearance for the enclosure door to be opened for wiring and service The door is hinged on the left side The LCD display should be visible and accessible for the on site operator When using a solar panel allow adequate clearance View of the sun should not be obstructed Allow adequate clearance and an obstructed location for ante
19. 1 10 Table 3 1 Power Consumption of the FloBoss and Powered Devices esee 3 2 Table 3 2 Power Consumption of the I O Card 3 2 Table 3 3 Power Consumption of the I O Cards 24 Channel utere eei 3 3 Table 3 4 Solar Panel Sizing 3 7 Table 3 5 Terminal Connectors 3 8 Table 4 1 Local Port LOT Terminations 4 1 Table 4 2 Communications Cards LED Indicators 4 4 Table 4 3 EIA 232 RS 232 Host Port Terminations fee ete 4 9 Table 4 4 EIA 485 RS 485 Host Port Terminations M D 4 10 Table 4 5 Dial up Modem Host Port Terminations 4 11 Table 5 1 I O Card Channels 5 1 Table 5 2 Analog Inputs 10 Channel 5 8 Table 5 3 Analog Inputs 24 Channel 5 8 Table 5 4 Analog Inputs Terminals 5 9 Table 5 5 Analog Outputs 10 Channel 5 10 Table 5 6 Analog Outputs 24 Channel 5 11 Table 5 7 Analog Output Terminals 5 11 Table 5 8 Discrete Inputs 10 Channel 5 12 Table 5 9 Default Discrete Inputs 24 Channel 5 12 Table 5 10 Discrete Inputs Terminals 5 12 Table 5 11 Discrete Outputs 10 Channel 5 14 Table 5 12 Default Discrete Outputs 24 Channel
20. 6 FloBoss 503 and FloBoss 504 Main Specifications 1 1 MANUAL OVERVIEW This manual includes the following sections 9 Section bi Installation and Use provides information concerning the installation and use of the FloBoss Section B Power Connections describes the power connections of the FloBoss 503 and FloBoss 504 Flow Managers focusing on calculating power and connecting wiring Section 4 Communications Installation and Wiring provides information and specifications for standard communications and the optional communications cards Section 51 Inputs and Outputs provides information and specifications for the standard inputs and outputs plus the optional Input Output I O cards which supplies additional inputs and outputs for expanded monitoring and control applications Section 6 Sensor for FloBoss 503 describes the Sensors included with the FloBoss 503 for sensing static pressure and differential pressure Section pi Sensor for FloBoss 504 describes the Sensor Module included with the FloBoss 504 for sensing static pressure and counting pulse inputs Section 8 Calibration describes how to calibrate the FloBoss 503 and FloBoss 504 Flow Managers Section 5i Troubleshooting describes how to troubleshoot the FloBoss 503 and FloBoss 504 Flow Managers lossary of Terms defines terms used in this manual alphabetically lists the items contained in this manual along with their page
21. Communication Cards Specifications The following tables list the specifications for each communications card Serial Card Specifications POWER REQUIREMENTS 4 75 to 5 25 V dc 0 03 W maximum supplied by processor board ENVIRONMENTAL Operating Temperature 40 to 75 40 to 167 F Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity To 95 relative non condensing DIMENSIONS 18 mm H by 51 mm W by 70 mm L 0 7 in H by 2 0 in W by 2 75 in L APPROVALS Covered by the CSA approval for the FloBoss 503 or FloBoss 504 unit in which it is installed EIA 232D RS 232D CARD Meets EIA 232 RS 232D standard for single ended data transmission over distances of up to 15 m 50 ft Data Rate Selectable from 1200 to 19 000 bps Format Asynchronous 7 or 8 bit software selectable with full handshaking Parity None odd or even software selectable EIA 485 RS 485 CARD Meets EIA 485 RS 485 standard for differential data transmission over distances of up to 1220 m 4000 ft Data Rate Selectable from 1200 to 19 200 bps Format Asynchronous 7 or 8 bit software selectable Parity None odd or even software selectable LED INDICATORS Individual LEDs for RXD TXD and RTS signals EIA 232D RS 232D card also has LEDs for DTR and DCD Rev 04 04 Communications Installation and Wiring 4 13 FloBoss 503 and 504 Instruction Manual OP 4 14 Dial up Modem Card Specif
22. Data unless you specify otherwise another Directory Drive before you click Save The report can be viewed using a text editor 6 Click Save If you are calibrating a pressure input read the following Caution and then isolate the Sensor from the process If you are calibrating a temperature input proceed to Step 8 Open the by pass valve on the valve manifold prior to isolating the sensor from the process to protect the differential cell of the Sensor This will keep one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied This should be done whether you are calibrating differential or static pressure Refer to Figure for the recommended sequence 8 2 Calibration Rev 04 04 FloBoss 503 and 504 Instruction Manual Bleed Bleed PEG a UBS za Pressure Remains e a Shutdown Sequence Operating Shutdn2 Figure 8 2 Removing the Sensor from Service 7 Ifyou are calibrating a pressure input setup the pressure calibrator and make the necessary connections to the Sensor 8 Ifyou are calibrating a temperature input disconnect the RTD sensor and connect a decade box or comparable equipment to the RTD terminals of the FloBoss 9 Click Calibrate under the desired input to calibrate Diff Press Stat Press or Temperature This displays the Set Zero calibration window as in Figure Point ATD Dead Weight T ester Value
23. FUSING 1 A for either the 115 or 230 V ac range DC OUTPUT 14 V dc no load Supplies 1 0 A maximum at 25 C 77 F Derate DC output power 10 for 50 Hz operations 3 16 Power Connections OUTPUT RIPPLE 5 0 mV peak to peak maximum EFFICIENCY 55 typical ENVIRONMENTAL Operating 40 to 65 C 40 to 149 F fully rated Storage 40 to 85 C 40 to 185 F EMI RFI SUSCEPTIBILITY Meets the requirements of FCC Docket 20780 for Class B equipment and VDE 0871 for Class B WEIGHT 0 9 kg 2 lbs including case APPROVALS Approved by CSA for hazardous locations Class I Division 2 Groups A B C and D Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 4 COMMUNICATIONS INSTALLATION AND WIRING This section describes the built in communications wiring and the communications cards used with the FloBoss 500 series Flow Managers The FloBoss unit communicates to external devices through either its Local Port LOD or its Host Port Comm1 The Local Port uses a special 3 pin connector to connect a PC running ROCLINK for Windows software The Comm1 Port has the flexibility to communicate to external devices using different protocols Wiring connections for the Comml Host Port are made using screw terminals on the optional communications card This section contains the following information Section 4 1 How to Wire the Local Port LOD sossnsssssssssnsessseseessoseesssssssssee 4 2 Communi
24. FloBoss main electronics board or another source 7 4 Configuration Use ROCLINK for Windows Configuration Software to configure the meter run and inputs associated with the SM For configuration procedures refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 7 4 4 Meter Run To configure the meter run select the Meter Setup This displays a screen that allows you to configure a flow calculation point Figure shows the Turbine Setup screen for an ISO 9951 flow point The parameters shown in this screen are described following the figure For details concerning each parameter refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 NOTE A FloBoss 504 supports 1992 AGAS compressibility depending on which firmware Flash was installed ISO 12213 2 compressibility is supported by all 504 firmware options NOTE To select the ISO 6551 API 5 5 Pulse Fidelity Level A through Level E use the Advanced tab as described in the ROCLINK for Windows Configuration Software User Manual Form A6091 Rev 04 04 Sensor for FloBoss 504 7 7 FloBoss 503 and 504 Instruction Manual 1992 Turbine Setup General Inputs Gas Quality Advanced Alarms Sampler Instrument Calib Point Number hoo Meter ID Meter 1 Meter Description PO Calc Type 1992 Turbine ISO Base Multiplier Period bmp fi minutes K Factor fi Pulses Ft3 Flow Alarming Sensor Alarming
25. Input terminal block Figure shows wiring for a 3 or 4 wire voltage transmitter Rev 04 04 Inputs and Outputs 5 9 FloBoss 503 and 504 Instruction Manual Current Limit External Self Powered Device Signal 1 to 5 V dc This device should not receive power from the Main Electronics Board or a ground loop may occur DOC98C5a Note This device should not receive power from the Main Electronic Board or a ground loop may occur Figure 5 8 Voltage Signal Self Powered Device on Analog Input FLOBOSS POWERED POWER Current Limit O V 3 OR 4 WIRE TRANSMITTER SIGNAL 1 TO 5 VOLTS SELF POWERED COMMON DEVICE SIGNAL T 12 24 VDC 22 mA max SIGNAL 1 TO 5 VDC DOCO0098A J Figure 5 9 Voltage Transmitter on Analog Input 5 3 2 Analog Output Analog Outputs AOs provide a current output for powering analog devices The I O Card Analog Output is a 4 20 mA loop signal with a maximum voltage of 24 V dc from the isolated power supply The Analog Output uses a 12 bit D A converter and a voltage to current converter Table and Table display the Analog Output s number the Point Number to which the AO is assigned in ROCLINK for Windows software and the number printed on the I O Card In the case of the 24 channel card the number in the software and on the label are the same Table 5 5 Analog Outputs 10 Channel 5 10 Analog Po
26. Integral Value Average FloBoss 504 Uncorrected Flow Today Accumulate 7 Instantaneous Flow Accumulate 8 Instantaneous Energy Accumulate The Average Archive Type 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 seven user configurable history points and Averaging Technique may be configured in ROCLINK for Windows software 1 4 3 1 Minute Historical Log The FloBoss unit 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 4 3 2 Hourly Historical Log The FloBoss unit has a total of 840 hourly historical logs available for every history point The Hourly Historical Log is also called the Periodic Log Normally the Hourly Log is recorded every hour at the top of the 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 for which the time stamp consists of the day hour minute and second 1 10 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual 1 4 3 3 Daily Historical Log The FloBoss unit has a to
27. P DP enables all readings from the sensor to be available to the Main Electronics Board The readings from the SM are configured as two Analog Input points and two Pulse Input points Table 7 1 Analog and Pulse Inputs Input Type EE Reading Analog Input Al Auxiliary Pressure Analog Input A2 Line Static Pressure Pulse Input A5 Pulse Count Pulse Input A6 Auxiliary Pulse Input Standard PI and AI alarming are implemented along with sensor and flow alarms If the sensor fails to communicate either during initialization or run time the Failure bit in the Pulse Input and Analog Input alarm code is set If alarms are enabled an alarm is also entered in the Alarm Log The sensor measurement in the SM for the static and auxiliary pressure inputs can be any combination of these ranges listed in Section Read the label on the SM to know the specific pressure ranges The SM informs the Main Electronics Board that it is ready for an update at least once per second The FloBoss converts this value and stores it in the proper Pulse Input and Analog Input for access by other functions within the FloBoss If an update does not occur in ten seconds the sensor is re initialized A Point Fail alarm is set if the sensor does not respond to the initialization Calibration is performed through the PI and AI routines As described in Section use ROCLINK for Windows Configuration Software to configure all Analog Input
28. Power Supply 3 13 Installation eee teer 3 14 Specifications une ep eR edet eme 3 16 ACC SSOTI S c RE 1 5 Liu c Rc EE 1 7 ACTA RE nn bbe aes aa ee ae 1 9 Alarm Og 2 desee een 1 11 Analog Inputs erret rediere End rere ER 7 4 Troubleshooting eene 9 3 WANDS sn NN aie hele hn ioe Su 5 8 Analog Outputs Troubleshooting eene 9 3 MINS hs sale ass 5 10 Antennds sente ne dete 2 2 ARP aise nina ren 1 7 Approvals ether dete 2 2 AT Conimand ertet eet 4 6 Automatic Self Tests sss 1 18 Auxiliary Output POWER esse dte even 3 15 Ivo 4 0 Pressure erc dee eee diera 1 7 Average Archive Type sese 1 10 B Backup e PE ERE EE 9 6 Base Multiplier Value BM Vissi sien ashe aem a ER 1 8 BAT estie coat ntantb dm aldea 3 11 Battery 4 2 tero pc et eee 1 6 3 7 Accessing the Compartment eseeseeeeeseeeeeseeeeeees 2 7 Capacity with Power Supply 3 13 Charger ses te mette ote 3 12 3 13 Conn ctioris etat npe to is 3 11 Requirements secte ee ues 3 7 Board rs ears tennis TR 1 4 Rev 04 04 C CPi ee ee ee C IN tes e LE Coates 1 8 Calculations 1992 AGA iiiter ette e ee ied 1 9 1992 FOW nt aceite E RH 1 8 Input and Extension 1 8 Instantaneous Rate 1 8 Calibrations rur Ree bare eiue 8 1 8 7 R port siemens eedem dale dee 8 2 Cathodic Protection sssesseeeeeeenene 3 5 Charger nate ee pt ea tee estesa 3 12
29. Shift If desired use the Zero Shift procedure after calibrating 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 Zero Shift procedure Once the Zero Shift window has closed the Meter Calibration window displays Refer to Figure Click Done to close the calibration window cancel the freeze values and cause the FloBoss to begin using live readings for the flow calculations 8 2 Calibrating I O 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 battery voltage Point Number E1 charge voltage Point Number E2 and board battery temperature Point Number E5 are not designed to be c
30. UE 5 14 Table 5 13 Discrete Outputs Terminals 5 15 Table 5 14 Discrete Output see 5 16 Table 5 15 Built in Discrete Outputs Terminals 5 17 Table 5 16 Pulse Inputs 10 Channel 5 18 Table 5 17 Pulse Inputs 24 Channel 5 18 Table 5 18 Pulse Inputs Terminals 5 18 l 5 FloBoss 503 and 504 Instruction Manual Table 5 19 PI and DI Point Numbers 10 Channel EE 5 20 Table 5 20 I O Card LEDs 10 Channel 5 21 Table 5 21 RTD Terminals sssseeeseesee seses eese 5 22 Table 5 22 RTD Input Wiring 5 23 Table 6 1 Configuration Inputs esss 6 3 Table 7 1 Analog and Pulse Inputs 7 2 Table 7 2 Pulse Inputs eene 7 3 Table 7 3 Analog Inputs eee 7 4 Table 7 4 PI Connections on the SM 7 6 Table 7 5 Configuration Inputs ss 7 8 TDO 2 taste eode epar 1 17 5 16 Temperature 1 7 1 18 2 1 Terminal Connections 3 8 Tests AUTOMATIC in eere tti te eerte etn ener n 1 18 Titer Interrupted in mel 1 19 G 5 Troubleshooting aae 9 1 Dial up Modem 9 2 Dual Variable Sensor 9 4 Guideli es nieder ied 9 1 Inputs and Outputs eene 9 3 Multi Variable Sensor 9 4 Powe
31. United States during winter months Call your local sales representative for a map detailing your specific geographic area Insolation from map hours Next calculate the amount of current required from the solar array per day using the following equation Isp is the system current requirement Refer to Section Totaling Power Requirements on page 3 3 Tarray Isr Amps x 24 hours Insolation hours Amps Figure 3 1 Solar Insolation in Hours for the United States Finally the number of solar panels can be determined using the following equation Number of Panels array Amps Ipanet Amps panel panels For example if Lay equals 0 54 Amps and La equals 0 29 Amps for a 5 watt panel then the number of panels required equals 1 86 which would be rounded up to 2 panels connected in parallel Alternatively the next larger solar panel can be used which in this case would be a 10 watt panel Table gives recommended Ij 54 values for solar 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 NOTE The current accepted by the FloBoss 500 series unit is limited by its charging circuit to around 1 Amp Therefore it is not practical to install a solar array that supplies significantly more than 1 Amp to the FloBoss unit 3 6 Power Connections Rev 04 04 FloBoss 503 and 504 Instruction Manual Table
32. amp D2 amp SO amp LOSO 1S7 60 for modem model W28146X0012 ATEOHOVOXIQO amp CI amp D2 amp SO0SO0 1S7 60 for modem model W28146X0022 LED indicators on the communications card show the status of the RXD TXD and RI control lines see Table 4 2 The modem card also provides EIA 232 RS 232 level output signals RXD and TXD for an analyzer 4 6 Communications Installation and Wiring Rev 11 11 FloBoss 503 and 504 Instruction Manual 4 3 Communications Card Installation and Setup Communications card installation is normally performed at the factory when the FloBoss is ordered However the modular design of the FloBoss 500 series makes it easy to change hardware configurations in the field The following procedures assume that this is a first time installation of a communications card in a FloBoss and that the unit is currently not in service For units currently in service refer to the procedures in Section D Troubleshooting When installing units in a hazardous area ensure that the components selected are labeled for use in such areas 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 Be sure to use proper electrostatic handling such as wearing a grounded wrist strap or components on the circuit cards may be damaged 4 3 1 How to Install a Communications Card All communications cards install into the FloBoss in the same
33. and Pulse Input points required for turbine metering Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 for detailed information 7 2 Sensor for FloBoss 504 Rev 04 04 FloBoss 503 and 504 Instruction Manual P10 1 2O00229 8888 no e 20000 a n I CARES os D q J DOC0300C Turbine Pulse Turbine Pulse Input PI 2 or Input PI 1 or Channel B Channel A Status LED js Figure 7 1 Sensor Module 7 1 1 Pulse Inputs The SM is capable of handling two channels points for Pulse Inputs The first Pulse Input PI is used to calculate the flow based on counts acquired from a turbine meter This Pulse Input is located at Pl on the SM The second Pulse Input called the auxiliary PI is typically used to perform Level A B or C pulse integrity checking When pulse integrity checking is not in use you may use the auxiliary PI in other ways such as calculating a correction value for a meter or calculating odor injection This Pulse Input is located at P2 on the SM Table 7 2 Pulse Inputs Input Type RER Reading Pulse Input A5 Pulse Count Pulse Input A6 Auxiliary Pulse Input The Pulse Input circuitry is based upon a two stage Schmidt trigger inverter Also provided is a source voltage for open collector drain turbines and for dry contacts This
34. are 4 18 NPT 7 4 Sensor for FloBoss 504 Rev 04 04 FloBoss 503 and 504 Instruction Manual CAUTION Be sure to use a pipe thread compound suitable for stainless steel or galling may occur LLL EY ET AAT ET BE I DOC0299B Ribbon Cable NM Auxiliary Pressure Static Pressure SKE Figure 7 2 Side Cut away View Showing Process Connections 7 3 Sensor Wiring The only field wiring connections to the SM are for the two Pulse Input channels Like the standard field wiring the wiring terminals for these inputs are accessed by opening the door of the FloBoss 500 enclosure The terminal designations S and COM are printed on the circuit board directly below each terminal as shown in Figure PI 1 Channel A is located at the left three terminals of the terminal block PI 2 Channel B is located at the right three terminals The Pulse Input PI terminals are detailed in Table FA When connecting the SM for Level A B or C pulse integrity checking use both Pulse Inputs the order does not matter When connecting the SM for Level D or E pulse integrity either channel may be used to acquire pulse counts in fact the pulse count could even come from an I O card The unused PI may be used in other ways such as for calculating odor injection Rev 04 04 Sensor for FloBoss 504 7 5 FloB
35. c 5 18 Witing to SM eerie e e E 7 6 R Radio Auxiliary Output Power 3 15 Br cketos c re tenta nt i 1 5 2 7 Mount 3 tr rer te et 2 7 Power Cycling 3 16 4 3 Power Requirements eese 3 3 Wiring Switched Auxilary Power 4 0 Radio Frequency Interference sees 3 5 RB Xi as fain antithesis eie 1 13 Real Time Clock 1 18 Rev 04 04 FloBoss 503 and 504 Instruction Manual R contig re eo seas tone tite bien this 9 7 RE pair iode e ep PEE ss 9 1 Replacing Communications Cards 4 11 Reports Calibration ss sine ins 8 2 Reset Jumper ss visa he heehee Heater 9 6 Reset the FloBoss rnnr iien ei a 9 6 Reset the FloBoss 503 DVS to Factory Defaults 9 5 Restart oeste aie hale 9 7 Restart and Reconfigure sse 9 7 REL 1 uiceconuet eneeiesmen due hd 3 5 3 9 RI eua eua ete os 4 4 ROM Flash nier nto eer 1 4 RST ius Ronmen pei 9 3 9 7 REID nante oon 1 7 1 17 1 18 Minim 5 22 RIS sch dart ani aee eaa iai 4 4 4 RXD z nica AEn ede at e eg 4 4 S DOCUIILY RP 1 5 1 12 1 16 Intrusion Switch 5 13 Sensor FIOBOSS 303 e EORR RARE REESE 6 1 FIOBOSS SA ni terere teer heredi 7 1 Wins DVS egest Idee 6 2 Wits SM iia oia dotem nit eti Manuel 7 5 Sensor Module Analog Inputs eese ene 7 4 Configuration esse sale oe atr 7 7 Configuration Inputs esee 7 8 COnnectIOD idco eee eee
36. displays after a power up sequence Normal Operation Flashing green Communication Fail Solid green for 20 seconds then alternating red processor reset and green Power Fail LED off If a failure is indicated check the P DP connector and restart the FloBoss Refer to Section How to Reset the FloBoss on page 9 6 9 3 Procedures 9 3 1 How to Reset the FloBoss 503 DVS to Factory Defaults To reset the DVS back to the original factory defaults 1 Launch ROCLINK for Windows software Select Configure I O AI Points Select Analog Inputs 1 Point Number A1 Select the Advanced tab Enter 32767 in the Adjusted A D 100 field Refer to Figure m D Analog Input EEB General Advanced Jal Calibration Filter B Adjusted A D 0 p Adjusted A D 100 26 Raw A D Input p Actual Scan E Seconds Average Raw Value Temp Compensation Clipping E Enabled f Enabled C Enabled Disabled Disabled Disabled Copy e Paste 2 Update v o x Cancel t Apply Figure 9 2 Analog Input Advanced 6 Click Apply Rev 04 04 Troubleshooting 9 5 FloBoss 503 and 504 Instruction Manual 9 3 2 How to Preserve Configuration and Log Data Perform this backup procedure before removing power to the FloBoss unit for repairs troubleshooting removing or adding components or upgrades This procedure preserves the current flow computer configuration and log da
37. drivers are designed for true multi point applications with multiple devices on a single bus This optional interface communications card for the Host Port activates Comml The P1 connector on the EIA 485 RS 485 communication card plugs into the Main Electronics Board at P3 The interface lines of RTS are supported to control transmission RTS must be active during TXD The default values for the EIA 485 RS 485 communications card are 9600 bps Rate 8 Data Bits 1 Stop Bit No Parity 10 millisecond Key On Delay and 10 millisecond Key Off Delay The maximum rate is 19 200 bps The EIA 485 RS 485 communications card includes LED indicators that display the status of the RXD TXD and RTS control lines LED indicators are detailed in Table 4 4 Communications Installation and Wiring Rev 04 04 FloBoss 503 and 504 Instruction Manual P I5 O O O O O O O O0 6 O06 Mating Connector C1 C2 FB1 CRI ARABHABE Qa J HEHHHH FB2 C3 TXD mo CR2 FLA AA a R2 LEDs x u2 UEHH C4 CRS CR4 CR5 RTS m DI DI R4 PTR1 rODOTOE Bi O sss O TB1 DOC0275A Figure 4 3 EIA 485 RS 485 Serial Communications Card 4 2 3 D
38. field device that uses a switch to ground a shorting switch can be accommodated by wiring the device between the and COM terminals and also connecting the S and terminals together Note that although the power for the pulse device is shown coming from power terminals on the FloBoss another suitable 12 volt source could be used but not the S terminal on the SM Pulse Input The field device is assumed to be opening and closing an isolated switch of some type The SM supplies the power to handle this wiring scheme The pulse device is typically a self powered device with a built in amplifier NOTE FloBoss powered means power is received from the Input Output or Module shown External Self powered means power received from the device a battery the FloBoss main electronics board or another source 7 6 Sensor for FloBoss 504 Rev 04 04 FloBoss 503 and 504 Instruction Manual PI ON SENSOR MODULE S vw o Vg PI FILTER AND PI LEVEL DETECTION DEVICE DOC0446A Figure 7 3 Pulse Input from FloBoss Powered Device PI ON SENSOR MODULE PI FILTER AND EXTERNAL SELF LEVEL DETECTION POWERED PULSE DEVICE DOC0432A Figure 7 4 Pulse Input from FloBoss Powered Device NOTE On External Self powered wiring locate an external fuse close to the power connector on the battery the
39. for the radio antenna cable to exit through the bottom of the enclosure Rev 04 04 General Information 1 5 FloBoss 503 and 504 Instruction Manual An optional FloBoss 500 series I O Cards provide additional inputs and outputs for expanded monitoring and control applications The I O Card contains Analog Inputs AI an Analog Output AO Discrete Inputs DI Pulse Inputs PI and Discrete Outputs DO The DI DO and PI circuitry is optically coupled to help isolate the processor board from the input signal Refer to Section 4 Communications Installation and Wiring for more information An internal AC power supply is available as a factory installed option The AC power supply converts AC line power to DC power for use with the FloBoss and the associated accessories The power supply typically is used in line powered installations If battery backup is used in the line powered installation the AC supply also functions as a battery charger The unit provides a fully regulated temperature compensated output that is protected from overcurrent conditions The AC supply is factory installed in the battery compartment of the FloBoss Refer to Section b Power Connections for details concerning the AC power supply The intrusion switch acts as a tamper detector for the FloBoss units The intrusion switch is a momentary contact switch used to detect whether the door to the enclosure is open or closed The switch which has a normally closed contac
40. iude mte 4 4 Deadband erit pn G 2 Diagnostic Inputs tp petes 1 18 Dial Up Modem Communications Cards 4 5 Troublshooting eene 9 2 bun cS 4 11 Differential Pressure 1 7 G 4 Discrete Inputs Troubleshooting eene 9 3 Using Pulse Inputs eee 5 20 Win ig d eene gue beatius 5 11 Discrete Outputs Built in sisi area od ener eden 1 17 Troubleshooting eene 9 3 Wiring Built in 5 16 Winne VO Cardini inn i een 5 14 DIVISION 2 nda th Nevis DE e e e 2 2 Download nuni e et its 9 7 9 8 D z Mode nit eter terere 1 19 DER dole eene hine 4 3 4 4 Dual Variable Sensor 6 1 Configuration iii i e s 6 2 Inputs c et eet cp e eredi 6 3 Meter Rut iae ett rre redet er eR 6 2 OVeErVIeW aen eire tu Gt e e e ere 6 1 Process Connections sssesseseenene 6 2 Reset to Factory Defaults sseeeseseeesereeseeeere ereere 9 5 Speci catons c i rrr tiet toe Het eene 6 4 Troubleshooting eene 9 4 WATS ient epe e e bie Pre ne 6 2 Duty Cycle Rr REP 3 1 3 3 E EPM M rte 1 2 EIA 232 RS 232 Communications Cards 4 3 Troubleshooting esee 9 2 A tte ete due 4 9 EIA 485 RS 485 Communication Cards sse 4 4 Troubleshooting eeseeeeeeeeene 9 2 Minnie en E mr PEE
41. lockable hasp The enclosure is fabricated from carbon steel Refer to the Specifications tables in Section FloBoss 503 and FloBoss 504 Main Specifications on page 1 20 for dimensional details Mounting Flange RII Operator Interface LOI Connector Figure 1 1 FloBoss 503 Flow Manager Rev 04 04 General Information 1 3 FloBoss 503 and 504 Instruction Manual Mounting Flange LCD Cover HI DS DOC0304C Operator Interface LOI Connector Figure 1 2 FloBoss 504 Flow Manager 1 3 1 Hardware The Main Electronics Board mounts on quick fastener stand offs located on top of the swing out panel The majority of the components are surface mounted with only the top side of the board used for components The Main Electronics Board has built in I O capabilities an LCD display provisions for an optional communications card and provisions for an optional I O card For more information on the Main Electronics Board refer to Section Main Electronics Board Overview on page 1 13 A Motorola 32 bit Complementary Metal Oxide Semiconductor CMOS microprocessor runs at 14 7 MHz and has low power operating modes including inactivity and low battery conditions The FloBoss comes standard with 512 KB of built in super capacitor backed Static Random Access Memory SRAM for storing data and history The FloBoss also has 512 KB of programmable Read Only Memory flash ROM for storing operating system firmware applications f
42. 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 Soft Points A type of ROC point with generic parameters that can be configured to hold data as desired by the user SP Setpoint when used in discussions of PID loops or Static Pressure when used in discussions of flow parameters SPI Slow Pulse Input SRAM Static Random Access Memory Stores data as long as power is applied typically backed up by a lithium battery or supercapacitor SRBX Spontaneous Report By Exception SVA Signal Value Analog SVD Signal Value Discrete T Z TDI Timed Discrete Input or Timed Duration Input TDO Timed Discrete Output or Timed Duration Output Tf Flowing temperature TLP Type of point Logical or point number and Parameter number For a list and explanation of the TLPs refer to the ROC Protocol Manual Form A4199 TX or TXD Transmitted Data communications signal G 6 Glossary Rev 04 04 FloBoss 503 and 504 Instruction Manual INDEX Symbols Difference Live Act Span sss 8 3 SET Tumper sees iie deor 5 9 0 Count NIMES 8 3 10 Channel I O Card see 5 2 24 Channel VO Card eese 5 3 1992 AGA Flow Calculations 1 8 1 9 32 bit CMOS Microprocessor s src 1 4 A AC
43. manner 1 Unplug the Power terminal block at P8 to ensure power is removed 2 Plug in the communications card connector P1 into connector P3 on the Main Electronics Board Figure shows the card location Gently press the connectors together until the card contacts a stand off 3 Ensuring that the three stand off holes in the communications card line up with the compression stand offs on the Main Electronics Board install by firmly pressing the communications card onto the stand offs 4 Plug in the Power terminal block at P8 to allow power to be applied 5 With the FloBoss powered up and a PC connected to the LOI port and running ROCLINK for Windows software verify that the configuration associated with the communications card is correct If not change as needed 6 Perform wiring as instructed in Section How to Connect Communications Card Wiring Rev 04 04 Communications Installation and Wiring 4 7 FloBoss 503 and 504 Instruction Manual Mating Connector Pt ee eee eeeood Stand off Hole Communications Card eo eo eo oo eo eo eo eo eo El Stand off Hole Stand off Hole dd PT2 PT3 O BLK WHT RED DOC0332B Figure 4 5 Communications Card Location 4 8 Communications Installation and Wiring Rev 04 04 FloBoss 503 and 504 Instruction Manual 4 4 How to Connect Communications Card Wiring Signal wiring connections to the communications cards are made through the terminal bloc
44. must be installed according to the National Electrical Code NEC Article 501 2 2 Installation and Use Rev 04 04 FloBoss 503 and 504 Instruction Manual 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 Federal Communications Commission 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 A FCC compliant telephone modular plug is provided with this equipment This equipment is designed to be connected to the telephone network or premises wiring using a compatible modular jack that is Part 68 compliant Refer to Installation Instructions for details 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
45. numbers Rev 04 04 General Information 1 1 FloBoss 503 and 504 Instruction Manual 1 2 ADDITIONAL INFORMATION The following manuals may be used to acquire additional information not found in this manual ROCLINK for Windows Configuration Software User Manual Form A6091 Part Number D301138X12 ROC FloBoss Accessories Instruction Manual Form A4637 Part Number D301061X012 ROC Protocol User Manual Form A4199 Part Number D301053X012 1 3 PRODUCT OVERVIEW The FloBoss 503 and FloBoss 504 are 32 bit microprocessor based Electronic Flow Measurement EFM computers that provide functions required for measuring the flow at a single meter run The FloBoss 503 provides functions required for orifice metering by measuring the differential pressure static pressure and temperature The FloBoss 504 provides functions required for turbine metering by measuring the pulse counts static pressure and temperature The FloBoss 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 gas flow calculations data archival remote communications and logic and sequencing control using a Function Sequence Table FST The FloBoss provides the following standard components and features A32 bit microprocessor 512 KB of flash read o
46. radio and bracket into the enclosure aligning the assembly over the two studs on the back panel of the enclosure and position the bracket over the 6 32 x 0 50 screw 5 Slide the bracket to the right to engage the slots and tighten the screw 6 Route the radio antenna either to the right or to the left and then out the bottom of the FloBoss enclosure 2 2 3 Accessing the Battery Compartment As many as four 7 Amp hour batteries can be mounted inside the FloBoss enclosure To access the battery compartment 1 Unscrew the two captive screws on the left side of the swing out mounting panel containing the Main Electronics Board 2 Unplug the ribbon cable going to the Sensor by pressing down on the connector tab and pulling straight out 3 Press down on the detent immediately below the Sensor P DP connector and swing the mounting panel out You now have full access to the battery compartment 2 3 Configuration The FloBoss 500 series Flow Managers have 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 for Windows software which runs on an personal computer The PC is normally connected to the Local Port LOI of the flow computer to transfer configuration data into the FloBoss unit although much of the configuration can be performed off line and later downloaded into the unit The configuration data can be downlo
47. radio communications locate the FloBoss unit away from electrical noise sources such as engines large electric motors and utility line transformers Locate the FloBoss unit away from heavy traffic areas to reduce the risk of being damaged by vehicles However provide adequate vehicle access to aid in monitoring and maintenance 2 1 3 Compliance with Hazardous Area Standards The FloBoss unit has hazardous location approval for Class I Division 2 Groups A to D exposures 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 2 locations are presumed to be hazardous only in an abnormal situation Group defines the hazardous material in the surrounding atmosphere Groups A to D are defined as follows Group A Atmosphere containing acetylene Group B Atmosphere containing hydrogen gases or vapors of equivalent nature Group C Atmosphere containing ethylene gases or vapors of equivalent hazards Group D Atmosphere containing propane gases or vapors of equivalent hazards For the FloBoss unit to be approved for hazardous locations it
48. remove the AC Power Supply 3 Move the Switch S1 on the back of the AC Power Supply to the desired position 4 Re install the AC Power Supply In installations where battery backup is used the AC Power Supply also functions as a battery charger When charging batteries temperature compensation of the output voltage is provided Battery temperature is sensed by a thermistor supplied connected to terminals T1 and T2 on the AC Power Supply For connection to the FloBoss when battery backup is being used refer to Figure If battery backup is not used ensure that the DC output of the AC Power Supply is connected to the CHG terminals 3 14 Power Connections Rev 04 04 FloBoss 503 and 504 Instruction Manual Through its DC Monitor terminals the AC Power Supply provides a means for monitoring its DC output remotely allowing an alarm to be produced when power is interrupted The DC Monitor terminals are typically connected to an unsourced Discrete Input DI To use a DI on the FloBoss 500 series I O Card which has sourced DIs use a relay between the DI and the DC Monitor terminals Refer to Figure POWER INTENAL TERMINAL BLOCK POWER SUPPLY BAT CHG AC INPUT L1 L2 GR 115 230 V ac 47 63 Hz Figure 3 6 AC Power Supply Connections 3 2 4 Auxiliary Output Power Refer to Figure These terminals can supply power pass through to external devices such as a radio or cell phone The power for this connector originates a
49. running and communications active with baud clocks running A Periodic Interrupt Timer PITR wakes up the FloBoss unit and starts the normal operating mode Wake up from Standby occurs when the FloBoss unit receives a 9 Timed Alarmed interrupt from the Real Time Clock Signal from the Local Port LOI Signal from connector P10 built in I O DO RTD or RTS Signal from the I O Card Signal Carrier Detect CD from a communications card Comml Signal Ring Indicator RI from a communications card Comml Sleep This mode is used if a low battery voltage is detected The battery voltage measured by diagnostic Analog Input Point Number El is compared to the LoLo alarm limit associated with this point This limit value defaults to 10 6 volts Wake up from Sleep occurs when the FloBoss unit receives a Timed Alarmed interrupt from the Real Time Clock Signal from the Local Port LOI If the battery voltage is less than the LoLo Alarm configured for AI Point Number El the unit 1 cr o uw Rev 04 04 Sets the Real Time Clock RTC alarm for 15 minutes from the present time if a charge voltage AI Point Number E2 is greater than the battery voltage AI Point Number EI or for 55 minutes if the charge voltage is less than the battery voltage Writes the message Low Battery Sleep Mode to the LCD Enters the Sleep mode Shuts down communications The unit wakes up from Sleep mode by
50. the Real Time Clock alarm set in Step 1 and rechecks the voltage to see if operation is possible If the voltage is greater than the LoLo Alarm limit for AI Point Number El a normal restart sequence initiates General Information 1 19 FloBoss 503 and 504 Instruction Manual 1 6 FLOBOSS 503 AND FLOBOSS 504 MAIN SPECIFICATIONS Refer to the following pages for specifications of the main electronics board and the optional AC power supply FloBoss 503 and FloBoss 504 Main Specifications PROCESSOR INFORMATION Motorola 32 bit running at 14 7 MHz Program Memory 512 KB flash ROM electrically programmable for firmware and configuration Data Memory 512 KB SRAM super capacitor backed for up to four weeks Memory Reset A reset jumper enables a cold start initialization when used during power up TIME FUNCTIONS Clock Type 32 kHz crystal oscillator with regulated supply super capacitor backed Year Month Day and Hour Minute Second with Daylight Savings Time control Clock Accuracy 0 01 Watchdog Timer Hardware monitor expires after 1 second and resets the processor DIAGNOSTICS These conditions are monitored and alarmed FloBoss 503 SRAM validity operation Sensor and RTD point fail battery and charging voltages and internal temperature FloBoss 504 SRAM validity operation pulse integrity SM Analog Inputs and RTD point fail battery and charging voltages and internal temperature COMMUNICATIONS Local Operat
51. the super capacitor is checked to ensure that it is continuously applied when the FloBoss unit is powered A memory validity self test is performed to ensure the integrity of memory 1 5 9 Diagnostic Monitoring The electronics board has three diagnostic inputs incorporated into the circuitry for monitoring battery voltage charging voltage and board temperature These inputs can be accessed by using the I O function of ROCLINK for Windows software The three values are available as the following Analog Input AI Point Numbers El battery voltage E2 input charging voltage E5 board battery temperature 1 18 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual 1 5 10 Low Power Modes The processor used in the FloBoss unit is capable of low power operation under predetermined conditions This feature is available because the Phase Lock Loop PLL is used to control the speed of the system clock The base crystal frequency is 3 6863 MHz and is raised by the PLL to 14 7 MHz for normal system operation During the low power modes the PLL and oscillator are in various states of shutdown Two low power modes are supported Standby and Sleep also called Doze Standby This mode is used during periods of inactivity When the operating system cannot find a task to run the FloBoss unit enters Standby mode Processor loading is calculated by using the amount of time spent in Standby mode This mode keeps the clocks
52. which is derived from internal voltage source Vs When a field device such as a relay contact is connected across and COM the closing of the contacts completes the circuit which causes a flow of current between Vs and ground at terminal COM This current flow activates the LED 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 5 12 Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual CAUTION The Discrete Input is designed to operate only with non powered discrete devices such as dry relay contacts or isolated solid state switches Use of the DI channel with powered devices may cause improper operation or damage to occur NOTE FloBoss powered means power is received from the Input Output or Module shown External or self powered means power is received from the device a battery the FloBoss Main Electronics Board or another source DI EXTERNAL SELF n POWERED DISCRETE DEVICE COM L AC Brae 6 65K 7 Figure 5 11 Discrete Input Wiring DOCOS309B 5 3 3 1 Intrusion Switch Wiring The intrusion switch acts as a tamper detector for the FloBoss units The optional intrusion switch is a momentary contact switc
53. 0 Hourly Historical Log 1 10 I O Builltan iuuenes os RES Cen een 5 1 Cards aii an een aee e eter rd 5 1 Power Requirements s s sseseseeereseerereerseereerereeeses 3 1 Troubleshooting eere 9 3 bend 5 8 Wiring Requirements eene 5 8 W O Card ie te tete Hte 5 1 DeSCPIDOD ii aen o ofer etes 5 1 Installation zer eee pee 5 4 LEDS ed ete eti ge e ares 5 21 Troubleshooting eene 9 3 WANT DR ne 5 8 I O Channel Power Consumed a 3 1 Impedance Gre ate DR te Epic erento qd 3 4 Input and Extension Calculation 1 8 Input Calculation eere 1 9 Input Terminal Wiring 3 8 Inputs and Outputs eee 5 1 Troubleshooting eere 9 3 Inst ll ti n 5 terea e iS 2 1 Communications Cards 4 7 I C Card 5 natn esa 5 4 Staph sss eto tee e REO 2 8 Witing FloBO0ss noinine 3 8 Instantaneous Rate Calculations 1 8 Integral Multiplier Value IM sese tec o br a tio te SERERE 1 8 Integral Value IV nosougeusspp en ura i te e agii 1 8 Intrusion Switch esee 5 13 Isolation 3 mu Shae Aree 3 4 FloBoss 503 and 504 Instruction Manual J K Jumper Reset etr eemper EE RIEN 9 6 WT fOr ET idee rte etre net oer qr aea 5 9 L LCD eee nate tirs 1 14 LEDs Comm Cards cienia nere ae NAME 4 4 I O Card 58558
54. 101 and 2000 Hz qualified as follows 45 C 815 F 1250 Hz maximum 90 C 270 F 1500 Hz maximum 180 C 356 F 2000 Hz maximum For Level B integrity phase must be between 45 C 315 F and frequency between 101 and 3000 Hz with Level B phase error at 15 maximum For Level C D or E integrity frequency is 10 kHz maximum INTEGRATED PRESSURE INPUTS OPTIONAL Quantity and Type Up to two pressure sensors selected from ranges in table below All are gauge pressure inputs except for the 0 to 1000 PSI sensor Accuracy Typical 0 5 of span from 20 to 50 C 4 to 122 F CONSTRUCTION Housing is 316 SST with Poron gasket between housing and controller enclosure PROCESS CONNECTIONS 1 4 18 NPT female on 1 56 inch center located on bottom surface WEIGHT FLOBOSS 504 10 4 kg 23 Ib nominal including SM but excluding batteries not supplied AC Power Supply adds 0 82 kg 1 8 Ib ENVIRONMENTAL Meets Environmental Specifications for the FloBoss 504 main electronics APPROVALS Approved by CSA as Model W40079 for hazardous locations Class Division 2 Groups A B C and D Accuracy Pressure Input Range 20 to 50 C Proof Pressure Burst Pressure 4 to 122F 0 5 PSIG 0 35 kPa 0 5 15 PSIG 103 kPa 25 PSIG 172 kPa 0 30 PSIG 0 207 kPa 0 5 90 PSIG 620 kPa 150 PSIG 1034 kPa 0 100 PSIG 0 689 kPa 0 5 300 PSIG 2068 kPa 500 PS
55. 3 4 Solar Panel Sizing Panel panel 4 5 watt 0 27 Amps 10 watt 0 58 Amps 11 watt 0 7 Amps 3 1 7 Batteries Batteries are used to supplement both line powered and solar powered installations When used in line powered installations the batteries serve as backup in case of line power failure When used in solar installations they provide power for the FloBoss unit when the solar panels are not generating sufficient output The standard battery configurations use a 12 volt sealed lead acid battery approximately 6 0 x 2 6 x 3 7 inches These configurations can provide 7 14 21 or 28 Amp hour capacities Recommended 7 Amp hour battery types up to four batteries for FloBoss 500 series units are listed below If other batteries are used rechargeable sealed gel cell lead acid batteries are recommended Powersonic PS 1270 7 0 Amp Hour Panasonic LCR12V7 2P 7 2 Amp Hour Yuasa NP7 12 7 0 Amp Hour The batteries are connected in parallel by a supplied wiring harness to achieve the required capacity The amount of battery capacity required for a particular installation depends upon the power requirements of the equipment and days of reserve autonomy desired Battery requirements are calculated based on power consumption of the FloBoss unit and all devices that will be powered by the batteries Battery reserve is the amount of time that the batteries can provide power without discharging below 20 percent of their total ou
56. 4 10 Electrical Isolation serene 3 4 Electromagnetic Interference sss 3 5 Electronics Board 1 4 1 13 EME 5o o EDO PRUEER G 2 EMI itio ttftt m n Rm 3 5 3 9 Enclosure eiit nPPRRERER 1 3 2 1 Energy Accumulation 1 8 Environmental Requirements tester eter 2 1 Event L8 eerte ede tede 1 11 Extension Calculation esee 1 8 F FCC Information 2 3 Fi ld Warbg out ae te Ree 3 8 Figure 1 1 FloBoss 503 Flow Manager 1 3 Figure 1 2 FloBoss 504 Flow Manager 1 4 Figure 1 3 Main Electronics Board 1 15 Figure 2 1 Outline and Mounting Dimensions FIOBOSS 303 2 reet ee ees 2 5 Figure 2 2 Outline and Mounting Dimensions FIGBOSS 3O4 so ieri oet 2 6 Figure 3 1 Solar Insolation in Hours for the United SLATES vee ssa ves erties es ds ated nn en Mn hais ls 3 6 Figure 3 2 Earth Ground Connection FloBoss 503 SROWN icai coven ecd ec eite ied ice eo 3 10 Figure 3 3 Power Input Terminal Connector 3 10 Figure 3 4 Battery and Solar Panel Connections 3 12 Figure 3 5 AC Power Supply Wiring 3 14 Figure 3 6 AC Power Supply Connections 3 15 Figure 3 7 Auxiliary Power Terminals 3 15 Figure 4 1 Local Port LOI Interface Wiring 4 2 Figure 4 2 EIA 232 RS 232 Serial Communications Cardigan 4 3
57. 504 10 4 kg 23 0 Ib nominal INTRUSION SWITCH OPTIONAL SPST normally closed hermetically sealed Uses Discrete Input on optional I O Card APPROVALS Approved by CSA as Model W40079 for hazardous locations Class I Division 2 Groups A B C and D FloBoss 503 Also includes C US 1 21 FloBoss 503 and 504 Instruction Manual 1 22 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 2 INSTALLATION AND USE This section describes the FloBoss 503 and FloBoss 504 Flow Managers focusing on meeting requirements and startup This section contains the following information Section Page 2 1 Installation Requitemiebllbs erao sorvsseskteuteuka s vu ca ter san bs Erase c tS Ren Ufo 4 2 2 Mounn acs P 2 3 2 3 COS EN ON ssis iseis naer rensa rE EaR UMEN a aiie 2 7 2 4 Startup and OD PANOMS nn mens nenoene 2 1 Installation Requirements This section provides generalized guidelines for successful installation and operation of the FloBoss unit 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 unit allows it to be used in many types of installations For additional information concerning a specific installation contact your local sales representative NOTE The FloBoss unit has been tested
58. 8 tek is oe petere teen 5 21 Troubleshooting SM sees 9 5 Eime Chargers due genet eee e 3 13 Liquid Crystal Display See LCD xin etie gio great ae eee 1 14 Local Port LOD ss 1 16 Troubleshooting eene 9 2 WINNS 5st gei he aA 4 1 Log data octo trottoir 9 6 Low Power Modes 1 19 M Main Electronics Board 1 4 1 13 MEB inter p iR Bm e RUE G 4 Memory ssh edes depen 1 13 Meter Menu Setup cas eoim eno oiii epe 6 2 7 7 MICTOPrOC SSOL iet pmi 1 4 1 13 M idporntz 2s epe is ee bee nel 8 1 Minute Historical Log 1 10 Modbus 5 crore aree eerte E s 1 12 Modular Oise nier G 4 Modeimn er deret 4 5 Modem Initialization String 4 6 Monitoring insertion 1 18 Mounting 4 edet bee tete 2 3 2 4 Radio tette dires 2 7 Multi Variable Sensor 6 1 Troubleshooting eene 9 4 N National Electrical Code NB ii ee tipo melee bate 2 2 NEM XA 3 ete nn aree UD ORE 2 1 O Operation asane a aae 2 8 Operator Interface Port 1 16 OPUONS cien den idi eee Hd e Doe E us 1 5 OV6T VIEW nasi eet ed e BE E HRS 1 2 P Q gib E 6 2 7 4 Periodic Timer Interrupt 1 19 G 5 Periodic Log l 4 See Hourly Historical Log esse 1 10 Phase Lock Loop etes G 5 PID Conttol eite mette 1 13 PIDIDBz i oisi eedem p EX
59. 9 Pulse Input PI 1 used as a Discrete Input 10 Channel 6 Typea name in the Tag field and configure the rest of the Discrete Input as detailed in the ROCLINK for Windows Configuration Software User Manual Form A6091 7 Wire the channel for the Discrete Input the same as described in Section Discrete Inputs on page 5 11 NOTE There is no jumper or software switch to set to change a PI into a DI or back again Both software Point Numbers such as B9 and B11 always exist for the same channel in this case PI 1 Make sure that the PI or DI point is configured for the channel s intended use 5 4 1 0 Card LEDs Six LED indicators are located on the 10 channel I O Card When a specific PI DI or DO is active then the corresponding LED lights Refer to Table and Figure Table 5 20 I O Card LEDs 10 Channel Type Point Number 1 0 Card Location LED Discrete Output B5 DO 1 CR6 Discrete Output B6 DO 2 CR9 Discrete Input B7 DI 1 CR4 Discrete Input B8 DI 2 CR5 Discrete Input B9 PI 1 CR2 Discrete Input B10 PI 2 CR3 Pulse Input B11 PI 1 CR2 Pulse Input B12 PI 2 CR3 NOTE The 24 channel I O Card does not have LEDs Rev 04 04 Inputs and Outputs 5 21 FloBoss 503 and 504 Instruction Manual 5 5 RTD Wiring The temperature is a direct input through the Resistance Temperature Detector RTD probe and circuitry An RTD temperature probe mounts directly to the piping
60. Analog Input is wired as a current loop 4 to 20 milliAmp device and operates in the upper half of its range 7596 of the time then 0 75 would be used as the Duty Cycle If the Analog Input channel generally operates around the midpoint of its span use 0 5 as the Duty Cycle To calculate the total power consumed by an I O channel use Table B 2 and read the minimum Pmin and maximum Pmax power consumption value from the table for the desired I O channel Use the following equation to calculate the power consumption for a channel with the Duty Cycle taken into account Power Pmax X Duty Cycle Pin 1 Duty Cycle Multiply this value by the Quantity of I O channels with the same Duty Cycle and enter the calculated value in the Subtotal column Repeat the procedure for all other I O channels used Total the values in the Subtotal column in Table and enter the value in the I O Card row of Table Rev 04 04 Power Connections 3 1 FloBoss 503 and 504 Instruction Manual Table 3 1 Power Consumption of the FloBoss and Powered Devices Power Consumption mW 12 V System Quantity Duty Cycle ane FloBoss 503 Main Electronics Board includes minimum built in I O power consumption RTD and DVS or MVS FloBoss 504 Main Electronics Board includes minimum built in I O power consumption RTD and Sensor Module Built in Discrete Output load dependent with a maximum of 15 volts and 0 3 Amps Serial Communications Card 30 Dial up Mo
61. 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 API American Petroleum Institute ASCII American Standard Code for Information Interchange AWG American Wire Gauge B BTU British Thermal Unit a measure of heat energy Built in I O Input Output channels that are fabricated into the ROC or FloBoss and do not require a separate module Also called on board I O C C1D2 Class 1 Division 2 hazardous area COMMI Port on the FloBoss that may be used for host communications This port is built in for EIA 232 RS 232 serial communications Configuration Typically the software setup of a device that can often be defined and changed by the user Can also mean the hardware assembly scheme CRC Cyclical Redundancy Check for communications integrity CSA Canadian Standards Association CTS Clear To Send modem communications signal D D A Digital to Analog 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 Rev 04 04 Glossary G 1 FloBoss 503 and 504 Instruction Manual Deadband A value that is an inactive zone above the low limits and below the high limits The purpose of the deadband is to prevent a value such a
62. Boss 503 and 504 Instruction Manual SECTION 3 POWER CONNECTIONS This section describes the power connections of the FloBoss 503 and FloBoss 504 Flow Managers focusing on calculating power and connecting wiring This section contains the following information Section Page 3 1 Calculating Power COnSUIDDLION eor terr st errat etra petas 3 1 3 2 Connecting the FloBoss to Wiring esee 3 8 3 3 Optional AC Power Supply Specifications esses 8 16 3 1 Calculating Power Consumption A FloBoss system s power consumption determines power supply and battery sizing for both line and solar power Table B 1 provides information to assist in determining power requirements The FloBoss unit has low power consumption due to a typical Duty Cycle of 10 to 20 for its microprocessor The other 80 to 9096 of the time the microprocessor is shut off with external wake up signals reactivating it 3 1 1 Determining I O Channel Power Consumption In estimating total I O power requirements the Duty Cycle of each I O channel must be estimated For example if a Discrete Output is active for 15 seconds out of every 60 seconds the Duty Cycle is Duty Cycle Active time Active time Inactive time 15 sec 60 sec 0 25 For an analog I O channel the Duty Cycle is approximated by estimating the percent of time that the channel spends in the upper half of its range span of operation For example if an
63. DCU DES os rose boxer e DR RERO aet ER uS VERON EVO DU VER as 6 3 Sensor Wine nds a no ieu nt m Mni uiro ETT E 6 3 JOVIS ODOCIIIGOHOIS 55e exten Idae itai dica eae E 6 1 Description of Sensor The DVS Sensor which uses Rosemount sensor technology measures differential pressure and static pressure absolute or gauge by converting the applied pressure to electrical signals and making the readings available to the Main Electronics Board The sensor housing screws into an adapter and this in turn mounts with four bolts to the bottom of the FloBoss enclosure The Sensor cable plugs directly into the Main Electronics Board at the P DP connector The readings from the DVS Sensor are stored in Analog Inputs on the FloBoss 503 The differential pressure value uses the Analog Input AI Point Number A1 and the static pressure value uses the AI Point Number A2 If the alarm for either point is enabled and the sensor fails to communicate during either initialization or operation an alarm is entered in the Alarm Log The DVS Sensor uses an interrupt to inform the Main Electronics Board that it is ready for an update This must occur at least once per second The FloBoss 503 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 sensor does not respond to the initialization
64. ER 2 4 6 2 PMAX E 3 1 Pintian een tisse 3 1 Polarity nitent be eia eet 1 18 Power Auxiliary Output Radio eese 3 15 Battery Connections 3 11 Charge Connections 3 12 ConsumptiOn 3 1 Control aen her sit Ris le ene 1 12 Cycling for Radio 4 3 V O Requirements eere 3 1 Low Modes cene 1 19 Mam DC enhn ene 3 11 Operating erede e tm ees 1 18 Radio Requirements esee 3 3 R quir ments sr amande dede 3 4 Sleep Mode nina itte 1 19 Solat POWEE ss osea e er ens 3 5 Standby Mode 1 19 Surge Protection eiua e pae 3 4 Troubleshooting eee 9 3 WADING re tod e taie enn 3 10 Power Connection 3 1 Power Consumption VO Cad enit e EH rtis 3 2 Total sessio ien tete ei cde een 3 1 Power Cycling Radio riae e e n 3 16 Power S pply iiem 3 11 3 13 Changing Input Voltage 3 14 Preserve Configuration and Log Data 9 6 PLOSSULE oos er eee pe Ee ne oce ut G 4 Pressure Connections 6 2 Process Connections 2 4 6 2 Processor eee etre R HE E 1 4 Product Overview ss 1 2 Pulse Inputs ener bte eter 7 3 Troubleshooting eene 9 3 Used as Discrete Inputs see 5 20 hy is
65. Figure 4 3 EIA 485 RS 485 Serial Communications Cards aee sut eH rr Pen 4 5 Figure 4 4 Dial up Modem Communications Card ire n LORD e ERU eset best e EUR i 4 6 Figure 4 5 Communications Card Location 4 8 Figure 4 6 Wiring Switched Auxiliary Radio Power esl 4 10 Figure 5 1 Input Output Card 10 Channel Front M 5 2 Figure 5 2 Input Output Card 24 Channel Front UivAghedd Ris Miia lb B ipn led et 5 3 Figure 5 3 Input Output Card 24 Channel Back 5 4 Figure 5 4 24 Channel I O Card Wiring Labels 5 6 Figure 5 5 I O Card Installation 10 channel Card ShOWD tn dati wih lah e iei 5 7 Figure 5 6 Back of Swing out Panel 10 channel Card SHOWD a sten lee accetto ide tee Sete ates 5 7 Figure 5 7 Current Signal on Analog Input 5 9 Figure 5 8 Voltage Signal Self Powered Device on Analog Input neret 5 10 Figure 5 9 Voltage Transmitter on Analog Input 5 10 Figure 5 10 Analog Output Field Wiring for Current Loop DEVICES occ ives ee te ed 5 11 Figure 5 11 Discrete Input Wiring 5 13 Figure 5 12 Intrusion Switch Wiring 5 13 Figure 5 13 Solid State Relays Discrete Outputs p EET 5 15 Figure 5 14 Relay Circuit Discrete Outputs 5 15 Figure 5 15 Selectable Circuit Discrete Outputs E 5 16 Figure 5 16 Built in Discrete Output Terminal Wiring n 5 17 Figure 5 17 Pul
66. Form Number A6050 Part Number D301100X012 November 201 1 FLOBOSS 503 AND 504 FLOW MANAGERS Instruction Manual EMERSON lagement Remote Automation Solutions www EmersonProcess com Remote FloBoss 503 and 504 Instruction Manual Revision Tracking Sheet November 2011 This manual may be revised periodically to incorporate new or updated information The date revision level of each page is indicated at the bottom of the page opposite the page number A major change in the content of the manual also changes the date of the manual which appears on the front cover Listed below is the date revision level of each page Page Revision Title page and page 4 6 11 11 All Pages 4 04 All Pages 9 03 All Pages 2 02 NOTICE Remote Automation Solutions a division of Emerson Process Management shall not be liable for technical or editorial errors in this manual or omissions from this manual REMOTE AUTOMATION SOLUTIONS MAKES NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND INNO EVENT SHALL REMOTE AUTOMATION SOLUTIONS BE LIABLE FOR ANY INCIDENTAL PUNITIVE SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PRODUCTION LOSS OF PROFITS LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL FUEL AND POWER AND CLAIMS OF THIRD PARTIES Bristol Inc Bristol Babcock Ltd Bristo
67. IG 3447 kPa 0 300 PSIG 0 2068 kPa 0 5 900 PSIG 6205 kPa 1500 PSIG 10340 kPa 0 500 PSIG 0 3447 kPa 0 5 1200 PSIG 8273 kPa 2400 PSIG 16540 kPa 0 1000 PSIA 0 6894 kPa t 0 5 96 3000 PSIA 20680 kPa 5000 PSIA 34470 kPa 1 Better accuracy is available using a FloBoss 500 series I O Board with off board transmitters 2 See Pressure Input Accuracy spec above for full operating temperature ranges 7 10 Sensor for FloBoss 504 Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 8 CALIBRATION This section describes how to calibrate the FloBoss 503 and FloBoss 504 Flow Managers This section contains the following information Section Page 8 1 Calibrating the PIOBOSS orca ences bismsateianessoiacateactareeeoiasdeninnsieree 8 1 NOR DO ise e ee te Een MCI 8 7 8 1 Calibrating the FloBoss Use ROCLINK for Windows 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 The calibration procedure allows you to perform a 5 point minimum maximum and up to three intermediate points calibration of the Analog Inputs associated with the flow calculation static pressure and temperature Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 and ROC FloBoss Accessories Instruction Manual Form A4637 for details The Calibration routine provides Verify Calibrate and Zero Shift func
68. Live Reading 25 26533 Difference 50 1 7 Live Test Span 8 SetZero X Cancel Figure 8 3 Set Zero Calibration for Differential Pressure 10 Calibrate the zero value 096 of range for Differential Pressure orifice only Static Pressure or Temperature This should correspond with the 0 Count and is the low value for the meter run Enter applied value in the Dead Weight Tester Value in engineering units field of the Set Zero dialog This should be a 0 zero value For a pressure input this would typically be open to atmosphere For static pressure on an absolute pressure device remember to enter the actual current atmospheric pressure such as 14 73 psi Refer to Figure 8 3 NOTE The Difference Live Test Span is the percentage of difference of the Live Reading divided by the Span 11 When the Live Reading is stable click Set Zero to calibrate the zero reading The Set Span window appears as in Figure Rev 04 04 Calibration 8 3 FloBoss 503 and 504 Instruction Manual Point RTD Dead Weight Tester Value 2500 Live Reading g 4759216 Difference 48 384 Live Test Span SetSpan X Cancel Figure 8 4 Set Span 12 Calibrate the span value 100 of range for Differential Pressure orifice only Static Pressure or Temperature Enter the Dead Weight Tester Value in engineering units This should correspond with the 100 Count and is the
69. MVS SPECIFICATIONS enorme 6 4 Section 7 Sensor for FloBoss 504 ssssssssssssccsssssssssssssscccssssscssssssssssesscsssssssssssess 7 1 DESCRIPTION OF SENSOR MODULE 25 5 retta idnadietadeddad aehedeansadiwad stdnases debegdadsucbadeatestiens sede 7 1 7 2 PROCESS CONNECTIONS Rs eaa otiose aE AEE e RD A er da p ERE 7 4 7 3 SENSOR WIRING aa dal E ce nan 7 5 74 CONBIGURAT ONG cerio au non nel ie 7 7 242 SENSOR MODULE SPECIFICATIONS nounou ins nent nant 7 10 Section CAND AUN me 8 1 8 1 CALIBRATING THE OB OSS naine om 8 1 8 2 CALIBRATING VO Pr ERa 8 7 Section 9 Troubleshooting csscssascssesscssssssseassessssesosessansssodscassesssnsstasssbesesessanssinsosassssees 9 1 9 1 TROUBLESHOOTING GUID BIN ES inner nirmein arte en tee 9 1 9 2 TROUBLESHOOTING CHECKLISTS sristi aa r iu aa r Ear rE EE 9 2 9 3 PROCEDURES ERE 9 5 Glossary Of TERMS nine lib I 1 iv Table of Contents Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 1 GENERAL INFORMATION This manual describes the FloBoss 503 and 504 Flow Managers part of the family of FloBoss 500 series flow computers Section 1 1 Manual Overview iii 1 2 Additional Information 1 3 Product Daun m 1 4 Product Functions ss 1 5 Product BlectrOnlGS iere terere ttt a t an toon Eee ree Eds 1
70. Main B d a II FB5 Rom h cR amp amp LP ain Boar B rim E B G t ren R2 TD ws us d b PT2 Screw pner DE jg u10 un eV ey P B J2 RT cal E q D o mc Ecer CINE re R3 m q D R24 d E d E R26 2 s Uo a B m 4 n r q pe m pus R25 Il CR16 CR17 u12 is r1 CR15 Fy p Lco n s Vis E rer C C13 q E E U14 M R28 oY d ch I c12 d E so o s Gs E Ue d Eon z R29 m d E u16 akom Pe o Ve il ate u17 R30 min 4 cs Z ps R SP BO nm cr cmo cmi LL s R35 m d E Wi R56 H s C15 se S E m TD ET R41 o e RS ed Lo uis CV nao R42 R43 ES z m ofc ER 12V 24V Ta m ei o 2 J Rag p II FB8 c17 8m H umper on l PT3 n H Q8 lee mi e back of card i R51 T1 Mae oy U22 Wi cue re n Compression Reena Le ET fm Tr o eel Standoff O O Sheng or Screw DOC0305B Figure 5 1 Input Output Card 10 Channel Front A 10 channel I O Card has no physical switches for the DI PI selections The DI PI are selected and the Point Numbers are configured in ROCLINK for Windows software The 10 channel I O Card receives its power from the main processor card The power converter produces enough current to support four current loops three AIs and one AO plus the power to run the analog to digital A D and digital to analog D A converters as well as the Discrete Inputs The power converter can turn off under processor control to reduce the load in low battery conditions UV NOTE The Pulse Inputs can be wi
71. Port on the ROC or FloBoss through which local communications are established typically for configuration software running on a PC Also referred to as Local Port or Op Port LRC Longitudinal Redundancy Checking a type of error checking Rev 04 04 Glossary G 3 FloBoss 503 and 504 Instruction Manual M mA Milliamps MCU Master Controller Unit MEB Main Electronics Board Modular I O I O channels that are provided on a ROC or FloBoss by means of I O modules See I O Module MPU Micro processor Unit MVS Multi Variable Sensor The MVS provides differential pressure static pressure and temperature inputs to the FloBoss or Remote MVS interface for orifice flow calculation mV Millivolts or 0 001 volt mW Milliwatts or 0 001 watt 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 ROC in a electronic file that is later loaded into the ROC 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 Opcode Type of messag
72. RET Return Common Reference 5 22 Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual 2 Wire RTD 3 Wire RTD 4 Wire RTD RTD Sensor DOCO0357A Figure 5 20 RTD Wiring Terminal Connections As shown in Figure the connections at the RTD terminals for the various RTD probes is defined as in Table 522 Table 5 22 RTD Input Wiring Terminal 4 Wire RTD 3 Wire RTD 2 Wire RTD REF Red Jumper to Jumper to Red Red Jumper to REF Red Jumper to REF White White White Jumper to RET RET White White Jumper to Rev 04 04 Inputs and Outputs 5 23 FloBoss 503 and 504 Instruction Manual 5 6 1 0 Card Specifications 10 Channel I O Card Specifications DISCRETE INPUTS Quantity Type Two contact sense Discrete Inputs Two additional Dis are available when Pulse Inputs are so configured see Pulse Inputs below Terminals positive input COM negative input common Signal Current 0 5 to 3 5 mA in the active on state 0 to 0 2 mA in the inactive off state Isolation 2500 V dc from processor Frequency 50 Hz maximum Sample Period 10 ms minimum DISCRETE OUTPUTS PU AN 5 24 Quantity Type Two dry contact solid state relay outputs Terminals normally open contact common Contact Rating 24 V dc 0 3 Amaximum Isolation 3000 V dc from process
73. Refer to Section 4 Communications Installation and Wiring The communications connectors on the Main Electronics Board provide the FloBoss unit with electrical access and mounting provisions for the optional communications cards The communications cards mount directly on the connectors at P3 on the Main Electronics Board and are held in place with three compression stand offs The stand offs on the Main Electronics Board pass through the communications card The communications cards available for the FloBoss unit allow the options of serial data communications and modem communications Refer to Section Communications Installation and Wiring 1 5 5 Built In Discrete Output The FloBoss unit provides a Discrete Output DO to provide control capabilities for a sampler or odorizer The Discrete Output is capable of switching up to 0 3 Amp of current The built in Discrete Output on the FloBoss unit is intended to perform sampler or odorizer functions but may be used as a standard DO This includes toggle mode latched mode and timed DO mode The Discrete Output is accessed by ROCLINK for Windows software as DO Point Number A4 When the Sampler function is enabled the FloBoss unit provides a Time Duration Output TDO based on the volume A control volume and a pulse duration must be specified with the Sampler function After each flow calculation an internal volume accumulator is compared to the control volume If the accumulator exceeds the contr
74. Variable Sensor DVS or a Multi Variable Sensor MVS The temperature input which is sampled and linearized once per second comes from an Resistance Temperature Detector RTD probe The primary function of the FloBoss 504 is to measure the flow of gas using a turbine meter with a single or dual pulse train in accordance with the American Gas Association AGA American Petroleum Institute API and International Standards Organization ISO standards The primary inputs used for turbine flow measurement are Pulse Input PI counts static line pressure and temperature The PI counts are acquired from a turbine meter the static pressure including auxiliary pressure input comes directly from the Sensor Module and the temperature input is read directly by the FloBoss unit from an RTD probe Rev 04 04 General Information 1 7 FloBoss 503 and 504 Instruction Manual 1 4 2 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 US 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 t
75. ace Port LOD Local Port Host Port for communication to a remote host Comml1 Port 1 5 4 1 Local Port LOI The Local Port LOI provides direct communications between the FloBoss unit and the serial port of an operator interface device such as a PC The interface allows you to access the FloBoss unit using ROCLINK for Windows software for configuration and transfer of stored data The LOI terminal plus the Ready to Send RTS terminal on the Main Electronics Board provide wiring access to a built in EIA 232 RS 232 serial interface which is capable of 19 200 bps operation The Local Port supports only ROC protocol communications The LOI also supports the log on security feature of the FloBoss unit if the Security on LOI is Enabled in ROCLINK for Windows software NOTE The following installation should not be used in Class 1 Division 2 hazardous C1D2 areas A cannon type waterproof connector on the bottom of the enclosure provides connection through a prefabricated cable for a Local Port device typically a personal computer PC running ROCLINK for Windows software Inside the FloBoss enclosure the cannon type connector is wired to three terminals LOI on the Main Electronics Board 1 5 4 2 Host Port Comm1 The Host Port Comml is activated by the installation of the optional communications card The Host Port is used to monitor or alter the FloBoss unit from a remote site using a host or ROCLINK for Windows soft
76. aded into the FloBoss while in the office or in the field Although configuration changes can be made remotely via the Host Port Comm1 it is not recommended except for minor changes due to the possibility of data being corrupted during transmission Default values for all parameters exist in the firmware of the FloBoss If the default firmware configuration is acceptable for your application it can be left as is Rev 04 04 Installation and Use 2 7 FloBoss 503 and 504 Instruction Manual 2 4 Startup and Operation Before starting the FloBoss unit perform the following checks to ensure the unit is properly installed Make sure the enclosure has a good earth ground connected to the earth ground bus inside the enclosure Check the field wiring for proper installation Refer to Section B Power Connections Make sure the input power has the correct polarity Make sure the input power is fused at the power source It is important to check the input power polarity before turning on the power Incorrect polarity can damage the FloBoss unit When installing equipment in a hazardous area ensure that all components are approved for use in such areas Check the product labels Change components only in an area known to be non hazardous Performing these procedures in a hazardous area could result in personal injury or property damage 2 4 4 Startup Apply power to the FloBoss unit by plugging the input power terminal block into the conn
77. al battery charger limits the current input to 1 Amp which is less than the output of a typical 22 watt solar panel To use a solar panel with an output exceeding 1 Amp ensure that the panel has its own regulator and is connected to the BAT terminals NOTE Keep in mind that a solar panel bigger than 11 watts may violate certain CSA Class I Division 2 ratings Be sure to use approved connectors on the bottom of the FloBoss enclosure for routing the power wiring Refer to Figure B 4 NOTE If the solar panel contains its own regulator connect it instead to the BAT terminals The charging source solar panel provides power for the charging of the backup batteries Overcharging is prevented by comparing the battery cell voltage to a maximum limit If this limit is exceeded the battery charge cycle is immediately terminated and cannot be re initiated until the cell voltage has dropped below the maximum limit The charge connections CHG are on the removable connector labeled POWER These connections provide the input voltage and power for the battery charging circuitry The charger circuitry provides reverse polarity protection and reverse discharge protection so no external circuitry is required The maximum voltage that can be applied to the terminals is 22 volts dc The terminals are labeled CHG for charge input positive and CHG for charge input negative A 12 volt solar panel with an output regulated to no more than 15 volts can
78. alibrated If the FloBoss unit has an optional I O Card installed then the Analog Inputs supplied by the card can likewise be calibrated using the ROCLINK for Windows software For a FloBoss 503 the built in inputs that are supported with the 5 point calibration are Differential pressure AI Point Number Al Static pressure AI Point Number A2 RTD temperature AI Point A3 For a FloBoss 504 the built in inputs that are supported with the 5 point calibration are Auxiliary pressure optional AI Point Number A1 Static line pressure AI Point Number A2 RTD temperature AI Point Number A3 These inputs are assigned to the first three Analog Input points The calibration procedure for these inputs is described in Section Calibrating the FloBoss on page 8 1 Rev 04 04 Calibration 8 7 FloBoss 503 and 504 Instruction Manual 8 8 Calibration Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 9 TROUBLESHOOTING This section provides generalized guidelines for troubleshooting of the FloBoss 503 and FloBoss 504 The procedures in this chapter should be performed before removing power for any reason after restoring power and if the unit is disassembled The ROCLINK for Windows software runs on the personal computer and is required for a majority of the troubleshooting performed on the FloBoss unit Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 for additional information
79. and found to comply with the limits for a Class A digital device pursuant to part 15 of the Federal Communications Commission FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated 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 unit may cause harmful interference to radio communications Operation of the equipment in a residential area is likely to cause harmful interference in which case you will be required to correct the interference at your own expense 2 1 1 Environmental Requirements The FloBoss case 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 unit is designed to operate over a wide range of temperatures However in extreme climates it may be necessary to moderate the temperature in which the unit must operate The FloBoss unit is designed to operate over a 40 to 75 C 40 to 167 F temperature range The LCD temperature range is 25 to 70 C 13 to 158 F When mounting the unit be aware of external devices that could have an effect on the operating temperature Operation beyond the recommended temperature range could cause errors and erratic performance Prolonged operation under extreme condit
80. ass A withstanding 8 kV Air Discharge and 4 kV Contact Discharge Radiated Immunity FloBoss 504 Complies with requirements in CENELEC document EN61000 4 3 and complies with FCC Part 15 Class Conducted Emissions FloBoss 504 Complies with requirements in CENELEC document EN55011 Class A Power Frequency Magnetic Field FloBoss 504 Complies with requirements in CENELEC document EN61000 4 8 Class A Conducted Immunity FloBoss 504 Complies with requirements in CENELEC document EN61000 4 6 Class A General Information ENCLOSURE Construction Powder coated gray polyurethane 14 gauge carbon steel with lockable hasp and gasketed door Coating is gray polyurethane paint All unpainted hardware is stainless steel Meets CSA Type 4 rating NEMA 4 equivalent Wiring access Three 0 88 in pre punched holes in bottom DIMENSIONS Overall Height includes top mounting flange and Sensor FloBoss 503 451 mm H by 350 mm W by 184 mm D 18 12 in H by 13 80 in W by 7 25 in D FloBoss 504 420 mm H by 350 mm W by 184 mm D 16 56 in H by 13 80 in W by 7 25 in D Wall Mounting 350 mm H by 72 mm W 13 80 in H by 2 81 in W between mounting hole 0 38 in diameter centers Pipestand Mounting Mounts on 2 inch pipe with U bolt mounting kit supplied WEIGHT Weight includes Sensor but excludes batteries not supplied AC Power Supply adds 0 82 kg 1 8 Ib FloBoss 503 13 0 kg 28 5 Ib nominal FloBoss
81. ation point Figure shows the Orifice Setup screen For details concerning each parameter refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 NOTE A FloBoss 503 supports 1992 AGA3 with AGAS compressibility NOTE To select the API 5 5 Pulse Fidelity Level A through Level E use the Advanced tab Features pushbutton as described in the ROCLINK for Windows Configuration Software User Manual Form A6091 6 2 Sensor for FloBoss 503 Rev 04 04 FloBoss 503 and 504 Instruction Manual General Inputs Gas Quality Advanced Alarms Sampler Instrument Calib Point Number X Meter ID Meter 1 Meter Description Orifice Meter Run 1 Daytona Alarming Calc Type 1992 Orifice AGAS C Disabled Integral Multiplier Period imp fi minutes Enabled Pipe Diameter fe 071 inches Orifice Diameter fa inches Low Flow CutDff fi inches H20 2 Update v_x X Cancel Apply Figure 6 1 Orifice Meter Setup for FloBoss 503 6 4 2 Configuring Inputs To configure parameters for the individual inputs associated with the Sensor and the flow calculation use the ROCLINK for Windows Configure gt I O menu as described in the ROCLINK for Windows Configuration Software User Manual Form A6091 The inputs and their Point Numbers are displayed in Table Table 6 1 Configuration Inputs Input Type nie Reading Analog Input Al Differential Pre
82. be directly connected to the BAT terminals 3 2 3 3 AC Power Supply Charge Connections The optional internal AC Power Supply is used as the primary source of power for the FloBoss 500 series unit in line powered installations The AC Power Supply is used to convert AC line power to DC power for the FloBoss 500 series unit and its accessories The supply is designed to be used either as a power supply only or as a combination power supply and battery charger Refer to Section Optional AC Power Supply Specifications on page 3 16 The AC Power Supply is powered by 110 to 240 volts ac 50 to 60 hertz and provides a regulated output of 14 volts dc at a maximum load of 1 Amp The charger is installed by the factory in the left most battery position Figure The installation and wiring of the ac voltages must meet local code and stated requirements for compliance to Class I Division 2 hazardous requirements When the power supply is installed there is room for three batteries for providing up to 21 Amp hours of battery backup capacity Rev 04 04 Power Connections 3 13 FloBoss 503 and 504 Instruction Manual 900 83 DOCO0306B AC POWER Figure 3 5 AC Power Supply Wiring The AC Power Supply is shipped ready for 115 volt operation It may be changed to 230 volt operation To change the voltage input 1 Loosen the four 4 inch hex head screws two above and two below 2 Pull the AC Power Supply straight out to
83. ble 5 16 Pulse Inputs 10 Channel Pulse Input Point Number Label Number 4 B9 DI 1 5 B10 DI 2 6 B11 PI 1 7 B12 PI 2 The Pulse Inputs provided on the 10 channel I O Card are located at Point Number B11 and B12 The Pulse Input at Point Number B11 can operate at up to 50 Hz with a maximum 50 duty cycle The Pulse Input at Point Number B12 can operate at up to 10 kHz with a maximum 50 duty cycle NOTE The Discrete Inputs located at Point Number B9 and Point Number B10 require the use of the two Pulse Inputs on the 10 channel I O Card Refer to Section How to Use Pulse Inputs as Discrete Inputs on page 5 20 Table 5 17 Pulse Inputs 24 Channel Pulse Input Point Number Label Number 4 C5 PI 1 5 C6 PI 2 The PI channel has two field terminals One terminal is a positive source voltage and the other is the signal return The terminals are designated as in Table Table 5 18 Pulse Inputs Terminals Terminal Function Positive Pulse Input Sourced COMM Common Inputs and Outputs FloBoss 503 and 504 Instruction Manual To use the channel as a Pulse Input shown in Figure connect the and field wires to terminals PI 1 or PI 2 and COM on the FloBoss 500 series I O Card Pulse Input channel When the field device completes the circuit between and COM
84. built in field wiring inputs and outputs A surge protection device installed at the service disconnect on line powered systems offers lightning and power surge protection for the installed equipment You may also consider a telephone surge protector for the 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 case ground lug and the earth ground rod or grid The grounding installation method for the FloBoss unit depends on whether the pipeline has cathodic protection On pipelines with cathodic protection the FloBoss unit 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 unit could be flange mounted or saddle clamp mounted directly on the meter run and grounded with a ground rod or grid system 3 4 Power Connections Rev 04 04 FloBoss 503 and 504 Instruction Manual On pipelines without cathodic protection the pipeline itself may provide an adequate earth ground and the FloBoss unit could mount directly on the meter run Test with a ground system tester to make sure the pipeline to earth impedance is less than 25 ohms If an adequate ground is provided by the pipeline do not install a separate ground rod or grid syste
85. cations Cards Product Descriptions 4 3 Communications Card Installation and Setup 4 4 How to Connect Communications Card Wiring 4 5 How to Replace a Communications Card 4 6 Communication Cards Specifications 4 1 How to Wire the Local Port LOI Figure displays the Local Port LOI located at P10 on the Main Electronics Board The Local Port LOI is intended for use with the ROCLINK for Windows software The Local Port provides connections for a built in EIA 232 RS 232 communications interface to a configuration and monitoring device The port signals originate on the Main Electronics Board terminations and are wired to the three terminal cannon style LOI connector located on the bottom of the enclosure A prefabricated LOI cable is available as an accessory A Ready to Send RTS terminal is provided on the Main Electronics Board not routed to the cannon connector and is intended for future applications such as using the Local Port as a second Host Port Table displays the signal routing of the Main Electronics Board terminations and the cannon style connector Table 4 1 Local Port LOI Terminations Board Label P10 Connector Signal BLK 1 Common WHT 2 RXD RED 3 TXD Rev 04 04 Communications Installation and Wiring 4 1 FloBoss 503 and 504 Instruction Manual
86. crete Output DO RTD input diagnostic monitoring Real Time Clock and backup power automatic self tests and power regulation modes 1 5 2 Microprocessor and Memory The FloBoss unit derives processing power from a 32 bit microprocessor The 32 bit CMOS micro processor features dual 32 bit internal data buses and a single 8 bit external data bus The unit can address up to 4 MB of memory including high speed direct memory access The Main Electronics Board has 512 KB of static random access memory SRAM for storing interrupt vectors Function Sequence Tables FST alarms events and history data The Main Electronics Board also has a 512 KB flash memory chip for storing the operating system factory code and configuration parameters Two of the 64 KB blocks are reserved for internal usage Rev 04 04 General Information 1 13 FloBoss 503 and 504 Instruction Manual 1 5 3 Liquid Crystal Display LCD A two line Liquid Crystal Display LCD panel is factory mounted directly to the Main Electronics Board and visible through the window on the front panel The panel has automatic contrast adjustment due to temperature sensing and bias adjustment circuitry on the Main Electronics Board The LCD panel remains on at all times when the power applied is in the valid operating range The built in LCD provides the ability to look at data and configuration parameters while on site without using the Local Port LOI and a PC Through this display y
87. ction of the ROCLINK for Windows software to achieve the required power cycling The switched method involves wiring the power through the EIA 232 RS 232 communications card as shown in Figure 4 6 If the auxiliary device already has a built in sleep mode or for some reason you do not need to cycle the auxiliary power you can wire directly to the RADIO terminals for power Rev 04 04 Communications Installation and Wiring 4 9 FloBoss 503 and 504 Instruction Manual EIS 232 RS232 Communications Card RTS TXD DTR Switched Power to Radio aux swch Figure 4 6 Wiring Switched Auxiliary Radio Power Refer to Section B Power Connections for additional information concerning auxiliary power 4 4 2 EIA 485 RS 485 Communications Card Wiring The EIA 485 RS 485 communications card provides for EIA 485 RS 485 signals on the Host Port located at Comm1 Wiring should be twisted pair cable This board also provides additional protection for the external wiring and the board circuitry LEDs are provided for diagnostic functions Table 4 4 EIA 485 RS 485 Host Port Terminations Terminal Function A EIA 485 RS 485 Positive B EIA 485 RS 485 Negative GND Ground Multiple units with communication cards installed may be daisy chained together without exceeding 1220 m 4000 feet When daisy chaining communication cards they should be connected in a sequential order For example
88. dem chip Registration No DWEUSA 21473 Md E REN 0 8B Registration Holder XECOM INC Communications Installation and Wiring Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 5 INPUTS AND OUTPUTS This section describes the built in Inputs Outputs I O and the optional I O Cards This section contains the following information Section Page Del VSS CHUN Lean m 5 2 How to Install an I O Card 53 WO uo ne de est I EUSie LEEDS a a T 59 RED WHN ee te 5 6 TO Card Specifications den ne 5 1 Description The FloBoss units have a built in RTD Input a Discrete Output DO and three diagnostic Analog Inputs The FloBoss 500 series Input Output I O cards shown in Figure Figure and Figure 5 3 provide additional inputs and outputs for expanded monitoring and control applications Table displays the types of additional I O channels for the FloBoss 500 series units that the I O Cards provide Two types of optional I O Cards are available 10 channel and 24 channel Table 5 1 I O Card Channels 1 0 Type 10 Channel 24 Channel Analog Input AI 3 8 Analog Output AO 1 2 Discrete Input DI 2 2 Discrete Output DO 2 2 Relay Pulse Input PI 2 Selectable DI PI 2 Selectable DI DO 8 The I O Cards use a microprocessor for monitoring control and acquisition of data from external devices connected to the I O channels The information is then relayed
89. dem Comm Card 280 NA do NA NA NA I O Card Total from Table B 2 Table 3 2 Power Consumption of the I O Cards 10 Channel Subtotal Device I O Card base amount Analog Input Notes 1 For analog I O channels the Duty Cycle is the percent of time spent in the upper half of the operating range 2 The Pmax amount includes any power drawn by a FloBoss powered field device such as a transmitter 3 2 Power Connections Rev 04 04 FloBoss 503 and 504 Instruction Manual Table 3 3 Power Consumption of the I O Cards 24 Channel Power Consumption Subtotal Device mW 12V System Quantity Duty Cycle I O Card base amount Analog Input Discrete Output Discrete Output Relay NE CENE E EE NEN MEN Pulse Input LIP ee A Total Pmax with all DO is 4930 mW EE 3 1 2 Determining Radio Power Consumption In determining power requirements for radios the Duty Cycle for the radio must be estimated The Duty Cycle is the percentage of time the radio is transmitting TX For example if a radio is transmitting 1 second out of every 60 seconds and for the remaining 59 seconds the radio is drawing receive RX power the Duty Cycle is Duty Cycle TX time TX time RX time 1 sec 60 sec 0 0167 To calculate the total power consumed by a radio obtain the power P consumption values for transmit and receive from the radio manufacturer s literature Use the following equat
90. dows software and the number printed on the I O Card In the case of the 24 channel card the number in the software and on the label are the same Table 5 2 Analog Inputs 10 Channel Analog Point Label Input Number Number 4 B2 AI 1 5 B3 Al 2 6 B4 Al 3 Table 5 3 Analog Inputs 24 Channel Point Label Number 4 B1 B2 B3 B4 B5 B6 B7 B8 Analog Input o Oojo a oO 5 8 Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual Table 5 4 Analog Inputs Terminals Terminal Function T Current limited positive battery voltage for transmitter power Positive Input T Negative Input Common The Analog Inputs have three field terminals per channel Refer to Table When using a 10 channel card the T terminal provides power for loop powered devices at either 12 or 24 volts depending on the position of jumper W1 not included on some of the first I O Cards manufactured As in Figure Bite jumper is actually found on the non component side of the board The T terminal on the 24 channel I O Card currently provides 12 volts Each channel has a current regulator in series with the T terminal to provide short circuit protection A 250 ohm scaling resistor is supplied for use between the and Analog Input terminals 66 99 The
91. e protocol used by the ROC to communicate with the configuration software as well as with host computers 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 P DP Pressure Differential Pressure PI Pulse Input G 4 Glossary Rev 04 04 FloBoss 503 and 504 Instruction Manual PID Proportional Integral and Derivative control feedback action PLL Phase Lock Loop 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 rack and number of an I O point as installed in the FloBoss system PRI Primary PID control loop PSTN Public switched telephone network PT Process Temperature PTI Periodic Timer Interrupt PTT Push to talk signal Pulse Transient variation of a signal whose value is normally constant PV Process variable Usually used in discussions of PID loops R Rack For a ROC a rack is a row of slots into which I O modules may be plugged The rack is given a letter to physically identify an I O channel location such as A for the first rack Built in I O channels are assigned a rack identifier of A while diagno
92. ector labeled POWER located at the bottom left of the Main Electronics Board After the FloBoss unit completes start up diagnostics RAM and other internal checks the LCD displays the date and time to indicate that the FloBoss unit completed a valid reset sequence If the LCD does not come on refer to Section b Troubleshooting for possible causes 2 4 2 Operation Once startup is successful it is necessary to configure the FloBoss unit to meet the requirements of the application ROCLINK for Windows Configuration Software User Manual Form A6091 details the procedure for configuring the FloBoss unit and calibrating the I O Once the FloBoss unit is configured and calibrated it can be placed into operation Local configuration or monitoring of the FloBoss unit through its Local Port LOI must be performed only in an area known to be non hazardous Performance of these procedures in a hazardous area could result in personal injury or property damage During operation the FloBoss unit 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 by using ROCLINK for Windows software on a PC connected through the LOI Local Port Remote monitoring is performed through the Host Port of the FloBoss unit typically using host software Remote monitoring can also be performed using ROCLINK for Windows software 2 8 Installation and Use Rev 04 04 Flo
93. erede 7 4 Flow Calculations sse 1 9 Inputs eere et et n eto eoe 7 2 PEDS gain eie epe 9 5 Meter Rn eei tree el ments 7 7 cuo ne E M 7 1 Pulse Inputs entr test 7 3 Sp cifications udo npe 7 10 Troubleshooting eene 9 4 MANN henri npn PERROS 7 5 Serial Communications Troubleshooting eene 9 2 Set Midpoint nee 8 1 Midpoint lisse esse titi 8 5 SPAM se int 8 1 8 4 PAS CR ERROR TREE UR ERR REERRERR 8 1 Setup Meter RUN Secs eatin aee mee 6 2 7 7 Site Requirements 2 2 Sleep Mode 2ai inre eee ede 1 19 Software Watchdog sse 1 18 solar Panels eren reete 2 2 POWER zd eie rr aeter iere ede 3 5 Rev 04 04 SIZ Gist th eU epu 3 6 SPA t 8 4 Specifications AC Power Supply 3 16 Communications Cards 4 13 Dual Variable Sensor 6 4 VO Card ieena n 5 24 Mn s doth esd aid Blais eee 1 20 Sensor Module 7 10 SRAM c dne eee ti tenda 1 4 SRBX arnaud E 1 13 Standby Mode eee tenere 1 19 STAMP scene erbe RIDERS de 2 8 Startup and Operation 2 8 Static Pressures iss nienean aa eed 1 7 Static Random Access Memory SRAM 3 canunt het i ners 1 13 Surge Protechion ss oe a hs oa dinars 3 4 Switched Auxiliary Power Wiring 4 0 System Voltage iret reete 3 4 T Table 1 1 History Points
94. f ROM In the ROC or 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 needs no backup power FloBoss A specialized Remote Operations Controller ROC microprocessor based unit from the Flow Computer Division of Emerson Process Management that provides remote monitoring and control G 2 Glossary Rev 04 04 FloBoss 503 and 504 Instruction Manual 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 Flow Computer Division One or more FSTs can be set up ina ROC or FloBoss G GFA Ground Fault Analysis GND Electrical ground such as used by the ROC power supply GP Gauge Pressure H HART Highway Addressable Remote Transducer hw Differential pressure I J ID Identification IEC Industrial Electrical Code IMV Integral Multiplier Value VO Input Output IRQ Interrupt Request Hardware address oriented IV Integral Value K Kbytes Kilobytes KB kHz Kilohertz L LCD Liquid Crystal Display Display only device used for reading data LED Light emitting diode LOI Local Operator Interface Refers to the serial ELA 232 RS 232 Local
95. fective 3 Ensure that the Sensor is not in manual mode by setting the Scanning field in Analog Input Point Number A1 to Enabled Refer to Figure Analog Input General Advanced Al Calibration Analog Inputs 1 Point Number Tag pit Pres Value Units IN H20 Scanning Alarming Scan Period 1 00 Secs Enabled PEE LowReadingEU 0 C Disabled e Disabied High Reading EU 0 Active Alarms Copy Paste 2 Update v_x X Cancel Apply Figure 9 1 Analog Input Scanning Enabled 4 Ensure all required inputs are Enabled If the DVS or MVS is still not responding reset the DVS to factory defaults to clear invalid calibration data Refer to Section p 3 1 How to Reset the FloBoss 503 DVS to Factory Defaults on page 9 5 No field repair or replacement parts are associated with the DVS DVS input MVS MVS input or RTD input Return the FloBoss to your local sales representative for repair or replacement 9 4 Troubleshooting Rev 04 04 FloBoss 503 and 504 Instruction Manual 9 2 7 FloBoss 504 Sensor Module No field repair or replacement parts are associated with the Sensor Module or RTD input Return the FloBoss 504 to your local sales representative for repair or replacement NOTE The SM sensor should only be installed and removed at the factory The SM contains an LED indicator viewable when the case is open LED indicates the status of the SM The Status LED indicator
96. h used to detect whether the door to the enclosure is open or closed The switch which has a normally closed contact mounts in the enclosure When the normally closed contacts are wired to a Discrete Input DI on the I O Card of the FloBoss Figure an Off status contacts open is detected when the door is closed and an On status contacts closed when the door is open The status of the switch can be configured to generate an alarm when the door to the enclosure is open Using ROCLINK for Windows the DI switch Status parameter can be configured to generate an alarm when the door is open The SRBX feature can be enabled on the alarm to automatically notify the host computer 1 0 Card Optional PI 1 PI 2 DIA DI 2 DOC0447A Figure 5 12 Intrusion Switch Wiring 10 channel Card Shown Rev 04 04 Inputs and Outputs 5 13 FloBoss 503 and 504 Instruction Manual 5 3 4 Discrete Outputs Discrete Outputs DO on the 10 channel I O Card provide a solid state switch to control relays and power small electrical loads The 24 channel I O Card Discrete Outputs DO control two state devices such as motor and pump relays The built in DO is detailed in Section 5 3 4 1 Built In Discrete Output Wiring on page 5 16 DO functions supported are Sustained Discrete Outputs Momentary Discrete Outputs Slow pulse train outputs The 10 channel I O Card provides two Discrete Output channels at B5 and B6 The Disc
97. hat 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 Every second the FloBoss unit stores the measured input for differential pressure static pressure and temperature and calculates the flow extension defined as the square root of the absolute upstream static pressure times the differential pressure Flow time averages of the inputs and the flow extension over the configured recalculation period are calculated unless there is no flow for an entire recalculation period Averages of the inputs are recorded to allow monitoring during no flow periods Instantaneous Rate Calculations The instantaneous value of the flow extension is used with the previous recalculation period s Integral Multiplier Value IMV C Prime C for orifice and Base Multiplier Value BMV for turbine metering 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 IV is defined as the flow extension 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 flow extension are used with the flow time to compute the flow and energy over the recalc
98. he pressure readings if necessary The RTD is internally re calibrated for every 5 C 9 F change as sensed by the enclosure temperature diagnostic input All resultant values are stored in the current value database The values are taken from the current value database and used to calculate the Minute Hour and Daily historical values Finally the MCU enters a low power mode and waits for the beginning of the next cycle Once a minute and once an hour the values are logged along with other configured values to the Historical Database At the configured Contract Hour the values are stored to the Daily Historical Log and zeroed for the start of a new day Rev 04 04 General Information 1 9 FloBoss 503 and 504 Instruction Manual 1 4 3 History Points A total of fifteen history points may be logged and accessed in the FloBoss unit The first eight are pre configured for flow metering history and cannot be changed Refer to Table Table 1 1 History Points History Point Value Archive Type Number 1 Flowing Minutes Today Accumulate 2 FloBoss 503 Differential Pressure Average FloBoss 504 Raw pulse count from Pulse Input Primary Device Totalize 3 Static or Line Pressure Average 4 Temperature Average 5 FloBoss 503 IMV Integral Multiplier Value or C Prime Average FloBoss 504 BMV Base Multiplier Value or C Prime Average 6 FloBoss 503 Pressure Extension or IV
99. 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 Sensor Specifications table If you are calibrating the Diff Press input and the Sensor is configured for Downstream operation apply the calibrator pressure to the low labeled L side of the sensor Enter the value as positive and the Live Reading appears as a negative value ROCLINK for Windows software automatically compensates Static pressure for Downstream is calibrated the same as for Upstream For static pressure on an absolute pressure device add the actual atmospheric pressure such as 300 14 73 13 When the Live Reading is stable click Set Span to calibrate the high reading The window advances to the Set Midpoint 1 window as in Figure 8 5 Point RTD Dead Weight Tester Value fe 75 Live Reading 25 00000 Difference 21 BB x Live Test Span H Set Mid 1 X Cancel yY Done Figure 8 5 Set Midpoint 1 14 To perform a two point calibration click Done Calibration for this input is complete 8 4 Calibration Rev 04 04 15 16 17 18 19 20 FloBoss 503 and 504 Instruction Manual If desired calibrate Midpoint 1 such as 25 of range for the Differential Pressure orifice only Static Pressure or Temperature Enter the Dead Weight Tester Value in engineering units Midpoint 1 allows you to s
100. his level provides continuous warning of errors by comparing two pulse streams from the turbine against each other For Level B the FloBoss 504 employs a patent pending algorithm Level C This level provides automatic warning of errors at specified intervals by comparing two pulse streams from the turbine against each other and requires a turbine with no more than 15 phase error between blades Level D This level provides manual warning of errors at specified intervals by comparing the results of one pulse stream from the turbine visually against another means of measurement such as a mechanical meter Level E This is the lowest level of integrity it provides no detection of errors by comparison of the one pulse stream from the turbine to any other results but instead depends entirely on the quality of the installed equipment After power up the Master Controller Unit MCU enters the normal operation mode The Sensor Module SM then counts the pulses as they occur Once every 992 ms the SM reports to the MCU the number of pulses received by its pulse inputs as well as the static and auxiliary pressures The values are stored in temporary memory Once every Scan Period the MCU processes the pulse counts determines the number of pulse counts since the last reading and calculates a rate Next the static pressure and auxiliary pressure values are read Then the temperature is read and linearizing compensation is applied to t
101. ial up Modem Communications Card The dial up modem communications card supports 2400 baud communications Bell 212A Bell 103 V 22 bis V 22 and V 21 with auto answer auto dial features Refer to Figure 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 The modem card has automatic adaptive and fixed compromise equalization This optional modem communications card for the Host Port activates Comml The dial up modem communications card s P1 connector plugs into the Main Electronics Board at P3 The defaults for the dial up modem communications card are 2400 bps 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 Rev 04 04 Communications Installation and Wiring 4 5 FloBoss 503 and 504 Instruction Manual Cl BIO O6 O 6 6 6 6 O6 6 6 ol p QO it O pce Ce Ci BIO O O O O O O Oo O O 6 p Al C2
102. ications ERATION Mode Full duplex 2 wire for dial up PSTN Bell 212 compatible Data Rate 1200 or 2400 bps asynchronous software selectable Parity None odd or even software selectable Format 8 9 10 or 11 bits including start stop and parity software selectable Modem Protocols Bell 212A Bell 103 V 21 V 22 and V 22 bis Transmit Carrier Frequencies Originate 1200 Hz 0 1 Answer 2400 Hz 0 1 Receive Carrier Frequencies Originate 2400 Hz 7 Hz Answer 1200 Hz 7 Hz Telephone Line Impedance 600 ohm typical RTS to Transmission Delay Configurable in 50 millisecond periods software selectable Receiver Sensitivity On hook Type B ringer 38 Vrms Maximum Output Level 0 dBm nominal into 600 ohms LED Indicators TXD RXD and RI Surge Protection Conforms to FCC part 68 and DOC OPERATION CONTINUED Surge Isolation 1000 V ac and 1500 volt peak Certification FCC Part 68 approved POWER REQUIREMENTS 4 75 to 5 25 V dc 0 25 W maximum supplied by processor board ENVIRONMENTAL Operating Temperature 35 to 70 C 31 to 158 F Storage Temperature 40 to 85 C 40 to 185 Operating Humidity To 95 relative non condensing DIMENSIONS 18 mm H by 51 mm W by 70 mm L 0 7 in H by 2 0 in W by 2 75 in L APPROVALS Covered by the CSA approval for the FloBoss 503 or FloBoss 504 unit in which it is installed This modem uses an FCC registered mo
103. ine power and solar power Care must be taken to route line power away from hazardous areas sensitive monitoring devices and radio equipment Local and company codes generally provide guidelines for line power installations Adhere rigorously to all local and National Electrical Code NEC requirements for line power installations 3 1 5 Grounding Installation Requirements Grounding wiring requirements for line powered equipment are governed by the National Electrical Code NEC When the equipment uses line power 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 Proper grounding of the FloBoss unit helps to reduce the effects of electrical noise on the unit s operation and protects against lightning Lightning protection is designed into the FloBoss unit providing lightning protection for
104. ing Time 100 us maximum Reset Action Output goes to zero percent output or last value software configurable on power up warm start or on watchdog timeout POWER Input 8 to 15 V dc supplied by main processor card 20 mA typical without I O devices Al Loop 12 or 24 V dc nominal provided for transmitter loop power from internal power converter Available at T terminal on each Analog Input channel FIELD I O ISOLATION 1000 V minimum DIMENSIONS 21 mm by 137 mm by 160 mm 0 8 in H by 5 4 in W by 6 3 in L WEIGHT 0 4 kg 0 9 Ib nominal ENVIRONMENTAL Meets the Environmental specifications of the FloBoss 500 unit in which the card is installed including Temperature and Voltage Surge specifications APPROVALS Covered by the CSA approval for the FloBoss 500 series unit in which it is installed Rev 04 04 Rev 04 04 FloBoss 503 and 504 Instruction Manual 24 Channel I O Card Specifications ANALOG INPUTS Quantity Type Eight single ended voltage sense Analog Inputs current loop if scaling resistor is used Terminals T loop power positive input gt negative input common Signal 1 to 5 V dc software configurable 4 to 20 mA with 2500 resistor supplied installed in sockets on back of I O Card Accuracy 0 1 over 40 to 65 C 40 to 149 F range Isolation 2500 V dc from processor Input Impedance 1 MQ Filter Double pole low pass Resolu
105. int Label Output Number Number 1 B1 AO Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual Table 5 6 Analog Outputs 24 Channel Analog Point Label Output Number 1 C3 2 C4 Table 5 7 Analog Output Terminals Terminal Function Positive load Negative load A schematic representation of the field wiring connections to the Analog Output channel is shown in Figure The AO can provide loop current to non powered field devices The Analog Output provides a 0 to 22 milliAmp current source output at terminal Terminal is isolated from the FloBoss common Refer to Table Figure shows wiring for a FloBoss powered current loop device NOTE FloBoss powered means power is received from the Input Output or Module shown External or self powered means power is received from the device a battery the FloBoss Main Electronics Board or another source AO I CONTROL a lt D Figure 5 10 Analog Output Field Wiring for Current Loop Devices FLOBOSS POWERED LOOP DEVICE DOC0311A 5 3 3 Discrete Inputs Discrete Inputs DIs monitor the status of relays solid state switches the intrusion switch or other two state devices DI functions support discrete latched inputs and discrete status inputs Table and Table display the Discrete Input s number the Point Number t
106. ion can be viewed when using ROCLINK for Windows software Figure in addition these Point Numbers appear on a label to the left of the terminals on the I O Card NOTE When using a PI as a DI be careful to configure the correct Point Number It may help to name the Pulse Input Tag field DISCRETE so you do not accidentally try to configure the Pulse Input when it is attached to a Discrete Input device To use a Pulse Input as a Discrete Input 1 Make sure the I O Card is installed correctly Refer to Section How to Install an I O Card on page 5 4 2 Attach a PC to the LOI port on the FloBoss and launch ROCLINK for Windows software 3 In ROCLINK for Windows connect to the FloBoss 500 series unit 4 Select Configure I O DI Points 5 Select Discrete Input 3 Point Number B9 to use PI 1 as a DI in the Point Number field Refer to Figure Discrete Input 4 Point Number B10 to use PI 2 as a DI in the Point Number field Refer to Figure 5 20 Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual Discrete Input KIES General Advanced Alarms Discrete Inputs 3 Point Number ps Tag pierna Scan Period ro DIM Type Standard Latched Status On Off Scanning Alarming Enabled Disabled Le Enabled Disabled Active Alarms None x Baste 2 Update v_x x Cancel Apply Figure 5 1
107. ion to calculate the power consumption for a particular Duty Cycle Power Prx x Duty Cycle Pax 1 Duty Cycle Determine the power consumption for all radios that use power from the FloBoss unit and enter the total calculated value in Table 3 1 3 Totaling Power Requirements To adequately meet the needs of the FloBoss system it is important to determine the total power consumption size of solar panel and battery backup requirements accordingly For total FloBoss power consumption add the device values in Table Although Table 3 1 takes into account the power supplied by the FloBoss unit to its connected devices be sure to add the power consumption in mW of any other devices used with the FloBoss unit in the same power system but not accounted for in the table Convert the total value in mW to watts by dividing it by 1000 mW 1000 z 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 Psr P X 1 25 watts Rev 04 04 Power Connections 3 3 FloBoss 503 and 504 Instruction Manual To convert Psp to current consumption in Amps Isp divide Psr by the system voltage V typically 12 volts Isp Psp V Amps 3 1 4 Power Installation Requirements Typical sources of primary power for FloBoss installations are l
108. ions could also result in failure of the unit Check the installation for mechanical vibration The FloBoss unit should not be exposed to levels of vibration that exceed 2 g for 15 to 150 hertz and 1g for 150 to 2000 hertz Rev 04 04 Installation and Use 2 1 FloBoss 503 and 504 Instruction Manual 2 1 2 Site Requirements Careful consideration in locating the FloBoss unit 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 unit to minimize the length of signal and power wiring By code line power wiring must not cross meter runs When using solar powered FloBoss 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 are equipped for radio communications and 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
109. irmware and configuration parameters The built in inputs and outputs I O on the FloBoss consist of a port for a Sensor a 4 wire Resistance Temperature Detector RTD input interface and a Discrete Output DO Three diagnostic Analog Inputs are dedicated to monitoring battery voltage charger voltage and enclosure battery temperature Refer to Section Product Electronics on page 1 13 for more information 1 4 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual On the FloBoss 503 the orifice metering Sensors measure differential pressure and static pressure absolute or gauge by converting the applied pressure to electrical signals and making the readings available to the Main Electronics Board The Sensor housing fastens to a flanged adapter which in turn mounts with four bolts to the bottom of the enclosure The Sensor cable plugs directly into the Main Electronics Board For more information on the Sensor for the FloBoss 503 refer to Section On the FloBoss 504 the turbine metering Sensor Module SM measures pulses and static pressure by electronically counting pulses and converting the applied pressure to electrical signals It makes the readings available to the Main Electronics Board The Sensor Module housing mounts with four bolts to the bottom of the enclosure The Sensor Module cable plugs directly into the Main Electronics Board For more information on the Sensor Module for the FloBoss 504 refer to Section
110. itive input for DI or normally open contact for DO common shared between pairs of channels DI Signal Current 0 5 to 3 5 mA in the active on state group sourced either from non isolated or isolated on board power jumper selectable 0 to 0 2 mA in the inactive off state DO Contact Rating 120 V dc 0 15 A maximum Isolation 2500 V dc for DI 3000 V dc for DO Frequency 50 Hz maximum for DI 5 Hz maximum for DO PULSE INPUTS Quantity Type Two sourced high speed pulse counter inputs Terminals positive input negative input common Isolation 2500 V dc Frequency 10 kHz maximum Signal Current 0 5 to 3 5 mA in the active on state 0 to 0 2 mA in the inactive off state POWER Input 8 to 15 V dc supplied by main processor card 40 mA typical without I O devices Al Loop 12 V dc nominal from internal power converter 24 V dc can be supplied externally Available at T terminals of all Al channels FIELD I O ISOLATION 1000 V dc minimum DIMENSIONS 21 mm H by 137 mm W by 160 mm L 0 8 in H by 5 4 in W by 6 3 in L WEIGHT 0 45 kg 1 Ib nominal Inputs and Outputs 5 25 FloBoss 503 and 504 Instruction Manual 24 Channel I O Card Specifications Continued APPROVALS Covered by the CSA approval for the FloBoss 503 or FloBoss 504 unit in which it is installed ENVIRONMENTAL Meets the Environmental specifications of the FloBoss 503 or FloBoss 504 unit i
111. ity when used with an AC power supply The batteries are mounted under the electronics swing out mounting panel and are retained by the panel when it is secured The AC Power Supply mounts in place of one of the batteries The batteries are connected to a harness that allows the batteries to be changed without removing power from the unit Make sure that the black wires of the harness are connected to the negative terminals of the batteries and the red wires are connected to the positive terminals Input wiring is connected at the POWER wiring terminal connector Rev 04 04 Power Connections 3 11 FloBoss 503 and 504 Instruction Manual DOC0361A Figure 3 4 Battery and Solar Panel Connections 3 2 3 2 Solar Panel Charge Connections The FloBoss unit contains an internal battery charger circuit for charge control of the 12 volt batteries The charger monitors the battery voltage charge voltage and the battery temperature which is actually the board enclosure temperature Based on these three conditions a charge rate is determined and applied to the battery Refer to Figure for the proper wiring connections CAUTION Remove the removable Power terminal block before removing the battery connections or the battery Power being sent to the FloBoss unit without batteries in operation could damage the FloBoss unit 3 12 Power Connections Rev 04 04 FloBoss 503 and 504 Instruction Manual NOTE The intern
112. k located on the serial communications cards or through the RJ11 TELCO connector supplied on the modem card The FloBoss unit communicates to external devices through either its Local Port LOD or its Host Port Comm1 The LOI Local Port uses a special 3 pin connector to connect a PC running ROCLINK for Windows software The Host Port has the flexibility to communicate to external devices using different protocols Wiring connections for the Host Port are made using screw terminals on the optional communications card 4 4 1 EIA 232 RS 232 Communications Card Wiring The EIA 232 RS 232 communications card provides for EIA 232 RS 232 signals on the Host Port Comml This communications card also provides a means to switch external power to communication devices to conserve power for example a radio LEDs are provided for diagnostic functions The screw terminals and their functions are defined in Table Table 4 3 EIA 232 RS 232 Host Port Terminations Terminal Function RXD Receive data TXD Transmit data DTR Data Terminal Ready RTS Ready to Send DCD Data Carrier Detect GND Ground IN Switched Power Input Out Switched Power Output 4 4 1 1 Switched Auxiliary Power Wiring Switched auxiliary power is used for radios or other devices that do not have a built in sleep mode to automatically shut the radio off Control of auxiliary power is set up by using the Radio Power Control fun
113. l Canada BBI SA de CV and the Flow Computer Division are wholly owned subsidiaries of Emerson Electric Co doing business as Remote Automation Solutions a division of Emerson Process Management FloBoss ROCLINK Bristol Bristol Babcock ControlWave TeleFlow and Helicoid are trademarks of Remote Automation Solutions AMS PlantWeb and the PlantWeb logo are marks of Emerson Electric Co The Emerson logo is a trademark and service mark of the Emerson Electric Co All other trademarks are property of their respective owners The contents of this publication are presented for informational purposes only While every effort has been made to ensure informational accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability Remote Automation Solutions reserves the right to modify or improve the designs or specifications of such products at any time without notice All sales are governed by Remote Automation Solutions terms and conditions which are available upon request Remote Automation Solutions does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Remote Automation Solutions product remains solely with the purchaser and end user 1997 2011 Remote Automation Solutions division of Emerson Process Management All right reserved i Rev 11 11 FloBos
114. lectronics Board 3 Ifthe communications card is a modem card unplug the RJ11 phone jack cable from the communications card connector J2 Using a rocking motion gently disengage the two stand off connectors located at the bottom of the communications card Using a rocking motion gently disengage the stand off connector located at the top in the middle of the communications card Using a rocking motion to disengage the connectors at P1 pull the card free from the Main Electronic Board at P3 To reinstall a communications card orient the card with the P1 connectors on the communications card mating with the connectors at P3 on the Main Electronics Board Plug the card into its stand off connectors and gently press until the connectors firmly seat 8 For a modem card connect the RJ11 phone jack cable to communications card connector J2 9 Reconnect power by plugging in the Power terminal connector at P8 on the Main Electronic 10 11 Board Check the configuration data and FSTs and load or modify them as required Verify that the FloBoss 500 series performs as required If you changed the configuration save the configuration data to Flash ROM If you changed the configuration history database or FSTs save them to disk Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 for more information Communications Installation and Wiring Rev 04 04 FloBoss 503 and 504 Instruction Manual 4 6
115. lignment Peg 1 O A Mounting ao Screw 6 G O lo DOC0365B Mounting Screw Mating Connector Location Alignment Peg Mounting Screw Figure 5 6 Back of Swing out Panel 10 channel Card Shown Rev 04 04 Inputs and Outputs 5 7 FloBoss 503 and 504 Instruction Manual 5 3 1 0 Wiring The field terminals on the FloBoss 500 series I O Card are connected as explained in the following sections 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 The Main Electronics Board containing the field wiring terminal connections is accessed by opening the front door after removing the lock if installed and releasing the hasp on the right hand side The input terminal wiring is arranged on the lower edge of the Main Electronics Board The terminal designations are printed on the circuit board 5 3 1 Analog Inputs Analog Inputs AIs monitor current loop and voltage input devices The I O Card s Analog Inputs each consist of a 12 V dc 4T 22 mA current source and a multiplexed A D converter The power for the A D is from the isolated power supply The A D signal input range is from 1 to 5 volts with 12 bit resolution Table 5 2 and Table display the Analog Input s number the Point Number to which the AO is assigned in ROCLINK for Win
116. llowing procedure Be sure to observe the cautions to avoid losing data and damaging equipment NOTE There is a possibility of losing the FloBoss 500 series configuration and historical data while performing the following procedure As a precaution save the current configuration and historical data to Config Memory on the ROC Flags screen of ROCLINK for Windows software Rev 04 04 Communications Installation and Wiring 4 11 FloBoss 503 and 504 Instruction Manual When repairing units in a hazardous area make sure that the components selected are labeled for use in such areas 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 Be sure to use proper electrostatic handling such as wearing a grounded wrist strap or components on the circuit cards may be damaged During this procedure all power will be removed from the FloBoss and devices powered by the FloBoss Make sure that all connected input devices output devices and processes will remain in a safe state when power is removed from the FloBoss and when power is restored to the FloBoss An unsafe state could result in property damage 1 As a precaution save the current configuration and historical data to Config Memory Use Write to Internal Config Memory ROC menu gt ROC Flags in ROCLINK for Windows software 2 Remove the Power terminal block at P8 on the Main E
117. loBoss enclosure through the pre punched holes in the bottom of the enclosure and is terminated at the charge CHG power terminals on the Main Electronics 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 radios 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 are used to generate electrical power for the FloBoss unit from solar radiation The size and number 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 Rev 04 04 Power Connections 3 5 FloBoss 503 and 504 Instruction Manual 3 1 6 1 System Solar Panel Sizing To determine solar panel output requirements first determine the solar insolation for your geographic area The map in Figure 3 1 shows solar insolation in hours for the
118. log on ID supplied to the ROCLINK for Windows software must match one of the IDs stored in the FloBoss unit The Local Port Security on LOD has security Enabled by default The Host Port Comm1 can likewise be configured to have security protection but is disabled by default Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 concerning security 1 4 5 Function Sequence Tables FST The FloBoss unit supports FST user programmability The two FST programs can be up to 4000 bytes each typically 200 or 300 lines of code The FST code resides in static Random Access Memory RAM and is backed up to flash memory when the Save Configuration function is issued through ROCLINK for Windows software Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 1 4 6 Modbus The Modbus Protocol Emulation Program is contained within the FloBoss firmware The Modbus application is designed to allow the FloBoss unit to emulate on the Host Port Comm1 the communications protocol used by Modbus devices The Modbus communications protocol is fully described in the reference guide entitled Modicon Modbus Protocol Reference Manual publication PI MBUS 300 not available from Emerson Process Management The Modbus protocol supports two modes of transmission American Standard Code for Information Interchange ASCII and Remote Terminal Unit RTU with RTU as the default Both modes of transmission are suppo
119. ludes reinitializing the Tasks Databases Sensors Communication Ports and I O while restoring the factory default configuration This Cold Start does not include any of the clearing options available in a Cold Start performed using ROCLINK for Windows software P1 NORM RST DOC0277U Figure 9 3 Reset Jumper Shown in Normal Position 9 6 Troubleshooting Rev 04 04 FloBoss 503 and 504 Instruction Manual NOTE This type of reset restores the factory configuration defaults Some user entered configuration parameters may be lost Therefore back up required data before performing this reset 1 Save the FloBoss Config and Data Refer to Section How to Preserve Configuration and Log Data on page 9 6 and perform the Backup Procedure Disconnect the Power terminal block to remove power Install the P1 jumper in the reset RST position B D Apply power by plugging in the Power terminal block at P8 5 Remove the P1 jumper and install it in the normal NORM position This reset action loads the factory default values into all configurable parameters 9 3 4 How to Restart and Reconfigure After removing power to the FloBoss unit and installing components as required perform the following steps to start your FloBoss unit and reconfigure your data The procedure assumes you are using ROCLINK for Windows software Ensure all input devices output devices and processes remain in a safe s
120. m All grounding should terminate at a single point If the pipeline to earth impedance is greater than 25 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 The twisted pair and the shielding minimize signal errors caused by ElectroMagnetic Interference EMI Radio Frequency Interference RFD and transients A ground bar is provided for terminating shield wires and other connections that require earth ground CAUTION Do not connect the earth ground to any wiring terminal on the Main Electronics Board It could result in property damage 3 1 6 Solar Powered Installations Solar power allows installation of the FloBoss unit in locations where line power is not available The two important elements in a solar installation are solar panels and batteries Solar panels and batteries must be properly sized for the application and geographic location to ensure continuous reliable operation A 12 volt solar panel can be installed to provide charging power for the backup batteries The panel can be rated at 5 or 10 watts and is sized depending upon the power requirements of the unit This is within the Canadian Standards Association CSA rating of the FloBoss 500 series unit The solar panel typically mounts to the same 2 inch pipe that supports the FloBoss unit The panel wiring is brought into the F
121. mplete Rev 04 04 Calibration 8 5 FloBoss 503 and 504 Instruction Manual 21 To calibrate a third midpoint apply the desired pressure or temperature and enter the applied value in the Dead Weight Tester Value such as 75 of range field 22 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 read the following Caution and then return the Dual Variable Sensor to service Do NOT close the by pass valve on the valve manifold until after process pressure has been reapplied to protect the differential cell of the Sensor This will keep one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied Refer to Figure 8 8 Pre Startup start2 Figure 8 8 Returning the Sensor to Service NOTE If you calibrated the Differential Pressure input refer to Section Zero Shift before completing the last step 23 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 8 6 Calibration Rev 04 04 FloBoss 503 and 504 Instruction Manual 8 1 1 Zero
122. n on process connections refer to Section 6 for the FloBoss 503 or to Section fl for the FloBoss 504 2 4 Installation and Use Rev 04 04 FloBoss 503 and 504 Instruction Manual DOC0278C Note All dimensions are in inches Figure 2 1 Outline and Mounting Dimensions FloBoss 503 CAUTION The FloBoss unit must be mounted vertically with the Sensor at its base Refer to Figure and Figure Mounting in other orientations could result in damage to the FloBoss unit or enclosure Rev 04 04 Installation and Use 2 5 FloBoss 503 and 504 Instruction Manual DOC0303B 1 4 18 NPT PROCESS CONNECTIONS Note All dimensions are in inches Figure 2 2 Outline and Mounting Dimensions FloBoss 504 2 6 Installation and Use Rev 04 04 FloBoss 503 and 504 Instruction Manual 2 2 2 Mounting a Radio A radio up to 57 15 mm 2 25 inches high can be mounted inside the FloBoss enclosure using the optional radio bracket at the top of the enclosure This bracket allows most radios to be secured in the compartment Fasten the radio to the bracket using one of the pre drilled mounting patterns and the four 6 32 x 0 25 pan head screws supplied 1 Remove the winged brackets supplied with the radio 2 Fasten the radio through the bottom of the radio bracket using the four 6 32 x 0 25 flat head screws supplied 3 Place the 6 32 x 0 50 screw in the threaded hole located in the upper left of the battery compartment 4 Place the
123. n which the card is installed including Temperature and Voltage Surge specifications 5 26 Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 6 SENSOR FOR FLOBOSS 503 This section describes the orifice metering Dual Variable Sensor DVS which provides differential pressure and static pressure inputs to the FloBoss 503 Flow Manager for orifice flow calculation The Multi Variable Sensor MVS may also be used with the FloBoss 503 For information on installation of the MVS refer to the ROC FloBoss Accessories Instruction Manual Form A4637 For information on configuration and calibration of the MVS refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 NOTE The DVS Sensor is not equipped to provide a temperature input to the FloBoss The DVS Sensor will only sense pressure and differential pressure when in use with a FloBoss 503 In both cases temperature input comes into the FloBoss by means of the RTD input NOTE The FloBoss 503 firmware must be version 2 30 or greater allows the RTD sensor either to be wired directly to the FloBoss 503 MCU at the RTD input or to be wired to the MVS sensor The firmware detects which method of wiring is in use at power up Refer to Section 5 Inputs and Outputs of this manual for more information on the RTD input This section contains the following information Section 6 1 Description of Sensores nn er sut 6 2 PROCESS C ODBDO
124. nal wiring such as the RTD cable should be connected to earth ground at one end to minimize signal errors caused by ElectroMagnetic Interference EMI Radio Frequency Interference RFI and transients CAUTION Do not connect the earth ground to any terminal on the Main Electronics Board It could result in property damage For line powered installations the grounding conductor must end at the service disconnect The grounding conductor can be wire or metallic conduit as long as the circuit provides a low impedance ground path Rev 04 04 Power Connections 3 9 FloBoss 503 and 504 Instruction Manual grnd503 Earth Ground Figure 3 2 Earth Ground Connection FloBoss 503 Shown 3 2 3 Connecting Main Power Wiring It is important that good wiring practices be used when sizing routing and connecting power wiring All wiring must conform to state local and NEC codes The POWER terminal block can accommodate up to 14 AWG wire Refer to Figure P8 Up to 15 volts C Y QM Up to 22 volts POWER BAT CHG FB500PWR Figure 3 3 Power Input Terminal Connector To make power connections 1 Unplug the left hand connector from its socket located at P8 on the Main Electronic Board 2 Insert each bared wire end into the clamp beneath its termination screw 3 Secure the screw 4 Plug the connector back into the socket at P8 3 10 Power Connections Rev 04 04 FloBoss 503 and 504 Instr
125. nd convert pressure store the pulse count and the pressure values temporarily and communicate the values to the FloBoss The inputs are used to determine an instantaneous flow and energy rate At the end of the Base Multiplier Period the accumulated inputs are averaged or totalized and stored in history The primary inputs used for turbine flow measurement are Pulse Input PI counts static pressure and temperature The Pulse Input counts are acquired from a turbine meter the static pressure including auxiliary pressure inputs come from the Sensor Module and the temperature input is read from an RTD probe After the static pressure and auxiliary pressure values are read the board temperature is read and compensation is applied to the pressure inputs if necessary The inputs are read by the FloBoss processor at the following rates Pulse counts are sampled once per second Static pressure is sampled once per second Temperature is sampled and linearized once per second The RTD is internally re calibrated for every 5 C 9 F temperature change as sensed by enclosure battery temperature Rev 04 04 Sensor for FloBoss 504 7 1 FloBoss 503 and 504 Instruction Manual The Sensor Module measures static pressure by converting the applied pressure to electrical signals in addition it counts and checks pulses applied to its Pulse Input terminals A factory installed ribbon cable see Figure that plugs into the Main Electronics Board at
126. nly memory ROM and 512 KB of static memory storage Built in Resistance Temperature Detector RTD Input Built in Discrete Output Extensive applications firmware Weather tight enclosure with covered display Space for up to four 7 Amp hour batteries Operator Interface LOI Local Port Port for optional host communications card Liquid Crystal Display LCD Optional Input Output I O card Optional sensor for either orifice FloBoss 503 or turbine FloBoss 504 metering Optional bracket for internally mounted radio Optional Communications Cards Optional AC Power Supply 1 2 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual Physically the FloBoss consists of a printed circuit Main Electronics Board and a display housed in a compact weather tight case The FloBoss is packaged in a National Electrical Manufacturer s Association NEMA 4 windowed enclosure that can mount on a wall or a pipestand A cover is fl for the display to protect it from adverse weather conditions Refer to Figure and Figure 1 2 The steel enclosure protects the electronics from physical damage and harsh environments The enclosure consists of two pieces the body and the door A foam rubber gasket seals the unit when the hinged door is closed The hinge located on the left side is stainless steel and fastened to the body with machine screws allowing removal of the door The door secures with a
127. nnas when using radios The Sensor is factory mounted directly to the FloBoss enclosure with four bolts On the FloBoss 503 this mounting uses a special coupler to join the Sensor to the four bolt mounting pattern on the bottom of the FloBoss enclosure Rev 04 04 Installation and Use 2 3 FloBoss 503 and 504 Instruction Manual 2 2 1 Mounting the FloBoss Mounting of the FloBoss unit can be accomplished using either of the following methods Pipe mounted The enclosure provides top and bottom mounting flanges with holes for 2 inch pipe clamps U bolts and brackets supplied The 2 inch pipe can be mounted to another pipe with a pipe saddle or it can be cemented into the ground deep enough to support the weight and conform to local building codes Wall or panel mounted Fasten to the wall or panel using the mounting flanges on the enclosure Use 5 16 inch bolts through all four holes Mounting dimensions are given in Figure CAUTION Do not mount the FloBoss unit with the Sensor supporting the entire weight of the unit such as in Integral Orifice mounting for the FloBoss 503 Due to the weight of the unit with batteries and possibly a radio the unit does not meet vibration requirements unless it is installed using its enclosure mounting flanges This could result in damage to the FloBoss unit or enclosure With either mounting method the pressure inputs must be piped to the process connections on the Sensor For more informatio
128. o the following pages for specifications of the DVS For other specifications see the Main Electronics Specifications in Section 1 MVS specifications are located in the ROC FloBoss Accessories Instruction Manual Form A4637 Dual Variable Sensor Specifications DIFFERENTIAL PRESSURE INPUT PROCESS CONNECTIONS Range 0 to 62 2 kPa 0 to 250 in H O 1 4 18 NPT on 2 1 8 in centers located on bottom Reference Accuracy 0 075 of span with a of Coplanar flange 10 1 of upper range limit turndown includes CONSTRUCTION i i i ility eff Inert ARM E ER ano tepestdbI D nee 316 SST Wetted O rings are glass filled TFE STATIC PRESSURE INPUT Coupler is stainless steel CF8M Range Either Absolute or Gauge ENVIRONMENTAL AND OTHER SPECS 0 to 5516 kPa 0 to 800 psia psig Meets the Environmental specifications of the 0 to 25 000 kPa 0 to 3626 psia psig FloBoss 500 series unit including Temperature Reference Accuracy 0 075 of span with a and Voltage Surge specifications 6 1 of upper range limit turndown includes linearity hysteresis and repeatability effects For spans with more than 6 1 turndown contact factory Stability 0 1 of upper range limit for 12 months Note Consult factory for special ranges and materials that may be available 6 4 Sensor for FloBoss 503 Rev 04 04 FloBoss 503 and 504 Instruction Manual SECTION 7 SENSOR FOR FLOBOSS 504 This section describes the Sensor Module SM which provides
129. o which the DI is assigned in ROCLINK for Windows software and the number printed on the I O Card In the case of the 24 channel card the number in the software and on the label are the same Rev 04 04 Inputs and Outputs 5 11 FloBoss 503 and 504 Instruction Manual Table 5 8 Discrete Inputs 10 Channel Discrete Input Point Number Label Number 4 B7 DI 1 5 B8 DI 2 6 B9 PI 1 7 B10 PI 2 1 The Discrete Inputs located at Point Number B9 and Point Number B10 requires the use of the two Pulse Inputs on the I O Card Refer to How to Use Pulse Inputs as Discrete Inputs on page 5 20 Table 5 9 Default Discrete Inputs 24 Channel Discrete Point Label Input Number 4 B11 B12 B13 B14 B15 B16 C1 C2 C7 C8 o jOojo OoO e Table 5 10 Discrete Inputs Terminals Terminal Function Positive Discrete Input COM Common When using a 10 channel I O Card the I O Card Discrete Inputs acquire power from the 24 volt power supply An LED indicator is included for each point on the field side The signal from the field is coupled through an optical isolator providing 2500 V dc isolation from the main FloBoss circuit board NOTE The 24 channel I O Card does not have LEDs The Discrete Input operates by providing a voltage across terminals and COM Figure 5 10
130. ol volume a pulse is output and the accumulator is reduced by the control volume This output may be used to drive an external totalizer odorizer gas sampler or similar device Refer to Section 5 Inputs and Outputs 1 5 6 RTD Input The FloBoss unit supports a direct input from a Resistance Temperature Detector RTD sensor An RTD temperature probe typically mounts in a thermowell on the metering pipe The terminals for the RTD wires are located at the bottom right of the Main Electronics Board and labeled RTD The RTD input is converted through a 16 bit RTD converter chip 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 performs calibration corrections and checks alarming The board temperature is monitored by the RTD routine If the temperature has changed by roughly 5 C 9 F the RTD circuitry is sent a command to re calibrate its reference Refer to Section 5 Inputs and Outputs Rev 04 04 General Information 1 17 FloBoss 503 and 504 Instruction Manual 1 5 7 Real Time Clock The Real Time Clock provides the FloBoss unit with the time of day month year and day of the week The time chip automatically switches to backup power when the Main Electronics board loses primary input power Backup power for the Real Time Clock comes from a super capacitor which al
131. ommunications card defaults are 9600 bps rate 8 data bits 1 stop bit no parity 10 millisecond Key On Delay and 10 millisecond Key Off Delay The maximum rate is 19 200 bps The EIA 232 RS 232 communications card includes LED indicators that display the status of the RXD TXD DTR DCD and RTS signal control lines Refer to Figure m for LED indicators 4 2 1 1 Power Cycling This function is available with the EIA 232 RS 232 communications card to provide power savings when using a radio or cell phone for communications Power cycling control is accomplished through Power Control Terminals or the DTR signal on the EIA 232 RS 232 communications card Connect wiring as described in Section Configure the power cycling using the Radio Power Control feature as described in the ROCLINK for Windows Configuration Software User Manual Form A6091 P1 o O O 6 O O O O9 O 9 9 G Mating Connector C1 FB1 OC C2 U1 e CR1 HEE 80 Ri C3 o a C4 R2 A CAEN R3 U2 R5 ol rat o LEDs eO C5 UUU M o Q2 eO n FB2 mj Oo M
132. or Frequency 5 Hz maximum LSE INPUTS Quantity Type Two sourced pulse counter inputs one medium speed and one high speed Both are also software configurable as Discrete Inputs Terminals positive input COM negative input common Isolation 2500 V dc from processor Frequency Medium speed input B11 is 50 Hz maximum high speed input B12 is 10 kHz maximum Signal Current 0 5 to 3 5 mA in the active on state 0 to 0 2 mA in the inactive off state ALOG INPUTS Quantity Type Three single ended voltage sense Analog Inputs current loop if scaling resistor is used Terminals T 12 or 24 V dc loop power positive input negative input common Signal 1 to 5 V dc software configurable 4 to 20 mA with 2500 resistor supplied installed across and terminals Accuracy 0 1 over 40 to 65 C 40 to 149 F range Isolation 2500 V dc from processor Input Impedance 1 MO Inputs and Outputs ANALOG INPUTS CONTINUED Filter Double pole low pass Resolution 12 bits Conversion Time 200 us Sample Period 50 ms minimum ANALOG OUTPUT Quantity Type One current loop signal output Terminals positive output and common Range 4 20 mA with 0 to 22 mA overranging Loop Resistance 300 ohm maximum at 12 V dc 600 ohm maximum at 24 V dc source voltage Resolution 12 bits Accuracy 0 196 of full scale output Settl
133. or Interface EIA 232 RS 232D format Software configured 600 to 19 200 bps rate selectable Screw cap protected connector Host Serial or modem interface with optional communications card is installed POWER Battery Input 8 to 15 V dc normally 10 8 V dc to start up FloBoss 503 0 2 W typical including Sensor power but excluding power for Discrete Output load communications card and I O Card FloBoss 504 0 35 W typical including Sensor power but excluding power for Discrete Output load communications card and I O Card Charging Input 14 to 22 V dc Charge current internally limited to 1 0 Amp Power Supply Optional 105 132 or 207 264 V ac 47 to 63 Hz Refer to the AC Power Supply Specifications table for additional information LOCAL DISPLAY Two line by 16 character LCD Continually updates approximately every 3 seconds See Environmental specification for operating temperature RTD INPUT BUILT IN Quantity Type Single input for a 2 3 or 4 wire RTD element with alpha of 0 00385 Terminals REF current source signal positive input signal negative and RET return common Sensing Range 50 to 100 C 58 to 212 F Accuracy 0 56 C 1 0 F over sensing range includes linearity hysteresis repeatability Ambient Temperature Effects per 28 C 50 F 0 50 C 90 F for process temperatures from 40 to 100 C 40 to 212 F Filter Band pass ha
134. ositive load Negative load The Discrete Output on the I O Card can be used in Toggle mode Latched mode Time Duration Output TDO mode When using a 24 channel card the external device must be powered directly from the battery or the terminal of the Radio Power Control terminal block When using a solid state selectable Discrete Output the card must be placed in BATT mode W1 and W2 jumpers located on the back of the board The negative terminal is not applicable for the selectable DO because the terminal is in one of two states not connected or short to BATT ground Figure shows a typical Discrete Output wiring diagram for solid state relays NOTE FloBoss powered means power is received from the Input Output or Module shown External or self powered means power is received from the device a battery the FloBoss Main Electronics Board or another source SELF POWERED DISCRETE DEVICE CONTROL DOC0098A Figure 5 13 Solid State Relays Discrete Outputs Figure shows a typical Discrete Output wiring diagram for mechanical relays DO SELF POWERED if NO O Vs DISCRETE DEVICE F d zi Figure 5 14 Relay Circuit Discrete Outputs Rev 04 04 Inputs and Outputs 5 15 FloBoss 503 and 504 Instruction Manual Figure shows a typical Discrete Output wiring diagram for selectable DOs
135. oss 503 and 504 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 with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap Table 7 4 PI Connections on the SM Terminal Primary Turbine Pulse Input 1 P1 Left Position SOURCE 1 S Pulse 1 source for open collector drain or dry contacts only PULSE 1 The positive side of the first Pulse Input Channel A This PI is identified as Point Number A5 when configuring COMMON COM Power supply and circuit common shared with PI 2 Auxiliary Turbine Pulse Input 2 P2 Right Position COMMON COM Power supply and circuit common shared with PI 1 SOURCE 2 S Pulse 2 source for open collector drain or dry contacts only PULSE 2 The positive side of the second Pulse Input Channel B This PI is identified as Point Number A6 when configuring The actual wiring connections for the Pulse Input counter depend on the application Refer to the following figures for typical hook ups A FloBoss powered Pre amp such as an universal type can be accommodated by wiring the device as shown in Figure If a dual pulse train is required wire the second PI channel in the same manner As shown in Figure a FloBoss powered
136. ou can view predetermined information stored in the FloBoss Up to 16 items can be defined for display The LCD automatically cycles through the configured list of items displaying a new value approximately every three seconds The first two displays which cannot be configured by the user show values for time and date operating voltages and battery condition The next five displays are configured by the factory to show certain flow parameters but you may change their configuration Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 for details on how to configure the list of values for the LCD panel 1 14 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual NORM Reset Jumper P1 Super Capacitor Liquid Crystal Battery Display LCD C3 O P3 mi 01 oll ol ol a lo oo SRAM Comm Card Connector 5 O U8 I O Card e Connector FLASH El CR6 CR7 PT2 PT3 FL1 O P9 P10 P11 Power Wiring QoooOOliooltEs dZHoOoOOO0O0G Se d a h Terminal Block O erminal BIOCKS BA OWEN iie RADIO VIS BLK pus RED ns REF RID RET DOCO0331B Sensor Connector Figure 1 3 Main Electronics Board Rev 04 04 General Information 1 15 FloBoss 503 and 504 Instruction Manual 1 5 4 Communications Ports The FloBoss unit provides two communication ports Local Operator Interf
137. pecify the low calibration point between the Zero and Span endpoints The Zero and Span endpoints you recently established are used in setting the Midpoints Midpoints 1 2 and 3 are values set between the Zero and Span values Midpoint 1 should have the lowest value of the three midpoints and should be between the Zero and Span values Midpoints should be entered in order from smallest to largest or vice versa 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 8 Point RTD Dead Weight T ester Value 25 Live Reading 7 598042 Difference 5 536 Live Test Span SetMid2 x Cancel W Done Figure 8 6 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 such as 50 of range 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 Point RTD Dead Weight T ester Value i 7 28 Live Reading 6 446073 Difference 1 4 405 x Live Test Span Set Mid 3 X Cancel yY Done Figure 8 7 Set Midpoint 3 To perform a four point calibration click Done Calibration for this input is co
138. ptical coupling and a DC DC power converter which supplies power for most of the I O circuits This converter helps isolate the field I O from the processor If you require additional power for the I O connect an external 24 V dc power source to the T and T on the I O Power terminal block If you require additional voltage for the I O connect an external DC DC to the B B T and T on the I O Power terminal block NOTE The isolation jumpers on the back of the 24 channel I O Card W1 and W2 should both be set at BATT when providing battery power to the Discrete Inputs Refer to Figure Rev 04 04 Inputs and Outputs 5 3 FloBoss 503 and 504 Instruction Manual o pe O ooon o CR29 CRe8 H Z Z S Al Scaling co T gt i 5 I Resistor R1 OC aes e e o ERS Ge Res D IRIS 9 pjoo m HOO H F R2 T UC m R 26 de k AIG rj RAE DRE pg deta bate DI DO Selector e Lr i CR32 due D B3 o o Switch ORB arc B M p B71 cess dom D B13 CRED o Wo P Ble o9 QU pee o o eet
139. pulse count and static pressure inputs to the FloBoss 504 Flow Manager for the turbine metered flow calculation Note that the SM is not equipped to provide a temperature input to the FloBoss this input comes directly into the FloBoss from an RTD by means of the built in RTD input This section contains the following information Section 7 1 Description of Sensor Module Dom uio RU ciini EA 7 3 Sensor dni ane nie TA OT OUT A UE ETE 7 5 Sensor Module Specifications 7 1 Description of Sensor Module The primary function of the FloBoss 504 is to measure the flow of natural gas using turbine metering in accordance with the American Gas Association AGA American Petroleum Institute API and International Standards Organization ISO standards When performing AGA7 calculations the FloBoss uses 1992 AGAS compressibility When performing ISO 9951 calculations the FloBoss uses ISO 12213 2 compressibility Five levels of pulse integrity checking Level A through Level E are available with either calculation scheme The Sensor Module provides volumetric flow measurement for a turbine meter used to measure the flow in a single meter run and can be configured for Metric or US units of measurement The Sensor Module provides terminals for its pulse counter PI inputs from a turbine meter and senses static line and auxiliary pressures from direct process connections The SM can count pulses acquired from a turbine meter read a
140. puts and Outputs If you are experiencing troubles with an I O point Analog Input Analog Output Discrete Input Discrete Output or Pulse Input Check to see how the channel is configured using ROCLINK for Windows software Ifthe configuration looks correct then simulate an input within the range of the input or force an output to be produced using ROCLINK for Windows 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 Card If a card appears to be operating improperly verify that the card is set up according to the information contained in Section b Inputs and Outputs The faulty card should be returned to your local sales representative for repair or replacement 9 2 4 ROCLINK for Windows Software If you are experiencing problems with the FloBoss 503 or FloBoss 504 that appear to be software related try resetting the FloBoss To reset the FloBoss open ROCLINK for Windows software connect to the FloBoss unit and select ROC gt Flags Refer to ROCLINK for Windows Configuration Software User Manual Form A6091 Use a Warm Start to restart without losing configuration or log data If you are still experiencing problems then perform a Cold Sta
141. r ISSUES cote perte Nate tem er 9 3 Replacing a Communications Card 4 11 Reset DVS to Factory Defaults 9 5 RST Jumper 4 eet hit 9 6 Sensor Module sees 9 4 9 5 Serial Communications eee 9 2 EXD Ln a t te ne CR ee Misti 4 4 U Use Pulse Inputs as Discrete Inputs 5 20 V Vibration eie re rH eiie 2 1 Voltage et RARE Us Peru Pierre 3 4 W X Y M TLJ tmper ince rte OI E EERRNRUNT 5 9 Watchdog Software and Hardware 1 18 Wiring AC Power Supply scsi 3 13 Analog Inputs meten 5 8 Analog Outputs eese 5 10 Auxiliary Power 4 9 Battery Connections 3 11 Battery Power Charger 3 12 Communications Cards 4 0 Dial Up Modem Communications Cards 4 11 Discrete Inputs ensien preiar 5 11 Discrete Outputs 5 14 Discrete Outputs Built in sssse 5 16 Dual Variable Sensor 6 2 EIA 232 RS 232 Communications Cards 4 9 EIA 485 RS 485 Communications Cards 4 10 FIOBOSS 4 eth et arre ee RE PRAES 3 8 General Connections 3 8 GIrOUDIDg z 4o e D e eite hab Aas te 3 9 Grounding Requirements eee 3 4 Host Port Comml sese 4 9 VO A ts baile 5 8 V O Wiring Requirements 5 8 Input Terminals
142. r details 1 6 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual 1 4 PRODUCT FUNCTIONS This section describes the functions of the FloBoss 503 and FloBoss 504 most of which is determined by firmware The features and applications provided by the firmware must be configured with ROCLINK for Windows software 1 4 4 Firmware The firmware contained in flash ROM on the electronics board determines much of the functionality of the FloBoss such as Memory logging of 240 alarms and 240 events Archival of data for up to 15 history points for up to 35 days AGA flow calculations Power cycling control Flow calculations for a single meter run Logic and sequencing control by means of two user defined Function Sequence Tables FST Closed loop PID control Communications based on either ROC protocol or Modbus protocol slave mode only Spontaneous Report by Exception SRBX communication to a host computer 9 9 User level security 1 4 2 Flow Measurement The primary function of the FloBoss 503 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 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 a Dual
143. rdware filter Resolution 16 bits Conversion Time 100 usec Sample Period 1 second minimum 1 20 General Information Rev 04 04 Rev 04 04 FloBoss 503 and 504 Instruction Manual Main Specifications Continued DISCRETE OUTPUT BUILT IN Quantity Type 1 sourced high side switched output Terminals positive output negative common Voltage Same as applied to Battery Input minus 0 7 volts Frequency 1 5 Hz maximum Sample Period 200 ms minimum Current Limit 300 mA automatic reset ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F excluding LCD display which is 25 to 70 C 13 to 158 F Refer to Section 7 for pressure accuracy in Operating Temperature for the SM Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity 5 to 95 non condensing Vibration FloBoss 503 Tested to SAMA 31 1 Condition 3 with an abbreviated endurance dwell test Radiated Conducted Transmissions Complies with requirements for Class A Information Technology Equipment per EN 55022 1995 and CISPR 22 1993 Also complies with FCC Part 15 Class A FloBoss 504 also complies with ICES 003 of the Canadian Interference Causing Equipment Regulations Voltage Surge Immunity FloBoss 503 Designed to meet IEC 801 4 and IEC 801 5 as required by EN 50082 2 Electrostatic Discharge FloBoss 504 Complies with requirements in CENELEC document EN61000 4 2 Cl
144. re 9 4 Open Configuration File 9 8 Figure 9 5 Download Configuration 9 8 Firmwares oie ctc pe iet Dec ches 1 7 Flash Memoty 2 ecce tre oe ires 1 13 Flash ROM gei RR p re te Rete athe 1 4 FloBoss 503 SENSOL d S 6 1 Troubleshooting eere 9 5 FloBoss 504 NI 7 1 Troubleshooting rirnan 9 5 FloBoss Flow Manager 1 1 Flow and Energy Accumulation 1 8 Flow Calculations 1992 AGA is gnasi omae enin 1 9 Flow Measurement 1 7 How Tunes ioter etd eon Ee 1 8 Freeze xii nete nme ett e E 8 2 Value esses tei de ete Dr rE 8 2 Function Sequence Tables PS RS e ien 1 12 Functio gnon 1 cr Pra o a eO ERE 1 7 G Grid Impedance ee eet 3 4 Ground Rod 5 5 datei e 3 4 Grounding Earth Ground 2e Rem 3 4 Ground Wiring 3 9 Wiring Requirements eee 3 4 Group Rev 04 04 Joc et e Eee 2 2 Bsp n HUE ees 2 2 Quisnam A etednteus 2 2 Din sentent E eei 2 2 H Hardware 5 inch ete 1 4 Watchdog ene Reus 1 18 Hazardous Locations eee 2 2 History quince 1 10 History Log pp REEVE 1 11 Hourly evista een be 1 10 Minute v eee eae epe 1 10 Host Port Comml sees 1 16 4 2 Installing Comm Card 4 7 Troubleshooting i 9 2 Wiring Comm Cards 4
145. red as a FloBoss powered pulse counters The pulse circuitry is optically coupled to isolate the processor board from the input signal The Pulse Inputs on the 10 channel card can also be configured as Discrete Inputs 5 2 Inputs and Outputs Rev 04 04 FloBoss 503 and 504 Instruction Manual C Ui d b Screw qp Screw 1 P CRI c P6 E US FBI2 T a P3 m d D a u H R4 qd tb Ed 1 TA u6 1 di th H o aod p s Reo dj Ih A nC UY gm qon o tm 7 2 o R29 FBS IT C10 Re7 di E m R31 qo ot B H Q R35 NE d H cem mas oU T Base 1 Ra7 gf i 4 o 5 B jl RO amp 18 R109 Ke a d 2 ao R108 X os p R44I1 M a Ba E H mI B E F E o RS THAR ssim S d pore we Ra 9 DR Oo io II R53 R43 Ul8 xj c19 I RSS q P pm EUCH g 7 soe
146. rete Output channel is a normally open single pole single throw switch An LED turns on to show when the switch is closed The Discrete Outputs are solid state switches enabled by individual signals from the processor I O lines The solid state switches are capable of handling 24 V dc at 300 mA The 24 channel I O Card provides two dedicated Discrete Output mechanical relay channels at B9 and B10 The 24 channel I O Card provides eight selectable DOs which can also be configured as DIs The DO relays provide normally open contacts while the selectable DOs are normally open solid state switches that are used for activating externally powered devices Table and Table display the Discrete Output s number the Point Number to which the AO is assigned in ROCLINK for Windows software and the number printed on the I O Card In the case of the 24 channel card the number in the software and on the label are the same Table 5 11 Discrete Outputs 10 Channel Discrete Point Number Label Number Output 4 B5 DO 1 5 B6 DO 2 Table 5 12 Default Discrete Outputs 24 Channel Discrete Output Point Label Number 2 B9 B10 B11 B12 B13 B14 B15 oloi NIIA co B16 C1 e oO C2 Inputs and Outputs FloBoss 503 and 504 Instruction Manual Table 5 13 Discrete Outputs Terminals Terminal Function P
147. rt Use a Cold Start to restart without a portion of the configuration log data or programming that may be the source of trouble To perform a Cold Start open ROCLINK for Windows software connect to the FloBoss unit and select ROC gt Flags Use the RST reset jumper on the FloBoss unit to restore the unit to factory defaults without connecting to ROCLINK for Windows software Refer to Section How to Reset the FloBoss on page 9 6 If these methods do not resolve the problem contact your local sales representative 9 2 5 Power Issues If you are experiencing trouble with powering up the FloBoss 503 or FloBoss 504 Check to make sure power is applied to the FloBoss unit Check the wiring connections at the power source Power CHG and BAT Check the batteries for voltage If the batteries are below nominal voltage replace them Refer to Specifications in Section l General Information and section B Power connection Rev 04 04 Troubleshooting 9 3 FloBoss 503 and 504 Instruction Manual 9 2 6 FloBoss 503 DVS or MVS Sensors If the DVS or MVS sensors are experiencing issues NOTE The DVS or MVS sensor should only be installed and removed at the factory If your sensor is not responding 1 Ensure that the Sensor is plugged into the P DP connector on the Main Electronics Board at P11 This ribbon cable fits into the P11 connector in only one direction 2 Ensure that the connector and cable do not appear to be de
148. rted by the FloBoss unit In addition a version of Modbus with EFM extensions can be emulated as a slave device Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 for details 1 4 7 Power Control The Power Control function is used with the EIA 232 RS 232 communications card to provide power savings when using a radio or cell phone for communications Two modes of Power Control are possible Second and Minute In Second mode the time base for the timers is in 100 millisecond increments and is primarily used with radios In Minute mode the time base for the timers is in 1 minute increments that are kept in tune with the Real Time Clock and is primarily used with cell phones Three cycling zones are provided but zones can be disabled as desired The EIA 232 RS 232 card provides the switching mechanism and is controlled by the Data Terminal Ready DTR signal The Power Control function calculates which zone should be currently active In Second mode the Power Control begins in the ON state and continues with a full On Time and then goes to the OFF state for the full Off Time In Minute mode the Power Control determines if it should be ON or OFF and how much time it needs until it switches Refer to Section b Power Connections and Section Communications Installation and Wiring 1 12 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual 1 4 8 PID Control The Proportional Integral and Deriva
149. ry uses a 16 bit A D converter The circuitry is designed to use_as much range of the reference as possible The sensors measurement ranges are listed in Section The 16 bit values are converted to 24 bit values 23 bits plus a sign bit for transmitting to the MCU Table 7 3 Analog Inputs Input Type Point Number Reading Analog Input Al Auxiliary Pressure Analog Input A2 Line Static Pressure 7 1 3 Sensor Module Connection The connection between the SM and the main electronics board is achieved entirely by means of a ribbon cable plugged in at the P DP connector In addition to all the signals a 12 volt power supply from the FloBoss is made available to the SM through the P DP interface cable The voltage of this power follows the battery voltage of the unit This supply operates under very low currents with an efficiency of 60 to 90 percent depending upon the current draw 7 2 Process Connections The process inputs are the static and auxiliary pressure connections which are located on the bottom of the SM housing Refer to Figure The static pressure connection is made to the front tap labeled 1 and the auxiliary pressure connection is made to the rear tap labeled 2 The static pressure connection is required for the AGAT flow calculation the auxiliary pressure sensor can be used for measuring any other pressure within its specified range or it may be left unused Both pressure connections
150. s 503 and 504 Instruction Manual Table of Contents Section 1 General Information scccccscsssssssssssssccssssssssscsssssccscssssssssssssscssssscees 1 1 1 1 MANUAL OVERVIEW name onda den adds ela Rada dde 1 1 1 2 VDDUHONAL INFORMATION and nee ami ennemie anne 1 2 1 3 PRODUCT OVERVIEW nn no ani diu Apa Iv a tin titane 1 2 1 4 PRODUCT FUNCTIONS wes ce c cassaddeteasccaacaesdenatcbceedasaviedaashdeedanasegacadabdenenses adustncnassedaedsothGaaeedacsicacess 1 5 1 5 PRODUCT ELECTRONICS is cssasisiesc 0s stan deceat doses Pra Eae ERE eda dee ERE sepas Vae La ER eed EFE LAE AE SERA ER 1 13 1 6 FLoBoss 503 AND FLOBOSS 504 MAIN SPECIFICATIONS sees eene enne enne 1 20 Section 2 Installation and Use eee reo evo aono n sap aerea v eoa an ka eoa aen RES aU P AUR YER Gran 2 1 INSTALLATION REQUIREMENTS 5 5 ree erre ta E bd beet ee rid Ede oa Pee pod REPE ie REN PEE EUdd 2 1 2 2 MOUNTING ssid sedecateiestnctceeteaasiicesacl Re ent donne ne led et nn etat anal eee Me ne leds ea neue dat 2 5 2 3 CONFIGURATION RN a m ni a aS 2 8 2 4 STARTUP AND OPERATION iesu endi voters de eau indien ain 2 9 Section 3 Power Connections ssssesesssocceessscceessooeceessoooceesosoceessosoocessoseseesssoesessseseee 3 1 CALCULATING POWER CONSUMPTION sic c sicseckdiadustisocatacveacaseinssdeasandondssensbdedaauacncssinabinaueeteudanenonda 3 1 3 2 CONNECTING THE FLOBOSS TO WIRING 3 incizsiucudzcnauterasndsueasaeicnsadsnavedioriidsnnbsbenannedscdane
151. s an alarm from being set and cleared continuously when the input value is oscillating around the specified limit This also prevents the logs or data storage location from being over filled with data 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 DTR Data Terminal Ready modem communications signal Duty Cycle Proportion of time during a cycle that a device is activated A short duty cycle conserves power for I O channels radios and such DVM Digital voltmeter DVS Dual Variable Sensor Provides static and differential pressure inputs to a FloBoss 503 Flow Manager E EEPROM Electrically Erasable Programmable Read Only Memory a form of permanent memory EFM Hlectronic Flow Metering or Measurement 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 EMF Electro motive force EMI Electro magnetic interference ESD Electro static discharge EU Engineering Units User selected units of measure F Firmware Internal software that is factory loaded into a form o
152. se Input Wiring 5 19 Figure 5 18 Pulse Input Wiring 24 Channel 5 19 Rev 04 04 FloBoss 503 and 504 Instruction Manual Figure 5 19 Pulse Input PI 1 used as a Discrete Input 10 Channel ttt ehe 5 21 Figure 5 20 RTD Wiring Terminal Connections 5 23 Figure 6 1 Orifice Meter Setup for FloBoss 50 6 3 Figure 7 1 Sensor Module 7 3 Figure 7 2 Side Cut away View Showing Process Connections ooh mile eee e eee DIES 7 5 Figure 7 3 Pulse Input from FloBoss Powered Device a E Ma owe 7 7 Figure 7 4 Pulse Input from FloBoss Powered Device SAG Bil ta LNs aoa te 7 7 Figure 7 5 Turbine Meter Setup for FloBoss 504 ISO 995 shown sideris 7 8 Figure 8 1 Meter Calibration sees 8 2 Figure 8 2 Removing the Sensor from Service 8 3 Figure 8 3 Set Zero Calibration for Differential Pressure ea ette o RR He pe etais 8 3 Figure 8 4 Set Span sse 8 4 Figure 8 5 Set Midpoint 1 sess 8 4 Figure 8 6 Set Midpoint 2 sess 8 5 Figure 8 7 Set Midpoint 3 sess 8 5 Figure 8 8 Returning the Sensor to Service 8 6 Figure 9 1 Analog Input Scanning Enabled 9 4 Figure 9 2 Analog Input Advanced 9 5 Figure 9 3 Reset Jumper Shown in Normal Position deu Sat pate e ee P Ee ege de Dr eer e es ret gd 9 6 Figu
153. sideadacrauidase 3 6 3 3 OPTIONAL AC POWER SUPPLY SPECIFICATIONS ccccsscccascsssssecssasssnecansscencssnsssecsnaesstcdeneaseseneaats 3 14 Section 4 Communications Installation and Wiring eee 4 1 4 1 How TO WIRE THE LOCAL PORT LOI iii 4 4 2 COMMUNICATIONS CARDS PRODUCT DESCRIPTIONS seins 4 2 4 3 COMMUNICATIONS CARD INSTALLATION AND SETUP essere 4 7 4 4 How TO CONNECT A COMMUNICATIONS CARD WIRING sccccessseceeeceenseeecsesneeeeeeseeeeeeeseaeeeenes 4 9 4 5 HOW TO REPLACE A COMMUNICATIONS CARD ccsssssscecesssscececsssseeecseaeseceeseueecessesaeeecnssaneess 4 11 4 6 COMMUNICATION CARDS SPECIFICATIONS 22 2 5 3 e Eirtcm e bna e EL MIC tuu eo cul ei pue ade i pae diu 4 13 Rev 04 04 Table of Contents iii FloBoss 503 and 504 Instruction Manual Section 5 Inputs and OUPS sde di te letters tester o near este 5 1 DESCRIPTION EUM 5 1 5 2 HOW TOTS TALL THE VO C ABD iudei cada none eaat EAR CE RU 5 4 5 3 VO WIRING Cn en ni Re ec 5 8 5d VOCARD LEDS e ns ode ee ne ee 5 21 5 5 SUBIT 5 22 5 6 VO CARD SPECIFICATIONS TT 5 24 Section 6 Sensor for FloBoss 503 ssssssccccececssssoscoccecccsesessoococceccecsessssooccececsesessosso 6 1 6 1 DESCRIPTION OF SENSOR Ra ea POM domiui ann en ie el ee 6 1 6 2 PROCESS ON NEC TIONS de ann E nn non 6 2 6 3 SENSOR WIRING nn un on anatomie 6 2 6 4 CONFIGURATION ire rhinite an lanta 6 2 6 5 DVS AND
154. so backs up the non volatile RAM and is adequate for at least three weeks with no power applied to the FloBoss unit 1 5 8 Automatic Self Tests The FloBoss unit 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 Charging voltage for the super capacitor Memory validity The FloBoss unit operates with 8 to 15 volts of de power The LCD becomes active when input power with the proper polarity and startup voltage typically set at 10 6 volts or greater is applied to the POWER terminal block provided the power input fusing protection 1s operational The battery voltage tests ensure that the FloBoss unit is operating in the optimum mode The software watchdog is controlled by the Main Electronics Board This watchdog checks the software for validity every 1 2 seconds If necessary the software automatically resets The hardware watchdog is controlled by the Main Electronics Board and monitors the power to the hardware If this voltage drops below 4 75 volts the FloBoss unit automatically shuts down RTD automatic temperature compensation is tested at approximately every 5 C 9 F temperature change of the board temperature The FloBoss 503 monitors its orifice metering Sensor for accurate and continuous operation while the FloBoss 504 similarly monitors its Sensor Module Voltage for charging
155. source voltage is a nominal 12 volts open circuit it provides approximately one milliAmp in shorted or closed contact positions The source voltage is load dependent Note that the circuit does not supply sufficient power for a pre amp Rev 04 04 Sensor for FloBoss 504 7 3 FloBoss 503 and 504 Instruction Manual Connect an external amplifier pre amp to the field terminations to provide gain for low level turbine signals The amplifier receives power through a source voltage other than the SM and the amplifier output connects to the input signal If the gain of the amplifier were 40 100 millivolt signals are amplified to 4 volts which is above the 3 5 volt active threshold The pulses accumulate in a 32 bit register that rolls over when the 25 bit is set Only 24 bits are sent to the FloBoss for updates The inputs for the Pulse Inputs are_acquired from devices such as a turbine meter Refer to the product specifications in Section 7 5 for details concerning pulse frequency and phase which vary depending on the level of integrity checking you are performing The SM accepts the signals shapes and filters them and sends the values to the MCU The Pulse Input connectors consist of a 5 pin removable terminal block with screw type compression connectors 7 1 2 Analog Inputs The static line pressure and auxiliary pressure readings from the SM sensors are configured as two Analog Input points in the FloBoss The pressure circuit
156. ssure Analog Input A2 Static Pressure Gauge or Absolute RTD A3 Resistance Temperature Detector The defaults contained within the Sensor are the initial pressures read Refer to the Specifications table on page 6 4 or the lable for the initial ranges You can change the ranges through the calibration routines The turndown on the range should not be greater than the values in the Specifications table on page The Sensor also supports the conversion of values to metric units To enter the metric mode use ROCLINK for Windows software Rev 04 04 Sensor for FloBoss 503 6 3 FloBoss 503 and 504 Instruction Manual The FloBoss automatically adjusts the units ranges alarm limits and calibration factors of the differential pressure static pressure RTD and enclosure battery temperature to the Metric mode Points starting with A such as A2 are associated with points either on the Main Electronics Board or on the Sensor that may be physically connected to external signals Points starting with B or C are associated with the optional FloBoss 500 series I O Cards The initial ranges are read from the defaults contained within the pressure sensor such as 0 to 300 psig depends on the sensor installed at the factory The ranges can be changed through the calibration routines Turndown is not recommended however if required the turndown on the ranges should not be greater than five 6 5 DVS Specifications Refer t
157. stic I O channels are considered to be in rack E RAM Random Access Memory In a FloBoss it is used to store history data most user programs and additional configuration data RBX Report by exception In a FloBoss it always refers to Spontaneous RBX in which the FloBoss contacts the host to report an alarm condition RFI Radio frequency interference RI Ring Indicator modem communications signal ROC Remote Operations Controller Emerson Process Management s microprocessor based unit that provides remote monitoring and control ROCLINK for Windows Configuration software used to configure ROC or FloBoss units to gather data as well as most other functions ROM Read only memory Typically used to store firmware Flash memory RS 232 Serial Communications Protocol using three or more signal lines intended for short distances Also referred to as EIA 232 RS 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 EIA 485 RTC Real time clock RTD Resistance Temperature Detector RTS Ready to Send modem communications signal Rev 04 04 Glossary G 5 FloBoss 503 and 504 Instruction Manual RTU Remote Terminal Unit RX or RXD Received Data communications signal S SAMA Scientific Apparatus Maker s Association Script A uncompiled text file such as keystrokes for a
158. t is designed to be mounted in the FloBoss enclosure Refer to the ROC FloBoss Accessories Instruction Manual Form A4637 for details An I O Card must be installed in order to use the intrusion switch The status of the switch can be configured to generate an alarm when the door to the enclosure is open Refer to Section 5 Inputs and Outputs for details The FloBoss enclosure can hold up to four sealed lead acid batteries The 12 volt batteries provide approximately 7 Amp hours each resulting in up to 28 Amp hours of backup capacity or up to 21 Amp hours of backup capacity when used with an AC power supply The batteries are mounted under the electronics swing out panel and are retained by the panel when it is secured The batteries are connected to a wiring harness that allows the batteries to be changed without removing power from the unit Refer to Section b Power Connections for further details A solar panel can be installed to recharge the backup batteries it connects to the POWER charge inputs on the Main Electronics Board Circuitry on the Main Electronics Board monitors and regulates the charge based on battery voltage charging voltage and temperature The typical panels used are 12 volt panels with output ratings of 5 or 10 watts The panels are typically bracket mounted on a pole or pipe and the wiring is brought into the bottom of the FloBoss enclosure through a liquid tight fitting Refer to Section 8 Power Connections for furthe
159. t and Reconfigure When power is applied to the FloBoss scanning of the I O Card automatically activates Use the ROCLINK for Windows software to configure the new I O points history database and other aspects as desired Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 Rev 04 04 Inputs and Outputs 5 5 FloBoss 503 and 504 Instruction Manual 24 CHANNEL 1 0 CARD SOO66606660666006 VSN M VSN A VSN M N eo o wo a wu a _ a M a N a a VSN A QVPVVYVVYVOG 1 SELECTABLE AS EITHER DI OR DO USE SWITCH S1 FOR CONFIGURATION SETTINGS 2FOR 24V T BY EXTERNAL CONVERTOR W11043A REFER TO INSTRUCTION MANUAL Figure 5 4 24 Channel I O Card Wiring Labels 5 6 Inputs and Outputs Rev 04 04 e Mating FloBoss 503 and 504 Instruction Manual Connector Location a Label Mounting Screw PI PI2 DI DIZ DO 2 DO Detent Mounting ATS Screw Mounting Screw DOC0308B Figure 5 5 1 0 Card Installation 10 channel Card Shown I Mounti 2 ounting Screw a e Mounting 2 Screw EE A
160. t the battery connection terminal and is not fused or controlled on the Main Electronics Board Fusing should be installed in the auxiliary output wiring and should not exceed the size of the fuse in the battery harness wiring The terminals are labeled for positive voltage and for common The auxiliary Mx ut power connections are on a fixed terminal block connector labeled RADIO Y L POWER RADIO P DP BAT CHG Radio cell phone or other constant powered device Figure 3 7 Auxiliary Power Terminals Direct Connect to Power Rev 04 04 Power Connections 3 15 FloBoss 503 and 504 Instruction Manual If power to the radio or other device needs to be cycled to conserve power recommended when batteries are used use an EIA 232 RS 232 communications card and connect wiring for switched radio power as described in Section Communications Cards Configure radio power cycling control as detailed in the ROCLINK for Windows Configuration Software User Manual Form A6091 and in Section Communications Installation and Wiring 3 3 Optional AC Power Supply Specifications Optional AC Power Supply Specifications AC INPUT 105 to 132 V ac or 207 to 264 V ac 47 to 63 Hz Input ranges are switch selectable REGULATION Output voltage varies no more than 0 05 for a 10 change in line voltage or for a 50 change in load current STABILITY 0 3 for 24 hours after warm up AC INPUT
161. ta held in RAM When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures 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 for Windows software 2 Ensure that the configuration is saved in flash memory by performing a Write to Internal Config Memory ROC menu gt Flags This saves all configuration settings including the current states of the ROC Flags and calibration values 3 If you will be replacing the flash chip save the current configuration data to disk by using File gt Save This action saves the configuration to an fcf file you can specify your own file name and path if desired 4 Select ROC gt Collect Data 5 Select the All checkbox and 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 9 3 3 How to Reset the FloBoss The Main Electronics Board has a jumper located at P1 in the upper right hand corner that can be used to perform a special type of Cold Start Refer to Figure This jumper permits a power up reset to re establish a known operating point This inc
162. tal 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 controlled logging 1 4 3 4 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 which include time and date stamp alarm clear or set indicator and either the tag name of the point which was alarmed with the current value or a 14 character ASCII description In addition to providing functionality for appending new alarms to the Alarms Log it 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 for Windows 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 operation and changes The Alarm Log is stored separately to prevent recurring alarms from overwriting configuration audit data 1 4 3 5 Event Log The Event Log contains changes to any parame
163. tantaneous Energy will not be performed correctly Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 7 8 Sensor for FloBoss 504 Rev 04 04 FloBoss 503 and 504 Instruction Manual Points starting with A such as A2 are associated with points either on the Main Electronics Board or on the SM that may be physically connected to external signals Points starting with B or C are associated with the optional FloBoss 500 series I O Cards The initial ranges are read from the defaults contained within the pressure sensor such as 0 to 300 psig depends on the sensor installed at the factory The ranges can be changed through the calibration routines Turndown is not recommended however if required the turndown on the ranges should not be greater than five Rev 04 04 Sensor for FloBoss 504 7 9 FloBoss 503 and 504 Instruction Manual 7 5 Sensor Module Specifications For other specifications refer to the Specifications tables in Section Sensor Module Specifications PULSE COUNTER INPUTS Quantity and Type Two voltage sensing inputs Field Wiring Terminals S COM Source Power Voltage is 12 V dc maximum current is 1 mA maximum designed for contact closure device Range Inactive 0 to 1 0 V dc active 3 5 V dc minimum Minimum Pulse Width 100 usec under 1 kHz Frequency and Phase For Level A integrity phase between pulse inputs must be between 45 C 315 F and frequency between
164. tate upon restoring power An unsafe state could result in property damage When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage 1 Reconnect power to the FloBoss unit by inserting the Power terminal plug into the P8 Power connector 2 Launch the ROCLINK for Windows software log in and connect to the FloBoss unit 3 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 4 Select File gt Download 5 Select the backup configuration file has extension FCF Refer to Figure Rev 04 04 Troubleshooting 9 7 FloBoss 503 and 504 Instruction Manual Open i21 xi ac CELLES X kup fcf Backup fcf Configuration Files fcf y LZ Figure 9 4 Open Configuration File 6 Select the Configuration Points checkboxes you desire to download restore Refer to Figure B Configuration Points XE XE XE SEL 4 XE XE XE SE SL 4 Figure 9 5 Download Configuration Points 7 Click Download to restore the configuration 9 8 Troubleshooting Rev 04 04 FloBoss 503 and 504 Instruction Manual GLOSSARY OF TERMS A A D Analog to Digital AGA American Gas
165. ter within the FloBoss unit made through the protocol This Event Log also contains other FloBoss unit events such as power cycles cold starts and disk configuration downloads 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 which include point type parameter number time and date stamp Point Number if applicable the operator identification and either the previous and current parameter values or a 14 byte detail string in ASCII format In addition to providing functionality for appending new events to the Events Log it 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 FSTs Event Logs are not stored to flash ROM when the Save Configuration function is issued in ROCLINK for Windows 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 Rev 04 04 General Information 1 11 FloBoss 503 and 504 Instruction Manual 1 4 4 Security The FloBoss unit provides for security within the unit A maximum of 16 log on identifiers Operator IDs may be stored In order for the unit to communicate the
166. terminals the PI indicator LED on the termination board lights to show an active circuit and the optical circuitry is triggered producing a signal to the FloBoss 500 series unit NOTE FloBoss powered means power is received from the Input Output or Module shown External or self powered means power is received from the device a battery the FloBoss Main Electronics Board or another source PI EXTERNAL FloBoss POWERED Vs PULSE DEVICE s COM c BMA2 7 CSK DOC0310B Figure 5 17 Pulse Input Wiring 10 Channel PI 15V PULSE EXTERNAL SELF ACCUMULATOR POWERED PULSE DEVICE C5 C6 DOCO430B Figure 5 18 Pulse Input Wiring 24 Channel Rev 04 04 Inputs and Outputs 5 19 FloBoss 503 and 504 Instruction Manual 5 3 5 1 How to Use Pulse Inputs as Discrete Inputs The two PI channels on the 10 channel card can be configured as both Pulse Inputs both Discrete Inputs or one of each in either order Table displays the type of channels on the I O Card and their respective Point Numbers Table 5 19 PI and DI Point Numbers 10 Channel Type Point Number 1 0 Card Location Discrete Input B7 DI 1 Discrete Input B8 DI 2 Discrete Input B9 PI 1 Discrete Input B10 PI 2 Pulse Input B11 PI 1 Pulse Input B12 PI 2 The Point Number designat
167. tion 12 bits Conversion Time 200 us Sample Period 50 ms minimum ANALOG OUTPUT Quantity Type Two current loop signal outputs Terminals positive output and common Range 4 20 mAwith 0 to 22 mA overranging Loop Resistance 300 ohm maximum at 12 V dc source voltage Resolution 12 bits Accuracy 0 1 of full scale output Settling Time 100 us maximum Reset Action Output goes to zero percent output or last value software configurable on power up warm start or on watchdog timeout DISCRETE INPUTS Quantity Type Two contact sense Discrete Inputs Up to eight additional DIs available when Selectable DI DO is so configured Terminals positive input negative input common shared between pair of Dls Signal Current 0 5 to 3 5 mA in the active on state 0 to 0 2 mA in the inactive off state Isolation 2500 V dc from processor Frequency 50 Hz maximum Sample Period 10 ms minimum DISCRETE OUTPUTS Quantity Type Two dry contact relay outputs Up to eight additional DOs available when Selectable DI DO is so configured DISCRETE OUTPUTS CONT D Terminals NO normally open contact common Contact Rating 30 V dc 5A maximum Isolation 3000 V dc Frequency 10 Hz maximum SELECTABLE DI DO Quantity Type Eight channels individually Switch selectable as either a contact sense DI or a solid state relay DO Terminals pos
168. tion It displays in the Comm Port settings screen in ROCLINK for Windows software Select ROC gt Comm Ports gt Modem tab The communications cards have no user serviceable parts If a card appears to be operatin improperly verify that the card is set up according to the information contained in Section Hi Communications Installation and Wiring If it still fails to operate properly the recommended repair procedure is to remove and replace the card The faulty card should be returned to your local sales representative for repair or replacement 9 2 2 Serial Communications If you are experiencing troubles with a serial communications connection LOI EIA 232 RS 232 or EIA 485 RS 485 Check to make sure power is applied to the FloBoss unit Check the wiring connections at the power source Power CHG and BAT Check the wiring to the termination block or connector Refer to Section k Communications Installation and Wiring The communications cards have no user serviceable parts If a card appears to be operatin improperly verify that the card is set up according to the information contained in Section Hi Communications Installation and Wiring If it still fails to operate properly the recommended repair procedure is to remove and replace the card The faulty card should be returned to your local sales representative for repair or replacement 9 2 Troubleshooting Rev 04 04 FloBoss 503 and 504 Instruction Manual 9 2 3 In
169. tions for each input of the meter run as applicable You can calibrate Differential Pressure orifice metering only may be High or Low Differential Pressure depending on the device Static Pressure or Temperature Calibration parameters include Set Zero Set Span and Set Midpoint 1 2 and 3 This allows you to specify the low calibration point between the Zero and Span endpoints The Zero and Span endpoints are used in setting the Midpoints Midpoints 1 2 and 3 are values set between the Zero and Span values All new calibration values are automatically logged in the Event Log NOTE When calibrating Stacked Differential Pressure you may calibrate either the low differential pressure Low DP input or the high differential pressure Diff Pressure input NOTE Click Cancel to exit the calibration without saving the changes The previous calibration settings are retained NOTE During calibration the FloBoss time outs and disconnects if it is left idle for an extended period You lose calibration values and must reconnect to start calibration from the beginning Perform the following steps 1 Launch ROCLINK for Windows software and connect to the FloBoss 503 or FloBoss 504 2 Perform one of the following Select the Meter Calibration tab from Quick Setup Select Meter gt Calibration Select Configuration gt I O gt AI Points gt AI Calibration tab in the Analog Inputs screen This opens the Meter Calibration windo
170. tive PID Control functionality calculates both the Primary Control and Override Control change in output It 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 PID Control can only be active if an I O card is installed in the FloBoss unit The Output of the PID functions can be implemented either through an Analog Output or through a pair of Discrete Outputs for open close control 1 4 9 Spontaneous Report By Exception SRBX Alarming The SRBX functionality allows a communications port to be set up to enable the FloBoss unit to contact the host computer when specified alarm conditions exist The host will be sent a message that an alarm condition exists 1 5 PRODUCT ELECTRONICS This section describes the FloBoss Main Electronics Board For calculating power and connecting to wiring refer to Section 5 Power Connections For Communications Installation and Wiring refer to Section 4 For I O Cards refer to Section 5 Inputs and Outputs For the Flow Sensors refer to Section 6 FloBoss 503 or Section fl FloBoss 504 1 5 1 Main Electronics Board Overview The Main Electronics Board components support the functionality of the FloBoss Refer to Figure The board provides 32 bit microprocessor built in static RAM Flash ROM Liquid Crystal Display LCD display communications card Host Port Local Port LOI built in Dis
171. to the FloBoss 500 series unit The I O channels have removable plug in terminal blocks for field wiring In addition the 10 channel card has six LEDs to indicate the state of the Discrete Inputs Discrete Outputs and Pulse Inputs Refer to Section I O Card LEDs Rev 04 04 Inputs and Outputs 5 1 FloBoss 503 and 504 Instruction Manual Compression CRI B B Standoff O n m E Q Screw or Screw ines Ale m E 1 LT R3 Q so C P CR2 P1 n J8 oo 2 m oo R4 oO OQ n 00 1 Ala R5 5 gus oo R6 00 mi AIRES oo R7 a O z LEDs 29 o He CR4 e2 n 00 R12 us R9 U3 oo R10 TD 4 E m OQ o 5 oo TI R13 md E H CR5 L oo R15 m m4 d B G pe kn a cag qus 5 E ILI F84 R160 Y1 U6 CR7 R17 BER a ga ec cg R19 D q b II CR8 T L_4 B ur i E PTI CR9 P4 B J 5 nnnnnnn cus x a
172. tput capacity For solar powered units a minimum reserve of five days is recommended with ten days of reserve preferred Add 24 hours of reserve capacity to allow for overnight discharge Space limitations cost and solar panel output are all factors that affect the actual amount of battery capacity available To determine the system capacity requirements multiply the system current load Isr on the batteries by the amount of reserve time required Compute Isr as described in Section Totaling Power Requirements on page 3 3 The equation is as follows System Requirement Isr Amps x Reserve hours Amp hours Finally determine the number of batteries required for the calculated power consumption by rounding up to the nearest multiple of 7 Amps 7 14 21 or 28 Amp hour capacity If more than 28 Amp hours are required an external battery enclosure with additional batteries may be used Rev 04 04 Power Connections 3 7 FloBoss 503 and 504 Instruction Manual 3 2 Connecting the FloBoss to Wiring The following paragraphs describe how to connect the FloBoss unit to power ground I O devices and communications devices Use the recommendations and procedures described in the following paragraphs to avoid damage to equipment Open the front door to access the field wiring terminations The wiring terminals are arranged on the lower edge of the Main Electronics Board The terminal designations are printed on the circuit board Always
173. 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 with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 3 2 1 Making Wiring Connections The FloBoss Main Electronics Board connectors use compression terminals that accommodate wiring up to 16 AWG in size The input power terminations use a removable connector and accommodate wiring up to 14 AWG in size In all cases connections are made by baring the end 4 inch maximum of the wire inserting the bared end into the clamp beneath the termination screw and then tightening the screw The inserted wires should have a minimum of bare wire exposed to prevent short circuits Allow some slack when making connections to prevent strain on the circuit board and to provide enough clearance to allow the Main Electronics Board to swing out This allows access to the batteries without removal of the field wiring The connectors are provided on the Main Electronics Board are defined in Table Table 3 5 Terminal Connectors Definition Connector Battery Input POWER BAT Charge Input POWER CHG Auxiliary Radio Power RADIO Flow Sensor P DP Discrete Output DO Resistance Temperature Detector RTD Local Port LOI Communications Card connector P3 I O Card connector P5
174. uction Manual As described in Sections and connect the batteries if used to the BAT and BAT terminals Connect the charging source solar panels or AC power supply to the CHG and CHG terminals Make sure the hook up polarity is correct NOTE If you are connecting a solar panel that has its own regulator connect the panel instead to the BAT terminals 3 2 3 1 Battery Connections The battery connections are on the removable terminal block labeled POWER Refer to Figure These connections provide the input power for the FloBoss electronics and are the output of the charge regulation circuitry A single 12 volt sealed lead acid battery or multiple batteries wired in parallel are connected to these terminals which are labeled BAT for battery positive and BAT for battery negative Remove the removable Power terminal block before removing the battery connections or the battery Power being sent to the FloBoss unit without batteries in operation could damage the FloBoss unit The maximum voltage that can be applied to the BAT terminals without damage to the electronics is 15 volts dc Excessive voltage could result in property damage The FloBoss enclosure can hold up to four sealed lead acid batteries Refer to Section Batteries for recommended battery types The 12 volt batteries can be installed to provide 7 14 21 or 28 Amp hours of backup capacity or up to 21 Amp hours of backup capac
175. ulation 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 1 8 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual 1 4 2 2 Flow Calculations for Turbine Metering The turbine flow calculation is in accordance both with 1996 AGA Report No 7 1993 API Chapter 21 1 and with ISO 9951 1993 E The FloBoss 504 performs 1992 AGA8 compressibility calculations in accordance with AGA Report No 8 1992 API Chapter 14 2 for ISO calculations the FloBoss 504 performs ISO 12213 2 compressibility The flow calculation may be configured to use either Metric or US units Pulse fidelity integrity checking at Level A through Level E is also performed according to AGA API 5 5 and ISO 6551 1982 E These integrity levels are summarized as follows Level A This is the highest level of integrity it provides continuous protection against errors Both verification and correction are performed by comparing two pulse streams from the turbine The two pulse streams are checked against each other to produce a corrected pulse stream which is then used in the flow calculation Errors are indicated even when corrected For Level A the FloBoss 504 employs a patent pending algorithm and requires a high precision turbine with no more than 146 phase error between blades Level B T
176. 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 conduit fitting on the bottom of the enclosure The RTD wires connect to the four screw terminals designated RTD on the Main Electronics Board Refer to Figure The FloBoss unit provides terminations for a four wire 100 ohm platinum RTD with a DIN 43760 curve The RTD has an alpha equal to 0 00385 A three wire or two wire RTD probe can be used instead of a four wire probe however they may produce measurement errors due to signal loss on the wiring Wiring between the RTD probe and the FloBoss unit must be shielded wire with the shield grounded only at one end to prevent ground loops Ground loops cause RTD input signal errors 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 performs calibration corrections and checks alarming The board temperature is monitored by the RTD routine If the temperature has changed by roughly 5 C 9 F the RTD circuitry is sent a command to re calibrate its reference The RTD terminals on the Main Electronics Board are designated and defined in Table Table 5 21 RTD Terminals Terminal Function REF Current Source Reference Signal Positive Input Signal Negative Input
177. w as in Figure 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 NOTE The Freeze Value function occurs automatically when using Quick Setup Rev 04 04 Calibration 8 1 FloBoss 503 and 504 Instruction Manual 3 Click Freeze to stop the values of the Differential Pressure Low Differential Pressure labeled Low DP Static Pressure and Temperature from being updated during verification or calibration This effectively freezes the values used in ongoing processing such as history logging while calibration is being performed This effectively freezes the values Freeze Values used in ongoing processing such as history logging while calibration is being performed ID z Meter Tag EFM5037 Meter F Freeze Values Diff Pressure LowDP Stat Pressure Temperature 52 000000 747 400024 25 250736 Figure 8 1 Meter Calibration 4 If desired select and specify a Calibration Report File Select Yes to create a report text file containing calibration and verification details Select No to continue without creating a report If you select Yes another dialog box appears 5 Type the name of the Calibration Report File in the File name field and use the extension cal to represent calibration The Calibration Report File is created in the default directory C Program Files ROCLINK for Windows
178. ware The Host Port automatically configures itself based upon the specific communications card installed The Host Port supports rates up to 19 200 bps Comml also supports the log on security feature of the FloBoss unit if the Security on Comml is Enabled in ROCLINK for Windows software One of the following card types can be accommodated EIA 232 RS 232 for asynchronous serial communications EIA 485 RS 485 for asynchronous serial communications Dial up modem for communications over a telephone network The Host Port can receive messages in either ROC or Modbus protocol and responds using the same protocol in which the message was received The Host Port is capable of initiating a message in support of Spontaneous Report by Exception SRBX and Store and Forward when using ROC protocol Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 1 16 General Information Rev 04 04 FloBoss 503 and 504 Instruction Manual For installations using radio communications battery power can be conserved by cycling power to the radio or a cellular telephone The power cycling control for a radio is acquired through the Data Terminal Ready DTR signal on the optional EIA 232 RS 232 communications card Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 concerning radio power control The radio is connected to the signal wiring terminals located on the EIA 232 RS 232 communications card

FloBoss 503 and 504 Instruction Manual

Contents

Download Pdf Manuals

Related Search

Related Contents