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FloBoss 407 Instruction Manual

1. DDOODDOO ODODOODOO S SY S Di S Y looo Beoeo joeleooaloa DUC0471A Figure B 7 Signal Hook Up for a Remote MVS Installation 3 The Address of each MVS must be set prior to final wiring of multiple MVS devices For proper operation of multiple MVS devices each MVS device must have a unique Address The FloBoss 407 allows up to four MVS devices to be connected on its communications bus in a multi drop connection scheme 4 Once a unique Address is set for each MVS in the multi drop configuration connect like terminals to like This means all the A terminals on the devices are electrically connected to the FloBoss A terminal and so on The wiring can be done entirely from the FloBoss with an individual cable to each Remote MVS or by wiring in parallel daisy chain though each Remote MVS Pay close attention to not reverse the power wires These connections should always be made with power removed from the FloBoss 407 Double check for proper orientation before applying power If the connections are reversed and power is applied the MVS and the FloBoss 407 processor board may be damaged B 3 1 MVS Lightning Protection To safeguard against lightning st
2. 5 10 Figure 5 7 Min Max History List Form at 5 10 Figure 5 8 Min Max History List Example 5 11 Figure 5 9 Min Max History Minimum Value Example Ce ee eee ee ee ene eee 5 11 Figure 5 10 Min Max History Maximum Value Example Ui cha E E A E pine E pena toe treater E 5 11 Figure 5 12 Minute History List Format 5 12 l 3 Figure I 1 Minute History List Example 5 12 Figure 5 14 Minute History Value Example 5 12 Figure 5 15 Hour History List Format 5 12 Figure 5 16 Hour History List Example 5 13 Figure 5 17 Hour History Value Example 5 13 Figure 5 18 Day History List Format 5 13 Figure 5 19 Day History List Example 5 13 Figure 5 20 Day History Value Example 5 14 Figure A 1 Lightning Protection Module A 1 Figure A 2 Typical Lighting Protection Module losta ation ceaanisitenceanescestastertantiiiemertavadsmancseenaats A 2 Figure B 1 MVS205 Remote Multi Variable Sensor N uate tacaneh sen euaiae eee aaneaaeeaee aaa B 2 Figure B 2 FloBoss 407 and Integral MVS Outline and Mounting Dimensions ccccceeeeeeeeeeeeeeeeeeeeeeees B 3 Figure B 3 Pipe Mounting of FloBoss 407 with Integral MV Steen epson a a canna ictherw iva datsaes B 4 Figure B 4 MVS Remote Pipe Mounting Horizontal and Vertical Pipe tacit cease ees B 5 Figure B 5 MV
3. eeeeee A 1 LV Start SWite hi esscichetetitccsicioreencstexcetarseecsis 1 11 2 19 M Memory MNO COMO IG 5 data eeuhar eee eres Gede elke estes 2 3 Memon WEA tani seinic be desen in 2 3 Metr CONTO 552408 ie dso vase eabebaveuestest saves 5 9 INN MAX ceecatecets tisha hata eect techs tase hha cdt eats 5 8 PO MMS soles iene eens ener 5 11 Min Max History Curtent Value Example acsstcacocsneas ctacoreroasetias 5 11 ECS ah 6 21a 0k Seen ne nee er oe Pe eee er een 5 10 Maximum Value Example cccccceeeees 5 11 Minimum Value Example cccccccceeeeees 5 11 MINUTE HIS Firini ate uta Ge aa ee 5 8 Minute Historical L0g ccccccccceceeeeeeeeeeeeeeeeeeeees 2 6 Mimate HIStory 3 c ce cerns thaininastoneraniteetseadeatested eenitalce 5 12 DS COTE RAMAN E se essere oa wae bas tinea A a 5 12 TiS FORMAL sssos ccacnek tun ronea tesa Eii 5 12 Vae 2 XAG ahs es este ees eens eee 5 12 Modem Dial Up Communications Cards 00000 4 7 Multi drop Communications ccccccceeeeeeeeeeees 4 12 Multi drop Configuration ccccccccccccceececeeeeeeeeeeees 4 4 Multi Variable Sensor ccccceeecceeeeccceeeceeeeeees 1 3 B 1 IO 007 1 eee eR ee eee ee ee B 5 Multi drop Configuration 0ccccccccceeeeeees B 10 MY Sia stiaha taoeeteuadtectolaneseen a S B 1 SPECI CATIONS eane B 16 Troubleshooting and Repait cccccccecseeeees B 16 WARNO 5502s ater a a a sewed B
4. 22 Press J to select APP VALUE and press ENTER E n Minimum Scale Calibration 23 Key in the minimum scale value and press ENTER to save the value 24 Press J to select SAVE and press ENTER to log the value to the Event Log and continue to the Calib Maximum Scale display EXIT returns the program to Calibration Step 5 Use the Calib Maximum Scale display to set the Span value 100 Calib Maximum Scale of range for Differential Pressure orifice only Static Pressure or Temperature This should correspond with the High Reading Timer 100 Count and is the high value to the input the top end of the expected operating range 25 Press 4 to select APP VALUE and press ENTER 26 Key in the maximum scale value and press ENTER to save the value Maximum Scale Calibration 27 Press 4 to select SAVE and press ENTER to log the value to the Event Log and continue to the CALIB MORE POINTS display EXIT returns the program to Calibration Step 4 B 14 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual 28 Press 4 to select NO and press ENTER to return to SELECT Calib More Points METER INPUT Step 4 or press J to select YES and continue iG to the CALIB MID POINT 1 2 3 display POSEE SEESE Calibrate Midpoint 1 such as 25 of range to specify the low Lou calibration point between the Zero Calib Minimum Scale and Span Calib More Powis Calib Maximum S
5. B 3 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual Solar Panel _ FloBoss 407 Nia Multi Variable Qs os pS sensor MVS J Orifice Plate f DOC0326A dxf Figure B 3 Pipe Mounting of FloBoss 407 with Integral MVS B 4 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual The Remote MVS uses a transmitter style head to house the interface electronics The interface circuit board is factory mounted inside the head which provides protection for the electronics a place for termination of the field wiring and ratings for hazardous locations The Remote MVS can be mounted to a pipe or panel Figure B 4 and Figur B 5 hwith the optional bracket kit which includes an L shaped bracket and a pipe clamp The bracket attaches to the Coplanar flange on the MVS The process pressure inputs are piped to the 4 18 NPT connections on the bottom of the MVS or to an intervening manifold valve The MVS can also be mounted directly not shown to flange taps using a manifold valve or an integral orifice assembly The MVS is an upstream device The static pressure line normally connects to the high pressure side of the sensor and the upstream values are calculated To use the MVS with a FloBoss 407 as a downstream device or in bi directional flow conditions refer to the ROC FloBoss Accessories Instruction Manual Form A4637 MVS205ac dsf Figure
6. Dimensions are 15 mm by 32 mm by 43 mm 0 6 in D by 1 265 in H by 1 69 in W not including pins ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D 3 4 Discrete Input Modules Source and Isolated Discrete Input Source Module Specifications FIELD WIRING TERMINALS A Not used B Discrete device source signal C Common INPUT Type Contact sense Range Inactive 0 to 0 5 mA Active 2 to 9 mA Source Voltage 11 to 30 V dc Source Current Determined by source voltage Vs loop resistance RI and scaling resistor Rs 10 Q supplied Vs 1 3 3K RI Rs 3 33 Input Output Modules POWER REQUIREMENTS Source Input 9 mA maximum from FloBoss power supply Module 4 9 to 5 1 V dc 1 mA maximum supplied by FloBoss INPUT ISOLATION Not isolated Terminal C tied to power supply common Rev Mar 05 FloBoss 407 Instruction Manual Discrete Input Isolated Module Specifications FIELD WIRING TERMINALS A Not used B Positive Discrete Input C Negative Discrete Input INPUT Type Two state current sense Range Inactive 0 to 0 5 mA Active 2 to 9 mA Current Determined by input voltage Vi loop resistance RI and scaling resistor Rs 10 Q supplied Vi 1
7. The Power Control function available in standard firmware only is used with a communications port to provide power savings when using a radio or cell phone for communications Three cycling zones are provided but zones can be disabled as desired Either a Discrete Output module COM1 or COM2 or the DTR signal COM2 only provides the switching mechanism The Power Control function calculates which zone should be currently active 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 2 2 11 Spontaneous Report By Exception SRBX Alarming SRBX alarming enables a communications port to be set up to enable the FloBoss to contact the host computer when specified alarm conditions exist 2 2 12 Fuses The FloBoss 407 uses the overload protection devices listed in Tabld 2 2 The overload protection devices are not field replaceable Table 2 2 Overload Protection Devices 1D Rating SS PTR1 1 25A Input power protection PTR2 0 30A Analog Input 24 V dc power T terminal 2 3 Installing the FloBoss 407 The FloBoss 407 with or without an Integral MVS can be mounted either on a wall or on a 2 inch pipestand When mounting the FloBoss 407 on a wall or panel fasten with 5 16 inch U bolts 8 mm through each of the four mounting holes Refer to Figure 2 2 for outline and mounting dimensions If the FloBoss 407 has an Integral MVS refer to the R
8. When using a transmitter with a maximum current requirement different from 20 milliamps R1 should be scaled to achieve full scale deflection at 5 volts dc The formula for determining a new value of R1 is given in Figure 3 2 where I Maximum is the upper end of the operating current range such as 0 025 amps for a 0 to 25 milliamps device R1 250 ROC POWERED CURRENT LOOP DEVICE TO SELECT PROPER VALUE OF R1 DOC0153J Vs SOURCE VOLTAGE FROM MODULE 11 TO 30 VDC 25 mA MAX _ 5 VOLTS MAXIMUM Figure 3 2 AI Loop Module Field Wiring for Current Loop Devices Figure 3 3 shows a typical voltage signal input Terminal B is the signal input and terminal C is the _ signal input These terminals accept a voltage signal in the 0 to 5 volts range Since terminal C connects to a signal ground non isolated logic ground the Analog Input must be a single ended Ensure that no scaling resistor R1 is installed when the module is used to sense a voltage signal SELF POWERED Vs VOLTAGE SIGNAL 1 TO 5 VDC DEVICE DOCO587A Figure 3 3 AI Loop Module Field Wiring for Voltage Devices 3 6 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 4 2 Analog Input Differential Module A schematic representation of the field wiring connections to the input circuit of the Analog Input Differential module is shown in Figure Figure 3 5 and Figurd 3 61 The Analog Input Differential module m
9. 20 to 0 C 4 to 32 F LINEARITY 0 03 1 LSB independent conformity to a straight line Available as an accessory 3 40 Input Output Modules POWER REQUIREMENT 11 to 30 V dc 38 mA maximum supplied by FloBoss power supply VIBRATION 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SHOCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature and Humidity WEIGHT 37 g 1 3 oz CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions are 15 mm D by 32 mm H by 43 mm W 0 60 in D by 1 265 in H by 1 69 in W not including pins APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual 3 11 HART Interface Module HART Interface Module Specifications FIELD WIRING TERMINALS A Loop Power T B Channel 1 CH1 C Channel 2 CH2 CHANNELS Two HART compatible channels which communicate via digital signals only Mode Half duplex Data Rate 1200 bps asynchronous Parity Odd Format 8 bit Modulation Phase coherent Frequency Shift Keyed FSK per Bell 202 Carrier Frequencies Mark 1200 Hz Space 2200 Hz 0 1 HART MODULES AND DEVICES SUPPORTED Up to six HART Modu
10. For use as Figure ROC POWERED CURRENT LOOP DEVICE Vs 11 TO 30 VDC T 24 VDC 250 OHM SIGNAL 4 TO 20 mA DOCO0098A Modified Figure 2 6 Current Signal on Built in Analog Input EXTERNAL SELF POWERED DEVICE Vs 11 TO 30 VDC T 24 VDC SIGNAL 1 TO 5 VDC DOCO098A Modified Figure 2 7 Voltage Signal on Built in Analog Input 2 14 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 4 4 Connecting Built in Pulse Input Wiring Equipment Required Flat blade 1 8 inch width screwdriver Changing the P4 jumper to the PI position allows the built in AI PI input channel to be used as either an isolated or a sourced Pulse Input This Pulse Input signal is optically isolated from the FloBoss 407 circuit board The Pulse Input can operate at up to 10 kilohertz with a maximum 50 Duty Cycle An LED indicator PI IND shows when the field input to the Pulse Input channel is active The AI PI channel has three field terminals Terminal T is a positive source voltage either 24 volts or a level that follows the voltage of the FloBoss 407 input power Terminal is the positive signal input Terminal is the negative signal input Remove the supplied 250 ohms resistor from the terminal block when using the AI PI channel as a Pulse Input To use the channel as an isolated input shown in Figurd 2 8 connect the
11. 5 6 Troubleshooting and Repair The processor board must be removed to replace the Keypad and Display See Section 2 Master Controller Unit I O Module Rack and Wiring for the processor board Keypad and Display removal procedures 5 15 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual APPENDIX A LIGHTNING PROTECTION MODULE This appendix describes the optional Lightning Protection Module LPM Topics covered include Section Page A 1 Product Description A 2 Initial Installation A 3 Connecting the LPM to Wiring A 4 Troubleshooting and Repair A 5 Lightning Protection Module Specifications A 1 Product Description Pianta A 1 thos a front and side view of the module The LPM is designed to prevent damage to I O modules and to built in I O circuitry from any high voltage transients that may occur in field wiring The LPMs plug into the field wiring I O termination sockets located on the termination card The LPM provides screw terminals for connecting to field wiring It has sockets for plugging in a range resistor especially when used with built in I O The module also provides a ground wire for connection to the enclosure ground bar BUILT IN FIELD WIRING TERMINATION BLOCK I O WIRING CONNECT GREEN WIRE TO ENCLOSURE GROUND BAR OR GROUND LUG FRONT VIEW SIDE VIEW DOC0138A Figure A 1 Lightning Protection Module In general it is recommended an LPM be used to protect the circuitry for eac
12. Calculate Total power consumption in Tabld 1 1 o No m p 11 Add the power consumption in mW of any other devices used with the FloBoss in the same nower system but not accounted for in the tables to the Total power consumption value in Table 1 Refer to Sectio Totaling Power Requirements on page 1 10 Table l 1 Power Consumption of the FloBoss 407 and Powered Devices Power Consumption mW D Sub Device 12 Volt 24 Volt QTY c uty Total ycle Prin Pmax Prin Pras aah Processor and I O Termination Board includes minimum built in I O power N A 800 N A 1200 1 N A pepe ek Built in Analog Input FloBoss Powered Current Loop wfe we Poe Built in Analog Input Externally Built in Pulse Input FloBoss Powered Built in Pulse Input Externally Powered SerialCommunicationsCard_ 185 f 153 NA Dialup Modem Communications Card 395 395 naf Leased Line Communications Card 110 no f Radio Modem Communications Card 10 o NA MVS Integral orRemote na 240 NA 480 NA VO Modules Total tom Tabi r2 NA o NA Radio Power Consumption __ N A NA NA TOTAL NOTE 1 For the Analog Input the Duty Cycle is the percent of time spent in the upper half of the operating range 1 8 General Information Rev Mar 05 FloBoss 407 Instruction Manual Table 1 2 Power Consumption of the I O Modules Power Consumption mW Dai Sub I O Module 12 Volt 24 Volt QTY aY
13. Memory Location 00000 to OO3FF Interrupt Vectors 00400 to OFFFF Boot Block Data 40000 to 1FFFF Event Logs Alarm Logs ROC Displays FST Data Audit Log Measurement Canada and other Flash Program Data 60000 to 6FFFF 70000 to 7FFFF User Program Data Flash Memory 80000 to 87FFF 88000 to 8FFFF 90000 to 9FFFF A0000 to AFFFF B0000 to BFFFF E0000 to EFFFF A two line Liquid Crystal Display LCD panel mounts on the display connector on the rear of the processor board This positions the display for viewing through the main door of the enclosure A membrane Keypad mounts on the main door of the enclosure to navigate within the LCD A gasketed door on the enclosure door protects the Keypad from the elements The Keypad connects to the processor board with a ribbon cable 2 3 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual The communications connectors J1 and J2 on the processor board provide the FloBoss 407 with electrical access and mounting provisions for the optional communications cards The communication card mounts directly on the connectors on the processor board and 1s held in place with a screw passing through the communications card to a standoff on the processor board The communications cards available for the FloBoss allow the options of serial data communication modem radio modem or leased line modem communications A 3 6 volts lithiu
14. RS 422 transmit mode The default setting RTS jumper on allows a multi drop configuration such as is normally possible with EIA 485 RS 485 communications The newer card design also includes Load jumper P3 that allows the termination load to remain or to be removed for EIA 485 RS 485 multi drop communications Refer to Section 4 5 2 TA 422 485 RS 422 485 Communications Card Wiring on page 4 14 for more information 4 4 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 3 1 Radio Modem Communications Card The Radio Modem Communications Card sends and receives full duplex or half duplex asynchronous Frequency Shift Keyed FSK signals to the audio circuit of a two way radio The modem incorporates a solid state push to talk PTT switch for keying the radio transmitter Refer to Figure 4 3 LED indicators_on the card show the status of the RXD TXD DTR DCD CTS and RTS control lines Refer to Tabld 4 1 Communications Cards LED Indicators on page 4 3 Jumper P6 determines whether the PTT signal is isolated or grounded Use connector P7 signals for monitoring or connecting to an analyzer Refer to Section 4 4 2 Setting Modem Card Jumpers on page 4 11 The output attenuation can be reduced to better match the modem output to the line or radio Plugging a resistor into the card at R2 makes the adjustment Refer to Sectio Setting Modem Card Attenuation Levels on page 4 12 Refer to Section 4 5 3 Radi
15. Radio Modem Communications Cards 4 5 4 9 Attenuation Levels eeeecc eens 4 5 4 10 4 13 WINDE head Ged eg ecole acne te eet 4 13 Radio Power Control sigs oacetestie seas udsedeuieteeiandeuees 2 8 Radio Power Requirement ccccccceeeeeeeeeeeeees 1 9 RAM Backup Proced ites sninen 2 18 Verifying RAMs icc scocem cette A vaetecutes oll 2 20 RAM Module Memory Allocation ccccccccsessseseeseeeeesserens 2 3 Reak Pinte C lokoensis 2 4 Se 0 1 Se tee e A 2 17 3 21 Replacing Communications Cards ccccccccccccccceeceeeeeeeeees 4 18 TRO arnt cn ccieinene toa R E da OnaeaR ear OR eRe nee 2 21 Warni otar Teese a TE 2 19 Reset WAU Maa a E 2 4 Resistance Temperature Detector RTD Input 3 4 bid EE EAE EEE E E ret rr terre 4 3 RUO ee e eet as estes eee rasta teales 2 5 4 7 4 14 4 16 TS A IOPU cance 3s aac ts futeathannedocauacataeen ease euatas 2 6 3 4 CAND LAU OM eeren o a rn 3 17 Trouples hooo csie A 3 27 WITIDO ei a RT 3 17 3 19 B 10 RES aS S 4 3 4 4 4 12 RX Docea E t 4 3 S Save Write to EEPROM or Flash Memory Save COMMCUTATION ca scceaadenadtstemaocessniontieaeneee 2 18 2 19 Scrolling with the Keypad cccccccccsscsssceceeeeeeeeees 5 3 Security KO y Pad sentient ee ielent See a es 5 14 Serial Port COM onean syns ast ed eateaiaacestevansan 2 5 CON DA ern errr the reer ts Rae marta Tiree ener 2 5 Operator InterlaGe sce encasement ees 2 5 PSPC 1 a
16. The RTD input module monitors the temperature signal from a Resistance Temperature Detector RTD sensor or probe The RTD module is isolated reducing the possibility of lightning damage A Lightning Protection Module LPM will not protect the RTD but it helps protect the rack in which the module is installed The RTD module must to be calibrated while disconnected from the RTD probe therefore it may be more convenient to perform calibration before connecting the field wiring However if the field wiring between the FloBoss and the RTD probe is long enough to add a significant resistance then calibration should be performed in a manner that takes this into account For a three or four wire RTD with the wires used to connect up each leg are of the same length and size the error generated will be zero or at least no different for any given length This is because the RTD input uses the resistance of the wire loop s not passing through the RTD to correct for the wire resistance of the loop with the RTD 3 4 15 1 Calibrating the RTD Module The following instructions describe how to calibrate an RTD input channel for use with an RTD probe having an alpha value of either 0 00385 or 0 00392 ohms degree C This procedure requires a resistance decade box with 0 01 ohm steps and an accuracy of 1 You also need a personal computer running ROCLINK configuration software NOTE In ROCLINK configuration software use the Calibrate button associate
17. Type of message protocol used by the FloBoss to communicate with the configuration software as well as host computers with ROC driver software P Q Parameter A property of a point that typically can be configured or set 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 PID Proportional Integral and Derivative feedback control PIT Periodic Timer Interrupt G 4 Glossary Rev Mar 05 FloBoss 407 Instruction Manual 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 Point Type The point type attribute defines the database point to be one of the possible types of points available to the system The point type determines the basic functions of a point PRI Primary PID control loop Protocol A set of standards that enables communication or file transfers between two computers PSTN Public switched telephone network PT Process Temperature PTT Push to talk signal Pulse Transient variation of a signal whose value is normally constant PV Process variable or process value R Rack Slo
18. data rates of 600 1200 2400 4800 or 9600 bps The card interfaces to a PSTN through an RJ11 jack The modem can be controlled using industry standard AT command software A 40 character command line is provided for the AT command set which is compatible with EIA document TR302 2 88 08006 The modem automatically hangs up after a configured period of communications inactivity Automated dial up alarm reporting capabilities are possible Refer to Spontaneous Report by Exception SRBX LED indicators_on the card show the status of the RXD TXD DTR DSR RI and OH control lines Refer to Figurd 4 5 hnd Table 4 1 The modem card also provides EIA 232 RS 232 level output signals for an analyzer When activated as described in Section 4 5 5 Dial Up Modem Communications Card Wiring on page 4 19 these signals are available at the COMM port connector on the front panel Refer to Section 4 5 5 Dial Up Modem Communications Card Wiring on page 4 19 J E CR1 C3 PTR2 Pe 000000000 0000000000 1000 O LED Indicators A x lt 4 A x lt H Y A g 7 A 4 I oO so ea je Dooooooo 0000008 Doo oBeE0000000L8 R3 oeo e_o DIAL UP ses COM PORTS 29 el_le DOC0389A Figure 4 5 Dial up Modem Communications Card 4 7 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 4 Initial Installation and Setup The following procedure assumes the first time installation of a communications card in
19. tighten the clip screw if you loosened it in Step 2 4 Ifthe old battery was too weak to power the clock Status LED blinking you need to reset the clock and reload the configuration Refer to Sectio h 2 5 3 After Installing Components on page 2 22 2 5 9 Performing a Cold Start To perform a Cold Start 1 Connect to ROCLINK configuration software 2 Perform the RAM Backup Procedure previously described in Section 2 5 2 RAM Backup Procedure Before Removing Power on page 2 21 if possible Select ROC gt Flags Select the Cold Start checkbox Click the Cold Start Options button 2 un e p Select the appropriate option and click OK 2 5 10 Performing a Reset When you have tried the previous methods for convincing your FloBoss to cooperate and all other troubleshooting procedures have failed perform a Reset before returning your FloBoss to the factory A Reset reloads all configuration data from Electrically Erasable Program Read Only Memory EEPROM clears all history clears the Event Log clears the Alarm Log and clears all ROC Displays disables all user program tasks and disables all user data types The Reset switch permits a restart from the boot block of the flash memory Cold Start rather than from RAM Warm Start 2 21 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual The following list shows the values that are saved to memory and re
20. y1 4 Legs BS 3 G a a G as a a Ee en en a cs ps a ad OO AAAANAAANNNOH oO 2 e4 if 6e POD TN a QO Zol Fa g 3 0 0 e sle oee P7 Connector 20 O 0 66 oggogggggy eo TN O CA w onla an Mee O V A Wy d POR Ul o D 5 25 y D a OU Figure 4 3 Radio Modem Communications Card 4 5 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 3 2 Leased Line Modem Communications Card The Leased Line Modem Communications Card is a 202T modem that is FCC part 68 tested for use with leased line or private line telephone lines Refer to Figure 4 4 Two or four wire half or full duplex asynchronous operation is supported at a software selectable 300 600 and 1200 baud to Bell and CCITT standards LED indicators on the card show the status of the RXD TXD DTR DCD CTS and RTS control lines Refer to Table 4 1 Communications Cards LED Indicators on page 4 3 The Leased Line Modem Communications Card has three jumpers P3 P4 and P5 that permit either two wire or four wire operation Use connector P7 signals for monitoring or connecting to an analyzer Refer to Section 4 4 2 Setting Modem Card Jumpers on page 4 11 for more information The output attenuation can be reduced to better match the modem output to the line or radio Plugging a resistor into the card at R2 makes the adjustment Refer to Sectio Setting Modem Card Attenuation Levels on page 4 12 Refer to Section 4 5 4 Leased Line Commu
21. 1 GENERAL INFORMATION 1 1 Scope of Manual This manual describes the FloBoss 407 Flow Manager and includes all versions of FloBoss units including the standard version and the Industry Measurement Canada custody transfer version For software aspects such as configuration refer to the respective software configuration user manual NOTE Certain hardware versions and functionality may require higher revisions of ROCLINK configuration software Verify the version of configuration software Section 1 2 Manual Contents 1 2 General Information 1 3 Product Overview 1 4 Installation Guidelines 1 5 Power Supply Requirements 1 6 Startup and Operation 1 2 Manual Contents This section contains the following information Section 2 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting provides information and specifications concerning the two main components of the FloBoss 407 the processor board and the termination board wiring built in inputs main power wiring and troubleshooting Section 3 Input Output Modules provides information and specifications for the optional I O modules Section 4 Communications Cards provides information and specifications for the communications card options Section 5 Display and Keypad describes the operation of the Keypad display and specifications Appendix A Lightning Protection Module describes the optional LPM and specifications Appendix B Mu
22. 1 FloBoss 407 Keypad Functions Parameter Ete History punctons iti Keypad eenue Logs out current user or displays password prompt Logs out current user or shuts the display off The DOWN ARROW key displays the next parameter in the list or changes the display to the next point The UP ARROW key displays the previous parameter in the list or changes the display to the previous point The ALT key activates the key functions labeled below each key For example pressing ALT and the 7 key would activate the I O DETAIL function which would display the entire set of parameters for the selected I O point ALT and ENTER activates the DISPLAY OFF function and turns off the LCD Press any key to reactivate the LCD The EDIT key activates the functions labeled in red on each key This includes the numeric digits the the and the backspace lt key The backspace key is an edit only function Those parameters that allow editing can be changed if the edit mode is selected The CANCEL key stops the edit mode and resumes list display 5 3 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual 5 3 Keypad Functions Table 5 2 defines the function associated with each of the Keypad labels fd 5 3 1 Normal Mode MARY The Keypad functions shown in the Normal Mode column of Table 5 2 operate when the key such as I O Summary is independently pressed Refer to aee i lO DETAIL 9 3 2 Edit Mode The functionalit
23. 232 RS 232D format for general use Software configured 300 to 9600 bps rate selectable Eight terminal connector provided on I O board COM2 Serial or modem interface with optional communications card Nine terminal connector provided on I O board POWER Input 11 to 30 V dc 0 8 W typical excluding power for input sourcing I O modules MVS and communi cations card Loop Source Normally 23 V dc minimum provided for transmitter power at the T terminals 25 mA maximum and at the A terminals on the modular I O channels 2 27 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting a 9 Terminals T loop power positive input negative input Common Voltage 0 to 5 V dc software configurable 4 to 20 mA with a 250 ohm resistor installed across terminals and Accuracy 0 1 over operating temperature range Impedance One megohm Filter Double pole low pass Resolution 12 bits Conversion Time 30 microseconds PULSE INPUT BUILT IN Quantity Type 1 high speed source or isolated pulse counter input when PI jumper is set Terminals T source power positive input negative input common Voltage 8 to 30 V dc ON state 0 to 4 V dc OFF state Frequency 10 kHz maximum Sample Period 50 ms minimum MVS INTERFACE Type High speed multi drop serial interface with power for as many as 4 MVS units locate
24. 3 19 For optimum efficiency R1 should be scaled for a loop current I of 3 milliamps R1 10 x SELF POWERED DISCRETE DEVICE TO OPTIMIZE SCALING RESISTOR R1 Vo lt 1 R1 R R1 Rw 3 3K LOOP RESISTANCE 4 5K OHMS LOOP CURRENT 3 mA Ry RESISTANCE OF FIELD V o VOLTAGE FROM DISCRETE DEVICE 11 TO 30 VDC DOC0152A Figure 3 19 Slow Pulse Input Isolated Module Field Wiring 3 16 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 4 14 Low Level Pulse Input Module A schematic representation of the field wiring connections to the input circuit of the Low Level Pulse Input module is shown in Figure 3 20 The field wiring connects through a separate terminal block that plugs in next to the module allowing replacement of the module without disconnecting field wiring NOTE The Low Level Pulse Input module is designed to operate only with pulse generating devices having their own power source The module does not work with non powered devices The Low Level Pulse Input module operates when a field device provides a pulsed voltage between 30 millivolts and 3 volts peak to peak across terminals B and C of the module The pulsed voltage is counted and accumulated by the module which provides the accumulated count to the FloBoss electronics on request PI LL SELF POWERED PULSE DEVICE DOC0150A Figure 3 20 Low Level Pulse Input Module Field Wiring Schematic 3 4 15 RTD Input Module
25. 6 N IN A ES E PPE E E E PR I ET N T A E SE 4 13 National Electrical Code NEC cruime 1 5 Nex SC beaa a tate 5 8 5 11 Normal WE OCC estasia a E 5 4 O OP eare E TA 4 3 On board Diagnostic Inputs cesses 2 6 Operator Interface Port acteer a 2 16 iee MI CUC TG sinc cnccstenaratantassantesnooussteawbaereolettatenns 2 6 OV er Current DEVICE rinrin 2 5 P Q PS UTNE reen 4 4 4 6 4 9 4 12 4 13 P4 UMPC eea 2 6 2 15 4 4 4 6 4 9 4 12 SUID Tronen A 4 6 4 9 l 5 Index POJOMPE irea oeasieeeelienaanes 4 5 4 9 4 13 P CONNEC Ol sai e eee 4 5 4 6 4 13 PAJU e 4 15 PESIO oa etc err wen serrate tier errr r ere 2 4 Padlock Adapter B Yers es i 0 4 C0 amare ate te ne ene oer ee ee erre reeetee eee 1 4 Metallion ea N ere ne ete Sora 2 9 Parameters Dp oaa 5 8 PASS Worde du iedchdasiuan Denedeabstoen 5 15 Performing a Cold Start eeeeeeeeeeeeeeeeeeeeees 2 21 Perroning a RESE rinore a S 2 21 PU IND sera a a deceteen Githe teas 2 6 2 15 g DB Oss 11 10 lacron r renee ene one Sere rete 2 7 PAINE EE E E EE ET E AEE T A 4 17 PI aa a a 4 17 Pins W EAE A AAT 2 4 POTTED YI CS seg Sas ER 5 8 Points Con euria a 3 28 Point to P int scssi aa 4 12 POr a A DS 2 4 Pont Numbers A oa S 2 23 Potentiometer to Analog Inputs c cesses C 4 Power Backup Tor RAM cored cvs adnsesthotwncesbecodeiicesamohedeaes 2 4 CONSP Oeris aa a 1 7 CONIMON sac tet nn gies ire ate ohne ila alee 2 8 VO REJUrEMEN Serana naa aa 1 7
26. A Calculations Pe ET EE T AE E E saa E E E 2 23 E EN E E E E 2 6 ATA nn keestststtststssessssestssnnnnsnsnnnnnnnsntntns 2 5 1 OOD TV EE eect ak 7 6 AGAT Flow Calculations ceseceeeeeeeeeeien 2 6 PT pata accusam thence eta takes ten wae 2 6 API Channel sesseeseeeteeeeeeteeeeeeeeineneeeeseesn 2 0 EL E i E E T E A A E E T 5 8 Alarm Log sssseeesiseesrssertrtreesseerrrtreeesseserrrreeeeressrrrerens 2 7 CS AMIDE AI i eae cet asada a a B 11 Alarms ccscereones seteneenneeeneceneeneeenneceneenaees 5 8 5 10 VO Module oooooocoooooooooooocooooocooooo a5 Alarm Summary Display 0 cess 5 10 UUDE CT i CA 3 17 ALT ROY escessecsececeeeeeeseeseeseeseeseeseeseeseeees 5 2 5 3 5 4 Cine lE aranira aietsdep 5 3 5 4 PAU IVIO NS urira e a a teteagatts 5 4 Cathodic Protection o ooo ooooooooeoooocececee ERS Analog Inputs CONT Sandie ates Reel atte sscaceahat eats 4 6 DIA NOSUC 0 eee eetes teeters teeseeneseeneeteneseenes 2 6 CTs A EEEE SEE AN aioe arte eee 1 5 Differential ese eeeenieeneen 3 2 TS ANNE OIE EEN A AO EA 2 20 Differential Wiring s ssssseessseessserssrerssrerssnerssrerssnes 3 7 ReaL Tine ee 2 4 Field sssssseessesssserertteeessesrrrtteesseerrrrreeesseerrrrreenreenren 2 0 CO an nery cena err ere ay oe 1 4 Loop E 3 2 Cold Start Loop Wiring seeeeeeeens eile ie eae i i 3 6 Portor miN aio a E E 2 21 On board Diagnostic cccccscsessesteseeesteseeseaees 2 6 COM PORTS Arrow ecsscscssesses
27. B 4 MVS Remote Pipe Mounting Horizontal and Vertical Pipe B 5 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual 6 15 156 N No O lt MVS205aa dsf Figure B 5 MVS Remote Panel Mounting B 3 MVS Field Wiring For an Integral MVS the FloBoss 407 and the Multi Variable Sensor are shipped from the factory with the wiring connected as shown in Figure B 6 The factory wiring uses yellow blue red and black wires from left to right in the MVS terminal block In FloBoss 407 installations with one or more Remote MVS units the signal wiring between the FloBoss 407 and the Remote MVS is connected as follows Use Sealtite or a similar product to provide a conduit path from the Remote MVS to the FloBoss 407 An armored cable requires no conduit to be used in a Class I Division 2 hazardous non incendiary area In a Class I Division 1 area unarmored cable may be used if installed in conduit and have seals per hazardous installation practices All installation wiring must follow code to meet the respective Class and Division ratings To configure a multi drop MVS setup connect each MVS to the FloBoss unit one at a time Make sure that each MVS 1s functioning correctly before installing the next MVS B 6 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual MVS Terminal Block ISA O Figure B 6 Signal Hook Up for a Integral MVS Installation CAUTION Befo
28. B and C that is derived from internal voltage source Vs When a field device such as a set of relay contacts is connected across terminals B and C the closing of the contacts completes a circuit which causes a flow of current between V and ground at terminal C This current flow is sensed by the SPI module which signals the FloBoss electronics that the relay contacts have closed When the contacts open current flow is interrupted and the SPI module signals the FloBoss electronics that the relay contacts have opened The FloBoss counts the number of times the contacts switch from open to closed and stores the count The FloBoss checks for the input transition every 50 milliseconds A 10 ohms scaling resistor R1 1s supplied and accommodates a source voltage V of 11 to 30 volts dc The source voltage is either the input voltage to the FloBoss However it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage The formula for determining the value of R1 is given in Figure For optimum efficiency R1 should be scaled for a loop current 1 of 3 milliamps 3 15 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual x R1 10 SPI SRC ROC POWERED DISCRETE DEVICE TO OPTIMIZE SCALING RESISTOR R1 A DOC0151 R1 E a E 3K Modified R1 Rw 3 3K LOOP RESISTANCE 4 5K OHMS LOOP CURRENT 3 mA Rw RESISTANCE O
29. C 40 to 149 F Settling Time 100 us maximum Reset Action Output returns to zero percent output or last value software configurable on power up Warm Start or on watchdog timeout Rev Mar 05 FloBoss 407 Instruction Manual Analog Output Source Specifications Continued CURRENT OUTPUT Type Current loop Range 4 to 20 mA with 0 to 22 mA overranging adjusted by scaling resistor A 0 Q resistor is supplied Loop Source 11 to 30 V dc as supplied by FloBoss for T power typically 24 V dc Loop Resistance at 12 V dc 0 Q minimum 250 Q maximum Loop Resistance at 24 V dc 200 Q minimum 750 Q maximum Resolution 12 bits Accuracy 0 1 of full scale output at 20 to 30 C 68 to 86 F 0 5 of full scale at 40 to 65 C 40 to 149 F Settling Time 100 us maximum Reset Action Output returns to zero percent output or last value software configurable on power up Warm Start or on watchdog timeout POWER REQUIREMENTS Module Alone 24 mW typical Module w Current Loop 400 mW 4 mA output to 590 mW 20 mA output OUTPUT ISOLATION Not isolated Terminal C tied to power supply common VIBRATION 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SHOCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F WEIGHT 37 g 1 3 oz typical CASE Solvent resistant thermoplastic polyester meets UL94V 0
30. Card has three jumpers P3 P4 and P5 that permit either two wire or four wire operation Use connector P7 signals for monitoring or connecting to an analyzer Refer to Section 4 4 2 Setting Modem Card Jumpers on page 4 11 for more information The output attenuation can be reduced to better match the modem output to the line or radio Plugging a resistor into the card at R2 makes the adjustment Refer to Section 4 4 3 Setting Modem Card Attenuation Levels on page 4 12 Figura 4 11 shows the wiring connections to the card NOTE Ifyou are installing a Dial up or Leased Line Modem Card it is recommended that you install a telephone style surge protector between the RJ11 jack and the outside line LEASED LINE MODEM CARD RJ11 LEASED LINE BLK p a ET 4 4 TIP1 ARRANGEMENT z RING2 COM2 PRIVATE TERMINAL BLOCK LINE 1 TIP2 g 7 gee a TTL RS232 a INTERFACE m ig Rer s RING1 SHUTDOWN 3 24 TF 2 TIP 9 DOC0215B Figure 4 11 Leased Line Modem Wiring Schematic The 9 terminal COM2 terminal block mounted on the termination card can also be used to connect the modem to a private line This connector is not FCC approved and cannot be used for leased line operation The terminal functions are COM2 Operating Mode Terminal The following signals used for monitoring or connecting to an analyzer are available at connector P7 located at the bottom edge of the card These signals are normally not active To act
31. MODE ALT MODE CONTROL Displays the following for a selected Displays digit 4 on MIN MAX PID loop LCD for data entry Displays Min Max history Control Type 8 bits Switch Status Actual Scan Time Pri Setpoint Pri Process Variable Pri Output EU Pri Proportional Gain Pri Integral Gain Pri Derivative Gain Pri Loop Period Pri Setpoint EU Min Pri Integral Deadband Pri Scale Factor ALARMS Alarm Log Displays digit 5 on CALIBRATE LCD for data entry Calibration procedure for the MVS HELP A key selection followed by Help Displays digit 6 on FST returns a description of the LCD for data entry FST execution status and functionality of the key that was register values display for selected the four FSTs HOLD The LCD shows and updates the Displays minus NEXT SET DISPLAY current display until the HOLD sign on LCD for Displays the next set of DISPLAY key is pressed again data entry parameters if applicable L Displays the next parameter in the CANCEL CANCEL list or changes the display to the next Stops Edit Mode and Cancels the operation in point resumes list display progress USER Displays parameters in user defined Displays digit 1 on MINUTE HIST LIST 1 list number 1 LCD for data entry Displays Minute History Log USER Displays parameters in user defined Displays digit 2 on HOUR HIST LIST 2 list number 2 LCD for data entry Displays Hour History Log USER Displays parameters in u
32. Module Field Wiring for Four Wire RTD With Compensation Loop 00 3 20 Figure 3 25 Field Wiring for Four Wire Single Element TRAD AE E E E E AE E E E T nae 3 20 Figure 4 1 EIA 232 RS 232 Serial Communications Card NEWT annir a sien 4 2 Figure 4 2 EIA 422 485 RS 422 485 Serial Communications Card Newet cccseeeseeeeeeeees 4 4 Figure 4 3 Radio Modem Communications Card 4 5 Figure 4 4 Leased Line Modem Communications Card se sialic EE A ch EE encuentra toned laste ag ae 4 6 Figure 4 5 Dial up Modem Communications Card Sel Soft el Bt as Stas cise Sasa isthe E E TT 4 7 Figure 4 6 Communications Card Location 4 9 Figure 4 7 EIA 232 RS 232 Wiring Schematic P EE TE EO E E OE E I ET T 4 12 Figure 4 8 EIA 422 RS 422 Wiring Schematic E T N ncee ted Sone cet oanee 4 12 Figure 4 9 EIA 485 RS 485 Wiring Schematic A E dso temachiatn aoa temenseeaca ERT 4 13 Figure 5 1 FloBoss 407 Display and Keypad 5 1 Figure 4 10 Radio Modem Wiring Schematic 4 14 Figure 4 11 Leased Line Modem Wiring Schematic PEE EE ee ene re 4 15 Figure 4 12 Dial Up Modem Wiring Schematic 4 17 Figure 5 2 Keypad Layout cccccccccceeeeeeeeeees 5 2 Figure 5 3 Operations Key ccccccceeeeeeeeeeeeees 5 4 Figure 5 4 General Display Format 06 5 8 Figure 5 5 User List Display 00000000000000000000000 5 10 Figure 5 6 Alarm Summary Display
33. Raw A D Input value changed and reflects the Adjusted A D 0 value 4 Change the resistance to reflect a high temperature as determined by the temperature to resistance conversion chart 5 Verify that the Raw A D Input value changed and reflects the Adjusted A D 100 value 3 5 13 HART Interface Module The HART Interface Module provides the source for the HART devices and uses two test procedures to verify correct operation Verify HART Integrity of Loop Power on page 3 30 Verify HART Communications on page 3 30 3 5 13 1 Verify HART Integrity of Loop Power Equipment Required Multimeter 1 Measure voltage between terminals A and B to verify channel 1 2 Measure voltage between terminals A and C to verify channel 2 3 The voltage read in both measurements should reflect the value of T less the voltage drop of the HART devices Zero voltage indicates an open circuit in the I O wiring a defective HART device or a defective module 3 27 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 5 13 2 Verify HART Communications Equipment Required Dual trace Oscilloscope In this test the HART module and the FloBoss act as the host and transmit a polling request to each HART device When polled the HART device responds Use the oscilloscope to observe the activity on the two HART communication channels There is normally one second from the start of one request to the start of the next request 1 Attach
34. Total Cycle Pmin Pmax Pmin Pmax ii wio O o mo o s S C Diferenta O e e ee o oo CiO ee R E E PAO Sours w e e e e iim e e ee S 58 F Pmax iS at 100 C hem Dises O O oo a o aa o a o a a C E E E T E T S A Pisar o o o a a E E A Pt to E A CsPiSowce o s a o a Towtee P o es o es o booa oo s aa a DO Source Paaisats7ma 30 es 30 15 DoReay t2vos s os na NA DO Relay 24 vots wa na 2 so o o CHART Interface Modue e5 ees es ies COo O O O MODULES TOTAL __ Notes 1 For analog I O channels the Duty Cycle is the percent of time spent in the upper half of the operating range A m mMM l l l na 2 The Pmax amount includes any power drawn by a FloBoss powered field device such as a transmitter 1 5 2 Determining Radio Power Consumption In determining power requirements for radios 1 Estimate the Duty Cycle for the radio 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 sec 60 sec 0 0167 2 Calculate the total power consumed by a radio obtain the power P consumption values for transmit and receive from the radio manufacturer s literature then use the following equation to calculate the po
35. ail a E A A E E ete ee ee eee Removal Addition and Replacement Procedures ccccecseseeeeccceeceeeeeceeeeaeesssseeeeeeeeeeeeeeeees KVO Moduak ope AON a E EEE EEE EEE Product Descrip HONS sareresisise ieni oe EEE EER AR ATE AEE EAE Ens EIA 422 485 RS 422 485 Serial Communications Card indl Installation and SEUD eeste e E E SEa Connecting Communication Cards to WIiring eeeeeererrrrerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrren Rey bilo Kore DOO AER PA ene EE E EA E E ee E E Commu uncanons Card SOECINICAIIONS Sessi gnan O a GEE Table of Contents Rev Mar 05 FloBoss 407 Instruction Manual Section 5 Display and Keypad eeecssscceccsscceccssscescssseecsssceccssscecsssscessssseessssseessssseeo 5 1 a 5 3 5 4 5 5 5 6 Appendix A Lightning Protection Module ooossseseeceecoocssssssseccocossssssscessoosssseses A I A 2 A 3 A 4 A S Appendix B Multi Variable Sensors sssssecccooossssssecccoooossssecesoooossssseeceesosossssesesesoo B 1 B 2 B 3 B 4 B 5 B 6 B 7 Appendix CO Simula NO aie cesses cre ctins ses cnccausevanecsiecesen cess cacewersesssvestasuecesetaceeessceess C 1 C2 C 3 C 4 C 5 C 6 C 7 CG TOSS DEY sees ccs ct esa se eees EE EEEE E E DACS sdacccacnecncececsacsuacsnevonsesseusscncesensatsaesaceusassescavaceussnacwoveessa cass suey ons onsesssus becavavsescsveseseres i 10 o AE E E E E E E E E A E Produc De PUO e
36. and field wires to terminals and on the FloBoss 407 Pulse Input channel When the field device sends a voltage through terminal on activation the PI indicator LED on the termination board lights to show an active circuit and the signal triggers the optical circuitry to signal the FloBoss 407 EXTERNALLY OR SELF 4 POWERED PULSE DEVICE DOC0209A Figure 2 8 Externally Powered Built in Pulse Input For use as a sourced input shown in Figure 2 9 connect the field device positive wire to terminal T and the field negative lead to terminal When the field device conducts the source power flows through the LED to show an active circuit and triggers the optical circuitry to signal the FloBoss Al Pl PULSE DEVICE rs DOC0210A Figure 2 9 FloBoss Powered Built in Pulse Input 2 15 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 4 5 Connecting Communications Wiring Equipment Required None The FloBoss 407 has the flexibility to communicate to external devices using several different formats and protocols A special 3 pin connector provides a port for an operator interface device Terminal blocks located on the termination board provide connections to the COM1 and COM2 ports Figure 2 10 bhows the COM1 COM2 and Operator Interface Local Port LOI locations The Operator Interface Local Port LO
37. and the termination board mounted in the main enclosure Built into the termination board are two Analog Input AI channels Moving jumper P4 on the termination board changes one of the built in Analog Inputs to a Pulse Input PI The Pulse Input can be wired either as a FloBoss powered or a device powered medium speed pulse counter The pulse circuitry is optically coupled to isolate the termination board from the input signal In addition the termination board has slots for four plug in input output I O modules modular I O The plug in I O modules allow any combination of Discrete Inputs Discrete Outputs Analog Inputs Analog Outputs or Pulse Inputs that an application requires NOTE I O modules must not be used as flow inputs for Industry Canada approved FloBoss units The built in Liquid Crystal Display LCD and membrane Keypad provide the ability to view data and configuration parameters while on site The Keypad also permits limited editing of parameter values The FloBoss 407 can have up to four Multi Variable Sensor MVS devices connected to it one of which can be an Integral MVS The MVS provides the differential pressure static pressure and temperature inputs required for performing orifice flow calculations The Integral MVS is factory mounted to the bottom of the enclosure with a coupler and further secured with a stiffening plate For detailed information on the MVS refer to Appendix B and the ROC FloBoss Ac
38. 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 NOTE Measurement Canada approved units normally require a sealed installation Refer to your local codes for specifics 1 5 General Information Rev Mar 05 FloBoss 407 Instruction Manual 1 4 4 Power Installation Requirements Typical sources of primary power for FloBoss 407 installations are line 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 Solar power allows installation of the FloBoss 407 in locations where line power 1s not available The two important elements in a solar installation are solar panels and batteries Each must be properly sized for the application and geographic location to ensure continuous reliable operation Information contained in the ROC FloBoss Accessories Instruction Manual Form A4637 can help you determine the solar panel and battery requirements to fit your installation As a site may have additional power requirements for radios repeaters and other monitoring devices the Flow Computer Division of Emerson Process Management offers power
39. by lifting straight up It may be necessary to rock the module gently while lifting If installing the module insert the module pins into the module socket Press the module firmly in place Tighten the module retaining screw Refer to Sectio Impact on I O Point Configuration on page 3 30 4 After the module is removed installed reconnect the input power oO 29 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 5 Check the configuration data FloBoss Displays and FSTs and load or modify them as required Load and start any user programs as needed 6 If you changed the configuration save the current configuration data to memory by selecting FloBoss gt Flags gt Write to EEPROM or Flash Memory Save Configuration as instructed in the applicable ROCLINK configuration software user manual 7 Ifyou changed the configuration 1 ding the history database FSTs and FloBoss Displays save them to disk Refer to Section 2 Troubleshooting and Repair for more information on performing saves 3 7 I O Module Specifications The specifications for the various I O modules are given in this section 3 1 Analog Input Modules Loop and Differential Analog Input Loop Module Specifications FIELD WIRING TERMINALS INPUT CONTINUED A Loop Power T Impedance Greater than 400 kQ without scaling B Analog Input resistor C Common Normal Mode Rejection 50 dB 60 Hz INPUT POWER REQUIREMENTS Type
40. card the T voltage can be software switched This feature allows the T supply to be turned on or off for field devices not requiring continuous T power To control the T voltage use the Aux Out 1 or Transmitter flag in ROCLINK configuration software The FloBoss 407 termination board provides a B voltage for the plug in field I O modules that require it For example the Discrete Output DO Relay modules can have either a 12 volts or a 24 volts coil The B voltage is the same as the input voltage applied to the FloBoss 407 and the I O module used must match the power supply input One over current device and a soldered fuse on the termination board provide input power protection The over current device protects the fuse Another over current device on the termination board protects the T outputs The FloBoss 407 termination board has four I O module connectors slots to accommodate a variety of I O modules The four plug in I O modules allow any combination of Discrete Inputs DIs Discrete Outputs DOs Analog Inputs AIs Analog Outputs AOs or Pulse Inputs PIs that an application requires I O modules should not be used for flow inputs on a Measurement Canada FloBoss When installed optional surge protection devices Lightning Protection Modules protect the built in and modular input channels from voltage transients These devices replace the field wiring terminal blocks providing terminations for connecting the I O wiring to
41. connected elements Input or output that 1s 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 E ESD Electronic Static Discharge EEPROM Electrically Erasable Programmable Read Only Memory a form of permanent memory EFM Electronic Flow Metering or Measurement EIA 232 RS 232 Serial Communications Protocol using three or more signal lines intended for short distances EIA 422 RS 422 Serial Communications Protocol using four signal lines EIA 485 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 EMF Electro motive force EMI Electro magnetic interference ESD Electro static discharge EU Engineering Units Units of measure such as MCF DAY gt FCC Federal Communications Commission Firmware Internal software that is factory loaded into a form of ROM In the FloBoss the firmware supplies the software used for gathering input data converting raw input data calculated values storing values and providing control signals Flash ROM A type of read on
42. excessive resistance or a break in the field wiring 3 23 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 5 3 Discrete Input Source Module Equipment Required Jumper wire 1 Place a jumper across terminals B and C 2 The LED on the module should light and the Status as read by ROCLINK configuration software should change to On 3 With no jumper on terminals B and C the LED should not be lit and the Status should be Off 4 Ifthe unit fails to operate make sure a correct value for the module resistor is being used 3 5 4 Discrete Input Isolated Module Equipment Required Voltage generator capable of generating 11 to 30 volts dc Personal Computer running ROCLINK configuration software 1 Supply an input voltage across terminals B and C 2 The LED on the module should light and the Status as read by ROCLINK configuration software should change to On 3 With no input on terminals B and C the LED should not be lit and the Status should be Off 4 Ifthe unit fails to operate make sure a correct value for the module resistor is being used 3 5 5 Discrete Output Source Module Equipment Required Multimeter Personal Computer running ROCLINK configuration software 1 Place the Discrete Output in manual mode Scanning Disabled using ROCLINK configuration software 2 With the output Status set to Off less than 0 5 volts dc should be measured across pins B and pin C 3 With th
43. for the board temperature point which can be selected with the ENTER key MIN MAX History Avg Brd Temp Filtered 5 10 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual Figure 5 8 Min Max History List Example Figurd 5 9 F igurel 5 10 and Figure 5 12 khow the minimum Min reading maximum Max reading and the current Cur reading displays for a selected point The time in the current contract day that the minimum and maximum events occurred is shown as hour minute Filtered 5 8 4 0 09 5 7 Filtered 442 0 16 5 4 Figure 5 10 Min Max History Maximum Value Example Brd Temp Filtered C UR 98 4420 Figure 5 11 Min Max History Current Value Example To review values of other configured MIN MAX points press ALT and NEXT SET The values for the next configured Min Max point display To return to the Min Max history list press ALT and then MIN MAX NEXT SET 5 4 9 Minute History Figure 5 12 shows the general format for the Minute History List display MINUTE History TYPE I O TAG PARAMETER Figure 5 12 Minute History List Format 5 11 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual The minute history configured points list scrolls when the ALT key and MINUTE HIST USER key is pressed Figure 5 13 shows a list display for the PID 1 point which can be LISTI selected from the scrolling list by pressing the ENTER key 1 MINUTE HIST Figure 5 13 Minute Histo
44. in such areas Procedures involving switching power on or off or procedures for installing or removing any wiring or components must be performed only when the area is known to be non hazardous Performance of these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working with the FloBoss use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap During this procedure all power will be removed from the FloBoss and devices powered by the FloBoss Ensure that all connected input devices output devices and processes will remain in a safe state when power is removed from the FloBoss and also when power is restored to the FloBoss NOTE For a Measurement Canada FloBoss 407 resealing of the case must be performed by authorized personnel only 1 Perform the RAM backup procedure Refer to Sectio 2 5 2 F AM Backup Procedure Before Removing Power on page 2 21 Disconnect the PWR input connector terminal block from the termination board Disconnect all connected field wiring including MVS built in inputs and I O modules This can be done by unplugging the terminal blocks Disconnect all communication card and RJ11 wiring if necessary Disconnect the ribbon cable at P3 on the termination board Disconnect operator interface Local Port wiring on the termination board at P2 Disconnect the processor board power connector from the termi
45. is a specialized type of Event Log set up only for the Measurement Industry Canada version of the FloBoss It contains changes to any flow related parameters made through the protocol Once the Audit Log fills up you must save the log to a disk file to clear the audit flag The FloBoss then allows parameter changes and resumes recording audit events The Audit Log has information fields that 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 ASCII description 2 2 8 Function Sequence Tables FSTs The FloBoss supports FST user programmability The four FST programs can consist of 300 lines each of code The FST code resides in battery backed up static RAM 2 2 9 PID Control The Proportional Integral and Derivative PID Control functionality is used to provide control of a Process Variable to a user entered Setpoint by automatically adjusting the output to a regulating device such as a control valve PID Control can only be implemented if I O modules are installed to provide a control output This output can be achieved either through an Analog Output or through a pair of Discrete Outputs for open close control Override Control of a secondary variable may also be set up 2 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 2 10 Power Control
46. is operating correctly 3 5 2 Analog Output Modules The Analog Output module is a source for current loop or voltage devices Two test procedures are provided to verify correct operation Check AO Current Loop Source Installations on page 3 25 Check AO Voltage Source Installations on page 3 25 3 22 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 5 2 1 Check AO Current Loop Source Installations Equipment Required Multimeter Personal Computer running ROCLINK configuration software 1 Taking appropriate precautions disconnect the field wiring going to the AO module terminations 2 Connect a multimeter between the B and C terminals of the module and set the multimeter to measure current in milliamps 3 Using ROCLINK configuration software put the AO point associated with the module under test in Manual mode Scanning Disabled 4 Set the output to the High Reading EU value 5 Verify a 20 milliamps reading on the multimeter 6 Calibrate the Analog Output High Reading EU value by increasing or decreasing the Adjusted D A 100 value 7 Set the output to the Low Reading EU value 8 Verify a 4 milliamps reading on the multimeter 9 Calibrate the Analog Output Low Reading EU value by increasing or decreasing the Adjusted D A 0 value 10 Enable scanning Scanning Enabled or Auto for the AO point remove the test equipment and reconnect the field device 11 If possible verify
47. ladica Oisc n i ea 2 17 TTP ATE E E E O 2 4 Maim Bb GO ieee mene meres a ae mrs a re 2 13 Radio Requirement s cccccccccccccccccceeeeeeeeeeeeeees 1 9 REMOVIDO csie 2 18 Reduir meni no ronon ra an E T 1 6 Solar POW Ch eei een ata tats 1 6 SUES CS Protectio Nena e cme 1 6 2 12 Totaling Requirements isisisi 1 10 Processor Board COMPONE eain nah ee teecd ee Roe eae 2 2 Site 0 F216 a 2 eee ee N 2 24 Product Descrip ONS ensi ih emmatepareances 4 1 PERD a ES 2 8 PER e a teen 2 8 PER een stansuttcarteRasvetor ent atastons te 4 5 4 9 Public Switched Telephone Networks DSCNS scicceven ciate laces torsion hues ta enl ated ait maw tvuiaactoduts 4 7 Pulse Inputs Uti eases tee hate S 2 15 DS OPUS cela ced tn tae Mracouethe tat t apeaeu tanec nana 3 3 Isolated Troubleshooting ccccccceeeeeeeeeeeees 3 25 Isolated Wiring cccccccccccccccccceeeeeceeeeeseeeeeeeeees 3 14 Low Lev ea asdeccatabeaiierackes 3 4 3 17 3 26 Slow Bolated eiia E 3 4 Rev Mar 05 FloBoss 407 Instruction Manual DOW SOULCE xi heiraheriiad ncdebiuhaohieieanttinehenlieamnchomanes 3 4 SOUTO isa eign apa es sagen aaa cieedseasuues uieendeeeuansaes 3 3 Source Troubleshooting cccccccceeeeeeeeeeeeeeees 3 25 Source WV MIN a reset ses fi E 3 13 Testie Bilteni iR 2 23 Wiring nin 52 oh sepia ces does oie eerie saad 2 15 Push to Talk PNT E TE E E E E E E E ss 4 9 R P tases ite aoe Mee sehameedsnnases 4 5 4 6 4 10
48. module The voltage sets up a flow of current sensed by the module that in turn signals the FloBoss electronics that the field device is active When the field device no longer provides a voltage current stops flowing and the DI module signals the FloBoss electronics that the device is inactive A 10 ohms scaling resistor R1 is supplied by the factory and accommodates an external voltage V of 11 to 30 volts dc However it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage The formula for determining the optimum value of R1 displays in Figurd 3 12 For best efficiency R1 should be scaled for a loop current I of 3 milliamps SELF POWERED DISCRETE DEVICE TO OPTIMIZE SCALING RESISTOR R1 R41 Yo71 _R 3 3K l DOC0144A R1 Ry 3 3K LOOP RESISTANCE 4 5K OHMS MAX LOOP CURRENT 3 mA TYPICAL Rw RESISTANCE OF FIELD WIRING Vo VOLTAGE FROM DISCRETE DEVICE 11 TO 30 VDC Figure 3 12 Discrete Input Isolated Module Field Wiring 3 4 7 Discrete Output Source Module A schematic representation of the feld4viring connections to the output circuit of the Discrete Output Source module displays in Figutel3 13 CAUTION The Discrete Output Source module is designed to operate only with non powered discrete devices such as relay coils or solid state switch inputs Using the module with powered devices may cause improp
49. of HART devices must be reduced The HART module polls one channel at a time If more than one device is connected to a channel in a multi drop configuration the module polls all devices on that channel before it polls the second channel The HART protocol allows one second per poll for each device so with five devices per channel the entire poll time for the module would be ten seconds In a point to point configuration only one HART device wires to each HART module channel In a multi drop configuration two to five HART devices can connect to a channel 3 20 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual In either case terminal A T is wired in parallel to the positive terminal on all of the HART devices regardless of the channel to which they are connected Channel terminal B is wired to the negative terminal of a single HART device or in parallel to the negative terminals of two to five devices Likewise channel 2 terminal C is wired to the negative terminal of a single HART device or in parallel to the negative terminals of a second group of two to five devices Refer to Figure 3 26 26 HART MODULE ROC POWERED em es CE LIMIT O T HART esn 1 f Ea MUX a MODEM POWERED DOC0295A HART 2 POWERED ROC POWERED HART 5 HART DEVICE ae ere gt el 1 MULTI DROP MODE ecru 7 eererseenal 2 POINT TO POINT MODE Figure 3 26 Field Wiring for a HART Inter
50. off by the DO Isolated module The switching 1s controlled by the FloBoss electronics SELF POWERED DISCRETE DEVICE DOC0146A TERMINAL A CONNECTION IS COMMON Modified TERMINAL B CONNECTION TO BE MADE FOR NORMALLY OPEN APPLICATIONS TERMINAL C CONNECTION IS NO CONNECT Vo VOLTAGE FROM DISCRETE DEVICE 11 TO 30 VDC 1 0 A MAX Figure 3 14 Discrete Output Isolated Module Field Wiring 3 12 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 4 9 Discrete Output Relay Module A schematic representation of the field wiring connections to the output circuit of the Discrete Output Relay module displays in Figure 3 15 NOTE The Discrete Output Relay module is designed to operate only with discrete devices having their own power source The module will be inoperative with non powered devices The Discrete Output Relay module operates by providing both normally closed and normally open contacts to a field device Normally closed contacts use terminals B and C and normally open contacts use terminals A and B ROCLINK configuration software controls the status of the contacts open or closed There are two versions of the DO Relay module The 12 volts version 12 volts energizing coil must be used when the FloBoss input voltage is a nominal 12 volts dc and the 24 volts version 24 volts energizing coil must be used when the FloBoss input voltage is a nominal 24 volts dc SELF POWERED DISCRETE DEVICE DOC0147A
51. one input probe to terminal B of the HART module and examine the signal for a polling request and response for each HART device connected to this channel 2 Attach the other input probe to terminal C and examine the signal for a polling request and response for each HART device connected 3 Compare the two traces Signal bursts should not appear on both channels simultaneously Each device on one channel is polled before the devices on the other channel are polled If a channel indicates no response this could be caused by faulty I O wiring or a faulty device If the HART module tries to poll both channels simultaneously this could be caused by a defective module in which case the module must be replaced 3 6 Removal Addition and Replacement Procedures Use the following when removing adding or replacing I O modules 3 6 1 Impact on I O Point Configuration When an I O module is replaced with the same type of I O module it is not necessary to reconfigure the FloBoss Modules that are treated as the same type include Discrete Input Isolated and DI Source Modules Discrete Output Isolated DO Source and DO Relay Modules Analog Input Loop AI Differential AI Source Modules and RTD Input Modules Pulse Input Isolated and PI Source Modules gt et 6 O Slow Pulse Input Isolated and SPI Source Modules If a module is to be replaced with one of the same type but configuration parameters need to be changed use ROCLINK co
52. or faulty Keypad or Display contact your local sales representative 2 5 17 Integral MVS Replacement To replace an Integral MVS contact your local sales representative 2 26 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 6 FloBoss 407 Specifications The following pages provide a table of specifications for the FloBoss 407 FloBoss 407 Specifications PROCESSOR ANALOG INPUTS BUILT IN NEC V25 running at 10 MHz Quantity Type 1 or 2 single ended voltage sense MEMORY current loop if scaling resistor is used Program 512 K flash ROM electrically programmable for firmware configuration etc Data 512 K battery backed SRAM Memory Reset When used during power up Reset switch initializes communication port hardware and communications port processing for all ports TIME FUNCTIONS Clock Type 32 kHz crystal oscillator with regulated supply battery backed Year Month Day and Hour Minute Second Clock Accuracy 0 01 Watchdog Timer Hardware monitor expires after 1 2 seconds and resets the processor Processor restart is automatic DIAGNOSTICS These values are monitored and alarmed RAM validity operation analog input mid scale voltage power input voltage and board temperature COMMUNICATIONS PORTS Operator Interface EIA 232 RS 232D format Software configured 300 to 19 200 bps rate selectable Screw cap protected connector COM1 EIA
53. personal injury or property damage To avoid circuit damage when working with the FloBoss use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Save the current configuration data by selecting ROC gt Flags gt Write to EEPROM or Flash Memory Save Configuration This action saves most of the FloBoss configuration but not logs or FST programs into the permanent memory accessed when a Cold Start is performed 2 Save the current configuration data to disk by using the Download gt Save ROC Configuration To Disk function When replacing or physically upgrading a Flash memory chip the only way to preserve configuration data is to save the data to disk and then retrieve the information after the chip is installed 3 Save all historical database logs Minute Hourly and Daily Event Log and Alarm Log to disk using ROC gt Collect Data All function as explained in the applicable ROCLINK configuration software user manual 4 Save the FSTs to disk using Utilities gt FST Editor gt FST gt Write function in the FST Editor Refer to the FST Editor in the applicable configuration software user manual 2 18 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 5 3 After Installing Components After removing power to the FloBoss and installing components as needed perform the following steps to start your FloBoss and reconfi
54. reset the MVS to factory default settings To restore factory default settings in an MVS 1 Connect the FloBoss 407 to a PC running ROCLINK configuration software 2 Select Utilities gt MVS Calibration 3 Click Set Back to Factory Defaults 4 Click Yes B 7 Multi Variable Sensor Specifications For Multi Variable Sensor Specifications refer to Specifications Sheet 2 5 MV S205 B 16 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual APPENDIX C I O SIMULATION This appendix describes how to simulate inputs and outputs to verify the proper operation of the FloBoss The simulations make use of the various types of I O modules available for the FloBoss Topics covered are Section Page C 1 Analog Outputs to Analog Inputs C 2 Analog Outputs to C 3 Discrete Outputs to Discrete Inputs C 4 Discrete Outputs to Pulse Inputs C 5 Potentiometer to Analog Inputs C 6 Switch to Discrete Inputs C 7 Switch to Pulse Inputs C 1 Analog Outputs to Analog Inputs The Analog Output source module simulates a transmitter by feeding a 4 to 20 milliamps current to either an Analog Input Loop module or an Analog Input Differential module FigurelC lland Figure C 2 bhow wiring connections R1 0 R1 250 AO SRC DOC0176A Figure C 1 Current Loop AO Source Module to AI Loop Module DOC0178A Figure C 2 Current Loop AO Source Module to AI Differential Module C 1 I O Simulation Rev Mar 05 FloBoss 407 I
55. signal from an RTD source The module can accommodate one input from a two three or four wire RTD source The active element of an RTD probe is a precision temperature dependent resistor made from a platinum alloy It has a predictable positive temperature coefficient meaning its resistance increases with temperature The RTD input module works by supplying a small current to the RTD probe and measuring the voltage drop across it Based on the voltage curve of the RTD the signal is converted to temperature by the FloBoss firmware 3 2 11 HART Interface Module The HART Interface Module provides communications between a FloBoss and other devices using the Highway Addressable Remote Transducer HART protocol The module has its own microprocessor and mounts in the I O module sockets The HART Interface Module communicates digitally to HART devices through the I O termination blocks associated with the module position Each HART module contains two separate channels Each channel polls all HART devices connected to it before the other channel is polled Each channel can be configured to operate in either the point to point mode or the multi drop mode In the point to point mode each module channel supports one HART device In the multi drop mode each channel can support up to five HART devices for a total of ten devices for each module By using the multi drop mode with multiple HART modules up to 32 HART devices limited by ROCLINK config
56. the FloBoss 407 Refer to Appendix A for additional information about the Lightning Protection Modules The COM 1 terminal block on the termination board provides wiring access to a built in EIA 232 RS 232 serial interface If the FloBoss 407 processor board has an optional communications card installed the COM2 terminal block on the termination board provides wiring access for the communications card Depending on the type of card this port allows the FloBoss 407 to connect to a radio to public leased or customer owned telephone lines to another device via serial communications The termination board has a bracket to hold an RJ11 connector for communications cards that provide a telephone line hook up The MVS port on the termination board allows the FloBoss 407 to communicate directly with a Multi Variable Sensor MVS The MVS is a flow monitoring device that collects temperature and pressure data making it available to the FloBoss 407 through this specialized serial port This port can function as a multi drop port for installations with as many as four MVS units connected to the FloBoss 407 Refer to Appendix B and the ROC FloBoss Accessories Instruction Manual Form A4637 The local operator interface LOI Local Port connector provides direct communications between the FloBoss 407 and the serial port of an operator interface device such as a notebook computer The interface allows you access to the FloBoss 407 for configuration for
57. the active element loop to increase the accuracy of the probe Various colors are used for the probe wires For example some probes have wire colors of red and white for the RTD element loop and black leads for the compensation loop while other probes use two red leads for the active element loop and two white leads for the compensation loop The connections in Figure 3 24 connect a 4 wire RTD with compensation loop to the 3 wire RTD module The RTD module designed for 3 wire use does not permit a 4 wire RTD to provide any additional accuracy over a 3 wire RTD RTD 4 WIRE RTD WITH COMPEN SATION LOOP DOC4008A Figure 3 24 RTD Input Module Field Wiring for Four Wire RTD With Compensation Loop Figurd 3 25 shows the connections for a single element 4 wire RTD The two leads for one side of the RTD are both red and for the other side they are both white 4 WIRE RTD WITH SINGLE ELEMENT DOC4009A Figure 3 25 Field Wiring for Four Wire Single Element RTD 3 4 16 HART Interface Module The HART Interface module allows the FloBoss to interface with up to ten Highway Addressable Remote Transducer HART devices per I O slot The HART module provides loop source power T on terminal A and two channels for communications on terminals B and C The T power is regulated by a current limit If the power required by all connected HART devices exceeds 40 milliamps more than an average of 4 milliamps each the total number
58. the risk of being damaged by vehicles However provide adequate vehicle access to aid in monitoring and maintenance 1 4 3 Compliance with Hazardous Area Standards The FloBoss 407 has hazardous location approval for Class I Division 2 Groups A B C and 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 hazards Group C Atmosphere containing ethylene gases or vapors of equivalent hazards Group D Atmosphere containing propane gases or vapors of equivalent hazards For the FloBoss 407 to be approved for hazardous locations it must be installed according to the National Electrical Code NEC Article 501 When installing units in a hazardous area make sure all installation components selected are labeled for use in such
59. to 50 mA externally powered only RESOLUTION 12 bits FILTER Single pole low pass 40 ms time constant CONVERSION TIME 30 us typical VIBRATION 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SHOCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F 3 31 Input Output Modules CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions are 15 mm D by 32 mm H by 43 mm W 0 60 in D by 1 265 in H by 1 69 in W not including pins ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection specifications WEIGHT 37 g 1 3 oz APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual 3 2 Analog Input Source Module Analog Input Source Specifications FIELD WIRING TERMINALS A 10 V de B Analog Input C Common INPUT Type Single ended voltage sense can be current loop if scaling resistor not supplied is used Voltage 0 to 5 V dc software configurable Resolution 12 bits Accuracy 0 1 of full scale at 20 to 30 C 68 to 86 F 0 5 of full scale at 40 to 65 C 40 to 149 F Impedance Greater than 400 kQ without scaling resistor Normal Mode Rejection 50 db 60 Hz SOURCE POWER 9 99 to 10 0
60. unit before you attempt any type of wiring Wiring of powered equipment could result in personal injury or property damage NOTE Use a standard screwdriver with a slotted flat bladed 1 8 width tip when wiring all terminal blocks Termination Board T Power Suppy O al P15 or W1 i ar Jumper RJ 11 Bracket a PI PS ee eg ee ZAA AAAA COM1 COM2 Power LED amp O C PWR MVS Ground Bus Bar Eas J 407Wire External Ground Terminal Figure 2 4 Termination Board Wiring Connections 2 11 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 4 1 Connecting Ground Wiring Equipment Required Small flat blade screwdriver The FloBoss 407 and related components must be connected to earth ground The National Electrical Code NEC governs the ground wiring requirements for all line powered devices It is recommended that 12 AWG wire be used for the ground wiring 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 407 case ground lug and the earth ground rod or grid The grounding installation method for the FloBoss depends on whether the pipeline has cathodic protection On pipelines with cathodic protection the FloBoss 407 must be electrically isolated from the pipeline Electrical
61. voltage The AI Loop module provides a source voltage for powering current loop devices and can be used as a single ended voltage output The AI Differential module monitors loop current or voltage input from externally powered devices and provides electrical isolation from the FloBoss power supplies 3 2 2 Analog Input Source Module The Analog Input Source AI Source module monitors current loop or voltage output devices The Analog Input Source module provides a regulated 10 volts source for powering a device usually a low power transmitter and uses a scaling resistor for converting loop current to input voltage 3 2 3 Analog Output Source Module The Analog Output Source AO Source module provides both a current and a voltage output for powering analog devices These outputs are isolated from each other and can be used simultaneously A scaling resistor provides a way to set the minimum loop resistance of the current loop to 0 ohms installed or 220 ohms removed 3 2 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 2 4 Discrete Input Source and Isolated Modules The Discrete Input Source DI Source and Discrete Input Isolated DI Isolated modules monitor the status of relays solid state switches or other two state devices Each module can accommodate one DI Both types of modules provide an LED that lights when the input is active Both types of modules use a scaling resistor for scaling the input range Func
62. 0 Discrete Output Isolated c ccc ccccccceceeeeeees 3 12 Discrete Output Relay oieccccscioctirens deaeeviorap ners 3 13 Discrete Output SOULCE cc cccceeeteeeeeeeeeeees 3 11 EIA 232 RS 232 Communications Cards 4 12 EIA 422 485 RS 422 485 Communications Cards ETET A EIEE A A E A ET E A E 4 12 OUN easi AA 2 12 Grounding Requirements ccccccceeeeeeeeeeees 1 6 HART Interface Module cccccccccccccceeeeeeees 3 20 VOModule easan 3 5 VOW IRI ioie eeni Seton aaa a petea Mas daes Rt 1 7 Leased Line Communications Cards 4 14 Leased Line Modem Communications Cards 4 15 Lightning Protection Module cccccceeeees A 3 Mam Powersin E Aaaa at otters eee 2 13 Multi Variable Sensor cccccccccscccccecececeeeeeeeeees B 6 Pulse Input Isolated ccccccceeeeeeeeeeeeeees 3 14 Pulse Tnput SOURCE naonin aa 3 13 Pulse Inputs Built in cccccceceeeeeeeeees 2 15 Radio Modem Communications Cards 4 13 ay ee eens ener rer eee een neers E emer ren B 10 PDI pUlscise2iaretesnsedtiaeetastetansdradeouesans 3 17 3 19 Slow Pulse Input Isolated cc eeeeeeeeeeeeeeeees 3 16 Slow Pulse Input Source cceeeeeeeeeeeeeeeeeeeeees 3 15 Wro Gra OC cers ater ctderected e 2 11 2 13 Write to EEPROM ceeccceesccceesescnenees 2 18 2 19 Rev Mar 05 FloBoss 407 Instruction Manual If you have comments or questions regarding this manual please dire
63. 1 10 Transmitter POW vovs icccbaediciessensetaelbnereedncancddaieavaceee 2 4 Troubleshooting cccccceeesesssessssseessssssssssesssseeees 2 17 Analos PU eana arco areca noone 3 22 Analop OUMU aisian a a 3 22 Backup Procedure Before Removing Power 2 18 Communications Cards ccccssccccccceceeeesseeeeens 4 17 Discrete Input Isolated cc ceeeeeeeeeeeeeeeeeeeees 3 24 Discrete Input Soule 2 2 2 16 0 5sviconadeulasnacetsesnsdendee 3 24 Discrete Output Isolated ccc eeeeeeeeeeeeeeeeees 3 24 Discrete Output Relay ceeeeeeeeessseeeeeeeeeeeees 3 25 Discrete Output SOULCE 000eeeeeseeeeenes 3 24 HART Interface Module cceccceeeeeeeees 3 27 TOs MIOCUICS setcetrcaicies vacmeunticnemesahsndelaculaamsvevntuduatiens 3 21 VO Simula Oiu E ETE C 1 Lightning Protection Module 00eeeeee A 3 Low Level Pulse Input scr acs on eects 3 26 Multi Variable Sensot cccccsssseseeeeseseeeeees B 16 Performing a Cold Start c ccceeeeeeeeeeseeeeeeeees 2 21 Performing a RCS Cle 55a cis A 2 21 Pulse TOPU 55553 ssccs eae aaeanee a 3 25 Replacing Processor Board c00c0eeeeeeereees 2 24 Replacing Termination Board cc ccccceceeees 2 23 TNS CU e E ce eaeatecaceetane 2 4 RTD AD UU a eden adiniaanadesin i renaicats gdudusiirebabenbadeaieiens 3 27 SCC LESNE cerna a ET 2 22 Slow Pulse Input Isolated cc ceccceeeeeeeeeee
64. 1 V dc 20 mA maximum POWER REQUIREMENTS 4 9 to 5 1 V dc 6 mA maximum 4 5 to 5 5 V dc 2 mA maximum all supplied by FloBoss INPUT ISOLATION Not isolated Terminal C is tied to power supply ground SURGE WITHSTAND Meets IEEE 472 ANSI C37 90a FILTER Single pole low pass 40 ms time constant CONVERSION TIME 30 us typical VIBRATION 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SHOCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions 15 mm D by 32 mm H by 43 mm W 0 6 in D by 1 265 in H by 1 690 in W not including pins ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection WEIGHT 37 g 1 3 oz APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D 3 7 3 Analog Output Source Module Analog Output Source Specifications FIELD WIRING TERMINALS A Voltage Output B Current Output C Common VOLTAGE OUTPUT Type Voltage source Range 1 to 5V dc with 0 to 5 25 V dc overranging 25 mA maximum Resolution 12 bits 3 32 Input Output Modules VOLTAGE OUTPUT CONTINUED Accuracy 0 1 of full scale output from 20 to 30 C 68 to 86 F 0 5 of full scale output for 40 to 65
65. 1 volt dc across scaling resistor Rs Adjusted A D 100 4000 5 volts dc across R Low Reading EU 0 0000 EU value with 1 volt dc across Rs High Reading EU 100 0 EU value with 5 volts dc across Rs Filter EUs Value read by Al module When the value of Filtered Engineering Units EU is 25 of span as configured above it is an indication of no current flow 0 milliamps which can result from open field wiring or a faulty field device When the value of Filtered EUs is in excess of 100 of span as configured above it is an indication of maximum current flow which can result from shorted field wiring or a faulty field device When the value of Filtered EUs 1s between the low and high readings you can verify the accuracy of the reading by measuring the voltage across scaling resistor R V s with the multimeter To convert this reading to the filtered EUs value perform the following Filtered EUs V s 1 4 x Span Low Reading EU where Span High Reading EU Low Reading EU This calculated value should be within one tenth of one percent of the Filtered EUs value measured by the FloBoss To verify an accuracy of 0 1 percent read the loop current with a multimeter connected in series with current loop Be sure to take into account that input values can change rapidly which can cause a greater error between the measured value and the calculated value If the calculated value and the measured value are the same the AI module
66. 14 4K 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 Modulation V 32 and V 32 bis V 21 and 103 binary phase coherent FSK V 22 and 212A and V 22 bis Transmit Amplitude 1 dB typical Telephone Line Impedance 600 Q typical RTS to Transmission Delay Configurable in 10 ms increments Receiver Sensitivity Off to On threshold 45 dBm On to Off threshold 48 dBm Maximum Output Level 0 dBm nominal into 600 Q LED Indicators TXD RXD DTR DSR RI and OH Surge Protection Conforms to FCC part 68 and DOC Surge Isolation 1000 V ac and 1500 V peak Certification FCC Part 68 approved Connector RJ11 type 4 21 Communications Cards POWER REQUIREMENTS 4 5 to 5 5 V dc 0 4 W maximum supplied by FloBoss ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity To 95 relative non condensing DIMENSIONS 25 mm H by 103 mm W by 135 mm L 1 in H by 4 05 in W by 5 3 in L WEIGHT 130 g 4 6 oz typical FCC INFORMATION Registration Number DWE 25983 M5 E Ringer Equivalent 1 0B APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual SECTION 5 DISPLAY AND KEYPAD 5 1
67. 3 3K RI Rs Maximum Voltage 30 V dc forward 5 V dc reverse POWER REQUIREMENTS 4 9 to 5 1 V dc 1 mA maximum supplied by FloBoss INPUT ISOLATION Isolation 100 Q minimum input to output and input or output to case Voltage 4 000 V ac RMS minimum input to output Capacitance 6 pF typical input to output Discrete Input Modules Source and Isolated Common Specifications INPUT Loop Resistance RI 4 5 KQ maximum Frequency Response 0 to 10 Hz maximum 50 Duty Cycle Input Filter Debounce Software filter is configured as the amount of time that the input must remain in the active state to be recognized VIBRATION 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SHOCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F 3 34 Input Output Modules WEIGHT 37 g 1 3 oz CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions are 15 mm D by 32 mm H by 43 mm W 0 60 in D by 1 27 in H by 1 69 in W not including pins ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection APPROVALS Approved by CSA for hazardous locations Class I Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual 3 5 Discrete Output Modules Source and Isolated Discrete Output Sou
68. 385 and can be used to measure temperatures in the range of 100 to 400 C 148 to 752 F The element is encased in a 316 Stainless Steel thermowell with a choice of either a 2 5 or 4 5 inch immersion length The tapered style thermowell mounts in a 4 14 NPT hole An explosion proof connection head union and nipple are included in the assembly The connection head meets requirements for Class I Division 1 Groups C and D hazardous locations Refer to Figure B 8 000000000009 RTD element EN E SS TE ja Q Thermowell X D Connection Head DOC0286R N A LA LA LA U U AT T y y y Figure B 8 RTD Assembly Details B 4 Configuring the MVS Use ROCLINK configuration software to configure the MVS and to set the unique interface Address This is essential if there is more than one MVS connected to a FloBoss 407 multi drop configuration All MVS units are sent from the factory with a default interface Address of 1 This allows for first time communications to be accomplished Do NOT use Address 240 in multi drop applications because all MVS devices with this address will try to respond to requests from the FloBoss To configure a multi drop MVS setup connect each MVS to the FloBoss 407 one at a time Ensure that each MVS is functioning correctly before installing the next MVS B 10 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual O
69. 5 5 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual NORMAL MODE EDIT MODE ALT MODE FLOW COMP Displays the following gas Displays digit 9 on SYS PARAM composition parameters for a LCD for data entry The following system selected meter run parameters display Specific Gravity Heating Value Viscosity Specific Heat Ratio Base Pressure Base Temperature N Nitrogen CO Carbon Dioxide H2S Hydrogen Sulfide H2O Water He Helium CH Methane C H Ethane C3Hs Propane C H n Butane C H19 i Butane Cs5H 2 n Pentane CsH 2 i Pentane C6H44 n Hexane C7H n Heptane CsH g n Octane CogH29 n Nonane C1pH22 n Decane O Oxygen CO Carbon Monoxide H Hydrogen Displays the following for selected meter run Pipe Diameter Orifice Diameter Latitude Elevation Calculation Method AGA Configuration Orifice Material Low Flow Cutoff T Displays the previous parameter in the list or changes the display to the previous point METER CONFIG Displays digit 0 on LCD for data entry Backspace on LCD for data entry 5 6 Display and Keypad Part Number ROC Address ROC Group Station Name Contract Hour PREV SET Displays the previous set of parameters if applicable TIME Displays the following Current Date Current Time Rev Mar 05 FloBoss 407 Instruction Manual NORMAL MODE EDIT
70. 85 CARD COM2 TERMINAL BLOCK EIA 422 21 Ryo RECEIVE 12 ao RECEIVE 24 pxo 2 IRAN GMI A ans TIRANSMI 257s B 20 22 4 com 15 COM 9 DOC0212B Figure 4 8 EIA 422 RS 422 Wiring Schematic 4 12 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual Figure 4 9 shows the relationship between the EIA 485 RS 485 signals and terminal numbers for the COM2 terminal block Wiring should be twisted pair cable On newer design cards Jumper P3 can be set to apply LD or remove N L a 140 ohms load Typically the load would be used in a point to point application and removed in multi drop applications except for one device on each end of the bus EIA 422 485 CARD COM2 TERMINAL BLOCK FIA 485 OUT OUT OR MDWA NNUWN COM OGVNOWONTrTo DOCO0213B Figure 4 9 EIA 485 RS 485 Wiring Schematic 4 5 3 Radio Modem Communications Card Wiring The following signal lines are used with most radios COM2 _ Push to talk switch 5 RXA_ Receivedata ae to talk return OO 7 TXA a data o com FloBoss power supply ground Jumper P6 determines whether the PTT signal is isolated or grounded Use connector P7 signals for monitoring or connecting to an analyzer Refer to Section 4 4 2 Setting Modem Card Jumpers on page 4 11 The output attenuation can be reduced to better match the modem output to the line or radio Plugging a resis
71. A E A i Ee a O OG A E E NEE EE AE E E E EE A E T i PIS ay O Pae eee T E EE A EE A BLM Y E A E E A EO E A T I E Lroubl eshoolin and IRC Dail 5 cessrgs asssgyseaapsrenstinsys a i E i aa ai E RE Product DE C0 aa aE E E E A E ER EE o a A E EE A E T AE A E Connec ie Tne EPTO Vy T a a E E A E E N AEE Tropie hoone and REDI ean E EEA Rees eeenae tT emne see Lichtiine Protechon Module Specifications errre senn E EEE NEESER DoD 0 0 ane ene ee A E E E E E NE TN MES TOA sec E E E E E E E E E A AE E My E AN a E E A E E COEIRE ne MEN e E nent nen mttaer reenter Calibrating the My S xscdicstncsiessnsecaiabauicattoennediastineshanasnenaebausaathoswsndiastnanianacinnsehabavbiaybosweniiadtenodasanet IVEY SOU ie SOO mend RONA E E E Multi V arable Sens r SPeCCIICAIOMSivisviccsnsnctcastxsssedsitsuencedeacdacsavesdeadeeasusqsevcateasec SEn TEESE Analog Outputs to Analog TPUS eriein i EE EEEE l Analog Outputs to Ammeter or a Volt Meter iesvecsvcesscssnsesscesevevsceveeevseervenvacnerecusaneuessnanseeescneeuess i Discrete Outputs to Discrete Inputs 0 0 00 ce eeccccccccccccceesesecccceeeeeaeseseeeccceeesssaesseeecceeesseaanaeeees D orce Odim VO USS IIS a E E A Potentiometer to Analog MES sereia E E TER Switch to Discrete TUS xcaassscuneesansaagece o nesdoevasuateusnasaoussianeeonnesioesaisne a tenoaseneiawnessecnetoconanassaress SWC Or OSS MAUI a E uous iomeenan nena ani E A E E Table of Contents Rev Mar 05 FloBoss 407 Instruction Manual SECTION
72. Boss 407 to the Remote MVS and connect them to the MVS terminal block on the termination board The wires should be a minimum size of 22 AWG and a maximum length of 1220 meters 4000 feet Two of the terminals provide power and the other two terminals provide a communication path The MVS is labeled as follows with terminal 1 on the left and terminal 8 located on the right C Terminai Usage A Power CAUTION Do not reverse polarity of the power wires and while wiring the Remote MVS units or circuits may be damaged Double check for proper connections before applying power 1 The terminals in the MVS head are labeled the same as the terminals on the MVS terminal block in the FloBoss 407 Connect the FloBoss 407 and Remote MVS terminals one for one AtoA BtoB to os Figure B 7 hows wiring for a typical Remote MVS installation 2 Connect the Remote MVS to a suitable earth ground per applicable codes and standards Two means of grounding are available on the unit internal and external To use the internal ground to meet U S and Canadian requirements connect to the ground terminal inside To meet IEC and CENELEC requirements use the external ground lug to connect to earth ground B 8 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual Se fo 5 a 2s oS KN J Zp Fo eS ae a NN Z Wore we
73. Boss 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 CAUTION If you have an MVS sensor refer to the Sensor Calibration section in the ROC FloBoss Accessories Instruction Manual for the recommended way to remove restore the MVS from to working pressure during calibration Failure to follow recommendations may cause sensor damage 1 Setup the pressure calibrator and make the necessary connections to the MVS NOTE Because any calibration changes are recorded in flash memory the power supplied to the FloBoss 407 must be at least 12 5 volts If it is not the changes are not saved and the previous settings may be lost NOTE To properly perform the calibration procedure you must know if the FloBoss 407 and MVS 1s set up to sense absolute pressure or gauge pressure 2 To start the Keypad calibration activate the display and enter the user Password In any of the scrolling list displays press HOLD DISPLAY to stop the scrolling and use the UP and DOWN arrow keys to move through the list At any time during calibration press ALT and CANCEL to quit penne Press EXIT to navigate backwards in the calibration process 5 3 Press ALT and CALIBRATE on the Keypad The following sequence begins CALIBRATE B 11 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual 4 Press J and ENTER to select a m
74. C Negative Pulse Input INPUT ISOLATION INPUT Isolation 100 MQ minimum input to output and Type Two state current pulse sense input or output to case Range Inactive 0 to 0 5 mA Active 3 to 12 mA Voltage 4 000 V ac RMS minimum input to Input Current Determined by input voltage Vi output loop resistance RI and scaling resistor Rs Capacitance 6 pF typical input to output Vi 1 2 2K RI Rs Pulse Input Modules Source and Isolated Common Specifications INPUT WEIGHT Scaling Resistor Rs 10 supplied see Input 37 g 1 3 oz Source Current equation to compute other value Frequency Response 0 to 12 kHz maximum CASE 50 Duty Cycle Solvent resistant thermoplastic polyester meets Input Filter Single pole low pass 10 us time UL94V 0 constant Dimensions are 15 mm D by 32 mm H by 43 mm W 0 60 in D by 1 27 in H by 1 69 in W not VIBRATION including pins 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 ENVIRONVENTAL o condition F Meets the Environmental specifications of the FloBoss in which the module is installed including MECHANICAL SHOCK Temperature Humidity and Transient Protection 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D 3 37 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 8 Slow Pulse Input Module
75. CAO crecesiorhichserns ee Si etalon tare rice ptenc 4 3 Display eeseeceeeseseeteeeeieeeeseeseeseeneeseesteeneeses 5 8 Locat ON riar a E E eee 4 9 AT Command a E E AAA A E E A E 4 7 Radio Modert e t 4 5 4 9 4 10 Attenuation Levels Ropice Denona nS Oe an en ena 4 18 Communications Cards 4 5 4 6 4 10 4 13 4 15 SPECIMCALIOMS e en nema test wads 4 19 PION EOD oaia a E 2 7 Troubleshooting c cccscecsssessssesessesessesesseeeeseeeeens 4 17 WIS einai e Heenan 4 11 B Configuration VOEON aimn ener Macnee Cente rch Renee 3 28 ID Mai eae arent omer eeee eee caeane 2 20 MVS Mullti drop annnars B 10 Pedra ccc asset ee estes eee gare 2 20 R ee Backspace lt Keyin n acted 5 3 P70 4 5 4 6 4 13 4 14 4 15 l 1 Index Rev Mar 05 FloBoss 407 Instruction Manual Cono L iiirelessenet calen gamnatattiebeott eonmabeeraneniwomeaietets 5 14 CIS E E ua nouns det TOA 4 3 D Daily Historical LO S ccccccccceeeeeeeeeeeeeeeeeeeeeees 2 7 DAY M Tae seuaetecenevage arene 5 8 Dav History ASU iien ee es 5 13 FE ATIC sasn a a i 5 13 Formal redenaar 5 13 Value BEXamp l Enen a Ea 5 14 DG P wer SOURCE erene aie ee aeotastean 2 13 DE D rure a O IE 4 3 DeadDa nirera eo teas atacand G 2 Diagnose Moutain E ted a ecole 2 6 Dial Up Modem Communications Cards 4 7 WIN a e AARE 4 16 Ditteretitial Pressure niai onsen 2 6 Discrete Inputs Iolite Geta ee lier sh ces tear selaalnatn arierclieudienamienalaaatad 3 3 Isolated Troub
76. Differential Module Field Wiring for Higher Voltage DeyitEg scrote 3 7 Figure 3 6 AI Differential Module Field Wiring for C rrent Loop DEVICES a 3 8 Figure 3 7 AI Source Module Field Wiring for Voltage DEVICES Corer T 3 8 Figure 3 8 AI Source Module Field Wiring for Current LOOP DEVICE Sirenas i E aed ote 3 9 Figure 3 9 Analog Output Source Module Field Wiring for Current Loop DEVICES i 4icwsitisieal ices 3 9 Figure 3 10 Analog Output Source Module Field Wiring TOE VOM Ae CIDE VICES ern Siena vend a a 3 10 Figure 3 11 Discrete Input Source Module Field Wiring i Sosgs erased onca etauo ene eine mgt enaen en een OLe enoue aman 3 10 Figure 3 12 Discrete Input Isolated Module Field Wiring EA dea he ace AAE A E A dines elastase E N ET 3 11 Figure 3 13 Discrete Output Source Module Field WY TTC erae e a O EA 3 12 Figure 3 14 Discrete Output Isolated Module Field WINDE eei E E A AO ETS 3 12 Rev Mar 05 FloBoss 407 Instruction Manual Figure 3 15 Discrete Output Relay Module Field Wiring Figure 3 19 Slow Pulse Input Isolated Module Field VY ME IAS ae hs Deka ce et Sik Se ae na era Dh ee ae a et Dense 3 16 Figure 3 20 Low Level Pulse Input Module Field Wirmo SCMEIMAU G pinana ni a aiai 3 17 Figure 3 21 Calibration Setup ccccccccceeeeees 3 18 Figure 3 22 RTD Input Module Field Wiring for Two WERT DS ei a a NN 3 19 Figure 3 23 RTD Input Module Field Wiring for Three Wre IT DS oinean sa todecsas 3 19 Figure 3 24 RTD Input
77. F FIELD Vs SOURCE VOLTAGE FROM MODULE 11 TO 30 Figure 3 18 Slow Pulse Input Source Module Field Wiring 3 4 13 Slow Pulse Input Isolated Module A schematic representation of the field wiring connections to the input circuit of the Slow Pulse Input Isolated module is shown in Figure NOTE The Slow Pulse Input isolated module is designed to operate only with devices having their own power source such as wet relay contacts or two state devices providing an output voltage The module is inoperative with non powered devices The Slow Pulse Input Isolated module operates when a field device provides a voltage across terminals B and C of the module The voltage sets up a flow of current sensed by the module which signals the FloBoss electronics that the field device 1s active When the field device no longer provides a voltage current stops flowing and the SPI module signals the FloBoss electronics that the device is inactive The FloBoss counts the number of times the current starts flowing and stores the count The FloBoss checks for the input transition every 50 milliseconds A 10 ohms scaling resistor R1 1s supplied by the factory which accommodates an external voltage V of 11 to 30 volts dc However it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage The formula for determining the value of R1 displays in Figure
78. Form A6013 Part Number D301080X012 March 2005 FLOBOSS 407 FLOW MANAGER Instruction Manual Ss Flow Computer Division EMERSON Website www EmersonProcess com FloBoss 407 Instruction Manual Revision Tracking Sheet March 2005 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 All Mar 05 All Dec 03 All May 00 All Nov 98 FloBoss and ROCLINK are marks of one of the Emerson Process Management companies The Emerson logo is a trademark and service mark of Emerson Electric Co All other marks are the property of their respective owners Fisher Controls International Inc 2002 2005 All rights reserved Printed in the U S A While this information is presented in good faith and believed to be accurate Fisher Controls does not guarantee satisfactory results from reliance upon such information Nothing contained herein is to be construed as a warranty or guarantee express or implied regarding the performance merchantability fitness or any other matter with respect to the products nor as a recommendation to use any product or process in conflict with any patent Fisher Controls reserves the right without notice to
79. I provides connections for a built in EIA 232 RS 232 communications interface to a configuration and monitoring device The configuration and monitoring device typically is a laptop A null modem cable transmit and receive wires cross connected plus ground must be used between the Operator Interface connector and the PC A prefabricated operator interface cable is available as an accessory The FloBoss 407 has a built in E A 232 RS 232 serial interface accessible through the COM1 communications port The port is an 8 terminal connector located on the termination board Refer to Tablg 2 3 for a description of the signals available at each terminal COM1 DD e QA AA 2 H J 22 22 22 2l 2222228 OPERATOR SR ij INTERFACE g 222 2 222 2 2 22 2 2 2 2 2 2 2 22 2 212 2 D PORT amp KS J gt oe 0 OOGGOGOOOGOGGG O i pi D ra o
80. Input Source and Isolated Modules The Slow Pulse Input Source SPI Source and Slow Pulse Input Isolated SPI Isolated modules count the changes in the status of relays solid state switches or other two state devices Each module can accommodate one Pulse Input The modules provide an LED that lights when the input 1s active Both types of modules use a scaling resistor for scaling the input range Functions supported are controlled by the FloBoss firmware For example Raw Pulse Accumulation Running Total Entered Rollover in engineering units EUs Rate Max Rollover in EUs Today s Total Max Rollover in EUs or Rate Alarm The SPI Source module provides a source voltage for dry relay contacts or for an open collector solid state switch The SPI Isolated module accepts an external voltage from a powered two state device and provides electrical isolation from the FloBoss power supplies 3 2 9 Low Level Pulse Input Module The Low Level Pulse Input module counts pulses from pulse generating devices having a voltage range of 30 millivolts to 3 volts peak to peak The module can accommodate one Pulse Input Input pulses are counted by a 16 bit counter that 1s capable of storing up to 22 seconds of pulse counts for a 3 kilohertz input signal The module provides electrical isolation between the input pulses and the FloBoss power supplies 3 2 10 RTD Input Module The Resistance Temperature Detector RTD module monitors the temperature
81. MINAL BLOCK DOC0250A Figure 2 5 Power Wiring Connections 2 13 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 4 3 Connecting Built in Analog Input Wiring Equipment Required Flat blade 1 8 inch width screwdriver The Analog Input channels have three field terminals per channel The T terminal provides 24 volts dc for loop powered devices Each channel has a current regulator in series with the T terminal to provide short circuit protection The maximum output of each terminal is 25 milliamps The FloBoss 407 is shipped with a 250 ohms scaling resistor between the and Analog Input terminals ce 99 The terminal is the positive signal input and the terminal is the negative signal input These terminals accept a voltage signal in the 1 to 5 volts range Because the terminal is internally connected to common the Analog Input channels function as a single ended input only For use with a 4 to 20 milliamps current signal leave the 250 ohms resistor installed between the and terminals Wire the device lead to the FloBoss 407 T terminal and the device lead to the FloBoss 407 terminal Figure 2 6 shows the wiring for a typical current signal 4 voltage input remove the 250 ohms resistor from the Analog Input terminal block shows a typical voltage signal Analog Input
82. Manual C 7 Switch to Pulse Inputs Figure C 14 bhows how to use a switch to simulate relay contacts to a Pulse Input Source module x R1 10 SWITCH AUX PWR OUT 1 DOC0190A Figure C 14 Switch to PI Source Module Figure C 15 shows how to use a switch and power supply to simulate a device transmitting discrete pulses turbine meter to a Pulse Input Isolated module SWITCH DOC0189A Figure C 15 Switch to PI Isolated Module C 6 I O Simulation Rev Mar 05 FloBoss 407 Instruction Manual GLOSSARY A A D Analog to Digital AGA American Gas Association AI Analog Input AO Analog Output Analog Analog data is represented by a continuous variable such as a electrical current signal AP Absolute Pressure API American Petroleum Institute ASCII American Standard Code for Information Interchange Attribute A parameter that provides information about an aspect of a database point For example the alarm attribute is an attribute that uniquely identifies the configured value of an alarm B BTU British Thermal Unit a measure of heat energy Built in I O I O channels that are fabricated into the FloBoss and do not require a separate module Also called on board I O C CMOS Complementary Metal Oxide Semiconductor Type of microprocessor used by the FloBoss COMI Communications port built in for E A 232 RS 232 serial communications COM2 Commun
83. OC FloBoss Accessories Manual Form A4637 for outline and mounting dimensions Take precautions to make sure the FloBoss is handled properly to prevent equipment damage and make sure that personnel are aware of any site hazards NOTE To prolong hinge life the FloBoss 407 should be mounted vertically If it is necessary to mount the FloBoss 407 horizontally make sure the hinges are located on top 2 8 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 5 12 Mounting Plate LO O w O N N 8 4 p lt a Q 8 peo Loot De SL RTD Cable Lw a Connector DO U ox JE UL UL Figure 2 2 FloBoss 407 Outline and Mounting Dimensions NOTE To install I O modules in the FloBoss 407 refer to Section 3 To install a communications card in the FloBoss 407 refer to Section 4 2 3 1 Installing the Padlock Adapter This section details how to install a padlock adapter Installation of other accessories for the FloBoss such as MVS solar panels and battery enclosures is discussed in the ROC FloBoss Accessories Instruction Manual Form A463 7 The optional padlock adapter not available for Measurement Canada installs on the captive screw that secures the electronics cover With the shank of the padlock purchased separately running through the stainless steel adapter the screw is inaccessible and the cover cannot be ope
84. OCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions are 15 mm D by 32 mm H by 43 W mm 0 6 in D by 1 265 in H by 1 690 in W not including pins 3 35 Input Output Modules ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection WEIGHT 37 g 1 3 oz typical APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual 3 6 Discrete Output Relay Module Discrete Output Relay Module Specifications FIELD WIRING TERMINALS A Normally open contacts B Common C Normally closed contacts OUTPUT Type SPDT dry relay contact Maximum Contact Rating Resistive Load 30 V dc 4 Amps 125 V ac 4 Amps 250 V ac 2 Amps Frequency 0 to 10 Hz maximum OUTPUT ISOLATION Isolation 10 MQ minimum input to output and input or output to case Voltage 3 000 V ac RMS minimum input to output POWER REQUIREMENTS 12 V dc Version 4 9 to 5 1 V dc 1 mA for module 12 V dc 25 mA for relay coil energized typical 24 V dc Version 4 9 to 5 1 V dc 1 mA for module 24 V dc 12 5 mA for relay coil energized typical VIBRATION 21 G peak or 0 06 double amplitude 10 2000 Hz per MIL Std 202 Method 204 Condition F MECHANICAL
85. OG DEVICE 0 TO 5 VDC Figure 3 4 AI Differential Module Field Wiring for Low Voltage Devices Al DIFF SELF POWERED ANALOG VOLTAGE DEVICE TO SCALE R1 AND R2 FOR Vo VOLTAGE FROM ANALOG DEVICE 5 TO 100 VDC R1 MUST BE LESS THAN 4 5K OHM 1 0K OHM TYPICAL R1 Vo 5 5 DOC0156A R2 Figure 3 5 AI Differential Module Field Wiring for Higher Voltage Devices 3 7 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual For current loop devices scaling resistor R1 generates a voltage across terminals B and C that is proportional to the loop current When connecting current loop devices the value of R1 must be selected such that the 5 volts input limit of the module is not exceeded under maximum operating current conditions For 0 to 20 milliamps or 4 to 20 milliamps devices the value of R1 would be 250 ohms In this case you can use the 250 ohms 0 1 1 8 watt scaling resistor supplied by the factory The formula for determining the value of R1 is given in Figure 3 6 where I Maximum is the upper end of the operating current range such as 0 025 amps for a 0 to 25 milliamps device Al DIFF SELF POWERED CURRENT LOOP DEVICE TO SELECT PROPER VALUE FOR R1 Vo VOLTAGE FROM ANALOG DEVICE 0 TO 5 VDC 5 VOLTS MAXIMUM Figure 3 6 AI Differential Module Field Wiring for Current Loop Devices DOC0154A R1 3 4 3 Analog Input Source Module Source module displays in Figure and Figurg 3 8 Th
86. PA ANE EEL 2 6 2 15 4 4 4 6 4 9 4 12 DPD PEE A A AN E T OE lust costae 4 6 4 9 PG S EE AE E E AE iene 4 5 4 9 4 13 DPF E E EEE E E TEES 4 5 4 14 4 15 P eaaa een eee me Ree ene mere te 2 4 Ao A EEE E E E AE A EEEE 2 4 2 22 2 23 K ICY AC rs ct eee a le 1 11 5 1 Display of Parameters xsc1c Scie ectesrseect etadccgerian 5 8 TTC COIS 3 acsacsacncacsanerescnatcetasassenesesedattaseadens 5 3 5 4 Functions and Operations cccccccccccceceeeeeeeeees 5 2 Scrolling Stoppin coii EEE EEA 5 3 ho 0 63 1 Gr2 8 0 8 soana ee ee 2 27 L ED eee re ee er en eee ee eee 4 13 Leased Line Modem Communications Card See Ree 4 6 4 9 4 15 Attenuation Levels eeeccc sees 4 6 4 10 4 15 MIELO Se cet ceeds ttn tara iteetl ens Busser aaatar meee 4 14 4 15 EE DulnGicaOrs iea cts atacctateee AAA 2 17 Communications Cards ccccccceecceeeeeeeeeeeeeeeeeees 4 3 Lightning Protection Module cccccceee 1 6 2 12 TS Ca WALI cess teresa arseueu tena aes enencene aan A 2 ERN Saleen tee chess A Yes eh E ine det A I Speci MCAMIONGS ense E a A 4 Troubleshooting neonin a ai A 3 WINO A A eens A 3 Liquid Crystal Display ccccceeeeees 1 3 1 11 2 3 EOD eae ee rere eee ere ee cere eee ern ey eee 5 1 POAC EIEE E E A E E A A 4 4 LOOT ai a eerie 5 15 OUP OF ec ae ee ee 2 5 Rev Mar 05 FloBoss 407 Instruction Manual Low Level Pulse Input 00 3 4 3 17 3 26 LPM Lightning Protection Module
87. R CONFIG 0 PREV SET Rev Mar 05 FloBoss 407 Instruction Manual 5 4 6 User List Keys The three USER LIST keys are USER LIST1 USER LIST2 and USER LIST3 The USER LIST USER keys display lists of parameters configured using ROCLINK for Windows or ROCLINK LIST1 800 Configuration Software Figurg 5 5 shows the format of the User List display LIST 1 MINUTE HIST DESCRIPTION Figure 5 5 User List Display 5 4 7 Alarms The ALARMS key causes the FloBoss 407 to scroll through the Alarm Log The display shows the date of the logged alarm as month day and the time as hour minute 12 06 ALARMS The SET CLR field indicates whether the alarm is set or cleared The TYPE field displays a 4 character alarm type description such as LOLO HIHI The TAG and VALUE fields identify the tag of the point alarmed and the value at the time of alarm CALIBRATE 5 Figure 5 6 shows the alarm summary display DATETIMESET CLR TYPE TAG VALUE Figure 5 6 Alarm Summary Display 5 4 8 Min Max History Figurd 5 7 through Figure 5 11 show examples of history displays on the FloBoss Press the ALT key and press the MIN MAX key Figure 5 7 shows the general format for the Min Max History List display CONTROL MIN MAX History TYPE 4 I O TAG PARAMETER MINIMAX Figure 5 7 Min Max History List Format A list of configured history points begins scrolling when the ALT key and MIN MAX is pressed Figure 5 8 shows a list display
88. ROCLINK configuration software to confirm the input value changes A positive result on the above tests would show the FloBoss 407 input is operational Check the field wiring and transmitters for a fault 2 5 12 Testing the Built in Pulse Input Equipment Required Multimeter Jumper wire PC with ROCLINK configuration software installed Use the following tests to verify operation of the AI PI channel when it is configured as a Pulse Input AI PI jumper in the PI position 1 Isolate the field device from the FloBoss 407 by disconnecting the AI PI terminal block 2 Ifthe FloBoss 407 provides power to the field device measure the voltage between terminal T and of the AI PI channel This voltage should be 23 volts dc minimum with jumper P15 in the 24 volts position W1 open or near 12 volts dc to input power voltage with jumper P15 in the 12 volts position W1 installed 3 Connect a jumper from terminal T to terminal on the AI PI connector The LED labeled PI IND on the termination board should light 4 Connect the FloBoss 407 to a PC running the configuration software Connect a jumper from terminal T to terminal on the Pulse Input connector The PI LED on the termination board should light Use ROCLINK configuration software to confirm that the input value changes for Point Number Replace the termination board if the above tests indicate failure Refer to Section 2 5 14 Replacing t
89. S are available MVS205P with reference accuracy of 0 075 MVS205E with reference accuracy of 0 10 The MVS consists of a transducer and an interface circuit The transducer contained in the sensor body uses capacitance cell technology to sense differential pressure and piezo resistive technology to sense the static absolute or gauge pressure The transducer electronics convert the pressure variables directly into a digital format allowing accurate correction and compensation The raw temperature is converted by the interface board into digital format A microprocessor linearizes and corrects the raw pressure signals from the sensor using characterization data stored in non volatile memory The interface circuit allows the MVS to connect to and communicate with a FloBoss using a serial 4 wire EIA 485 RS 485 connection In a Remote MVS this interface circuit board is enclosed in an explosion proof electronics head An external three or four wire RTD is used to sense the process temperature The RTD sensor is connected directly to the interface circuit board of the MVS A separate RTD cable assembly is required for the connection Attached to the bottom of the sensor body is a Coplanar flange This flange which provides drain vent valves allows the MVS to be mounted on a pipestand on a wall or panel or on an integral orifice assembly or manifold valve B 1 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Ma
90. S 422 485 communication cards Figure 4 2 meet EIA 422 485 RS 422 485 specifications for differential asynchronous transmission of data over distances of up to 1220 meters 4000 feet The EIA 422 RS 422 drivers are designed for party line applications where one driver 1s connected to and transmits on a bus with up to ten receivers The EIA 485 RS 485 drivers are designed for true multi point applications with up to 32 drivers and 32 receivers on a single bus NOTE EIA 422 RS 422 devices should not be used in a true multi point application where multiple drivers and receivers are connected to a single bus and any one of them can transmit or receive data 30 0000000000000 00000000000000 Ci 00pm00p0p020p00 000 tA n n 2 00 0 0 0 0 0 0 0 0 A A a a a e 2 op lt U x LED Indicators v O w 0 0 0 0 0 0 0 0 0 0 0 0 p a g d 0 0 0 0 0 0 0 0 0 0 a A a a e 30 D a4 O iss P4 Jumper P3 Jumper LD mars RTS PA 2 2 ON E RST Load 2 00 0 0 000000000 0 0 0 0000 DOC0370A Figure 4 2 EIA 422 485 RS 422 485 Serial Communications Card Newer The EIA 422 485 RS 422 485 communications card includes LED indicators along the left hand side display the status of the RXD TXD and RTS signal control lines DTR DCD and CTS are unused LED indicators are detailed in Table 4 1 on page 4 3 The jumper P4 newer card or P3 older card applies to the EIA 422
91. S Remote Panel Mounting B 6 Figure B 6 Signal Hook Up for a Integral MVS TS tal AMO ace annsniesteeveeaestnsil EA B 7 Figure B 7 Signal Hook Up for a Remote MVS l stalla oi a B 9 Figure B 8 RTD Assembly Details 0 B 10 Figure C 1 Current Loop AO Source Module to AI Loop Module ohinsstiass soe stetaswid ha in Seoetas thease ia C 1 Figure C 2 Current Loop AO Source Module to AI Difterential Mod le siicrshens srno C 1 Figure C 3 Voltage Input AO Source Module to AI Diferential Module seis teaaddossndeenvetdandetaers C 2 Figure C 4 Current Loop AO Source Module to AMME aA aeneheaiecanioeanieasstans C 2 Figure C 5 Voltage Output AO Source to Voltmeter I A E A MEE A a nl E A EE A EA EE C 2 Figure C 6 DO Source Module to DI Isolated Module EEIE EE EEE TEA SE EE EET T C 3 Figure C 7 DO Isolated Module to DI Source Module E TEE A O ENEE C 3 Figure C 8 DO Source Module to PI Isolated Module E E E N cuca E E wa aes C 3 Figure C 9 DO Isolated Module to PI Source Module er A R C 4 Figure C 10 Potentiometer Input to AI Loop Module EAEE APEN TNE E E SEE S C 4 Figure C 11 Potentiometer Input to AI Differential MOU eae acneatahsiaatedt lunes banda tinade C 4 Figure C 12 Switch Input to DI Isolated Module C 5 Figure C 13 Switch Input to DI Source Module C 5 Figure C 14 Switch to PI Source Module C 6 Figure C 15 Switch to PI Isolated Module C 6 I PATA
92. SHOCK 1500 G 0 5 ms half sine per MIL Std 202 Method 213 Condition F WEIGHT 37 g 1 3 oz typical CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions are 15 mm D by 32 mm H by 43 mm W 0 6 in D by 1 265 in H by 1 690 in W not including pins ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D 3 7 7 Pulse Input Modules Source and Isolated Pulse Input Source Module Specifications FIELD WIRING TERMINALS A Not used B Pulse Input source voltage C Common INPUT Type Contact sense Source Voltage 11 to 30 V dc Range Inactive 0 to 0 5 mA Active 3 to 12 mA Source Current Determined by source voltage Vs loop resistance RI and scaling resistor Rs Vs 1 2 2K RI Rs 3 36 Input Output Modules POWER REQUIREMENTS Source Input 11 to 30 V dc 6 mA maximum from FloBoss power supply Module 4 9 to 5 1 V dc 1 mA maximum supplied by FloBoss INPUT ISOLATION Not isolated Terminal C tied to power supply common Rev Mar 05 FloBoss 407 Instruction Manual Pulse Input Isolated Module Specifications FIELD WIRING TERMINALS POWER REQUIREMENTS A Not used 4 9 to 5 1 V dc 2 mA maximum supplied by B Positive Pulse Input FloBoss
93. Scope This section describes the FloBoss 407 display that includes Liquid Crystal Display LCD and Keypad The LCD and Keypad allows you to access data and configuration parameters in the FloBoss 407 Flow Manager Topics covered in this section include J Section ag 5 2 Product Description 5 3 Keypad Functions g gt 5 4 Display of Parameters 5 5 Security 5 6 Troubleshooting and Repair 5 2 Product Description The display is a 2 line by 20 character Liquid Crystal Display LCD visible through the FloBoss 407 enclosure cover Refer to Figure 5 1 The temperature compensated display mounted on the processor board allows you to view point a parameters and related point data values on site without requiring an additional device such as a PC Figure 5 1 FloBoss 407 Display and Keypad 5 1 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual A membrane Keypad Figurg 5 2 with three rows of five keys allows you to interface with the flow computer and activate the various displays configured for the local system The Keypad provides you with on site parameter editing and monitoring capabilities The Keypad is mounted in the main door of the flow computer enclosure and has a gasket cover to protect it from the elements when not in use The Keypad communicates with the FloBoss and receives its power through the Keypad connector located on the processor board Each key on the Keypad can be used in three differen
94. Single ended voltage sense Current loop Loop Source 25 mA maximum from FloBoss with scaling resistor R1 power supply Vs 11 to 30 V dc Loop Current 0 to 25 mA maximum range Module 4 9to 5 1 V dc 6 mA maximum 4 5 to Actual range depends on scaling resistor used 5 5 V de 2 mA maximum supplied by FloBoss Voltage Sensing 0 to 5 V dc software ISOLATION configured Not isolated Terminal C tied to power supply Accuracy 0 1 of full scale at 20 to 30 C 68 to common 86 F 0 5 of full scale at 40 to 70 C 40 to 158 F Analog Input Differential Module Specifications FIELD WIRING TERMINALS INPUT CONTINUED A Not used Normal Mode Rejection 50 dB 60 Hz B Positive Analog Input Impedance Greater than 400 kQ without scaling C Negative Analog Input resistor INPUT POWER REQUIREMENTS Type Voltage sense Externally powered current 4 9 to 5 1 V dc 6 mA maximum 4 5 to 5 5 V de loop sensing with scaling resistor R1 2 mA maximum supplied by FloBoss Voltage 0 to 5 V dc software configured Accuracy 0 1 of full scale at 20 to 30 C 68 to 86 F 0 5 of full scale at 40 to 70 C 40 to 158 F INPUT ISOLATION Greater than 400 kQ input to power supply common 3 30 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual Analog Input Modules Loop and Differential Common Specifications SCALING RESISTOR 250 Q supplied for O to 20 mA full scale 100 Q for 0
95. TERMINAL A CONNECTION TO BE MADE FOR NORMALLY OPEN APPLICATIONS TERMINAL B IS COMMON TERMINAL C CONNECTION TO BE MADE FOR NORMALLY CLOSED APPLICATIONS Vo VOLTAGE FROM DISCRETE DEVICE 0 TO 30 VDC OR 0 TO 115 VAC 5 A MAX Figure 3 15 Discrete Output Relay Module Field Wiring 3 4 10 Pulse Input Source Module A schematic representation of the field wiring connections to the input circuit of the Pulse Input Source module is shown in Figure 3 16 CAUTION The Pulse Input Source module is designed to operate only with non powered discrete devices such as dry relay contacts or isolated solid state switches Use of the module with powered devices may cause improper operation or damage to occur The Pulse Input Source module provides a voltage across terminals B and C that is derived from internal voltage source V When a field device such as a set of relay contacts is connected across terminals B and C the opening and closing of the contacts causes current to either flow or not flow between V and ground at terminal C This interrupted or pulsed current flow is counted and accumulated by the PI Source module which provides the accumulated count to the FloBoss electronics upon request 3 13 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual A 10 ohms scaling resistor R1 is supplied by the factory and accommodates a source voltage V of 11 to 30 volts dc and a pulse source with a 50 Duty Cycle The source v
96. V START switch Switch S1 on Revision E or later allows the FloBoss to power up under low voltage conditions Normally the FloBoss will not start up below 12 5 volts This 1s a cut off feature designed to avoid draining down the power supply battery 1 Remove power from the FloBoss 2 Hold the LV START switch down during power up to initiate this startup 1 6 2 Operation Once startup is successful it is necessary to configure the FloBoss 407 to meet the requirements of the application The manual that comes with the configuration software describes the procedures for configuring the FloBoss and calibrating the I O Once the FloBoss is configured and calibrated it can be placed into operation Local configuration or monitoring of the FloBoss 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 1 6 2 1 Display and Keypad The Display and Keypad allow you to access data and configuration parameters in the FloBoss 407 while on site Refer to Section 5 Display and Keypad 1 11 General Information Rev Mar 05 FloBoss 407 Instruction Manual SECTION 2 FUNCTIONALITY WIRING BUILT IN I O WIRING THE FLOBOSS AND TROUBLESHOOTING 2 1 Scope This section provides information and specifications concerning the two main components of the FloBoss 407 the processor board the termination board wir
97. WV Oey cease cnet reasdnins see ne a anasesteuaiade cane 2 1 I AI as cots sos seeccireseedseachcutamemsdire sonst seesbadeeabes 2 26 MeS ON Sers nT a T 2 3 Flash Memo an a E E eee 2 3 Flash Memory Save Configuration 2 18 2 19 Rev Mar 05 FloBoss 407 Instruction Manual FOBOS eiiecatagsarnalagist antennae ieee eee 1 1 Flow Calculations IOSIS is Basses o en Ant 2 6 TII A GAng actie ei euate earettd sack eceet 2 6 ACTA oh octet ad taatactpat dyads e dyeaoeece 2 6 FOW COM a ARA 5 9 Flow Measurement eneurrrre ia n NE 2 5 FOW RIE unnan e a anea 5 5 5 8 5 9 Frequency Shift Keyed T E O ETA E A AN O P E E ene 4 5 FoTo A T ee eee 2 7 FORC 9 0 01 1 V a a a ene ener 2 1 IES S AEE E EE AA A E E E EE AN 2 5 2 8 G OND e e a R 4 9 Gid Impedanca a 1 6 2 12 CO ROG jig ex ccch ails asstae siaicas wl ast eeatea esas 1 6 2 12 Grounding Earth Ground icc sinks hussdextrostacdobesceeeaasede tenses 1 6 2 12 Ground WID 2 lt on cscuntaasncutactses oometemectsetwoteee 2 12 Wiring Requirement ccccessesessseesseseseeeeeees 1 6 Groups A B C and cree eee otis basen tcaa neh a teens 1 5 H HART Interface Module cccccccceeeeeeeeeeeeeeees 3 4 Troubleshooting 55 cashed cshacadoaanacectesdatanccobatdutias 3 27 WIRDE 5a rere neal ese a este A TRE 3 20 Hazardous Locations cccccccceeeeeeeeeeeeeeeeeeeeeeees 1 5 PE kere oerte ee eer emcee Seer emt nee earn tern ane 5 14 Highway Addressable Remote T
98. a FloBoss that is currently not in service For FloBoss units currently in service refer to the procedures in Section 4 6 Troubleshooting and Repair on page 4 20 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 4 1 Installing Communications Cards All communications cards install into the FloBoss 407 in the same manner To install a communications card proceed as follows 1 Loosen the captive screw that holds the door in place and open the door 2 Install the communications card onto the processor board located on the door Plug the card into its mating connectors J1 and J2 on the processor board and gently press until the connectors firmly seat 3 Install the retaining screw to secure the card Orient the card with the COM PORTS arrow pointing down Figure 4 6 shows the correct communications card orientation 4 For communications cards with an external telephone jack install the jack in the bracket mounted on the termination card at J1 Connect the jack cable to the board connector labeled P2 Figurel 4 6 shows the jack location 5 Ifyou are installing a modem c
99. alter or improve the designs or specifications of the products described herein il Rev Mar 05 FloBoss 407 Instruction Manual Section 1 General Information ccccccccccsscsscscccccsccscccccsccscccccsscsccccccscscccsceccscess 1 1 1 2 1 3 1 4 1 5 1 6 Table of Contents CO O M r eee AA E EA AEN EE E EEA l Manual On A E TEE T EE E E E E E A E l Product Overview ccccceccccsccccecccccceccececcecsceccecceecsceecscaecscaececsececseeecscaessesuscscescscessscsascnsasescacens Installation Guidelines 0aenonoenenensenenensesesereesesenerersesenersesesenererseserersesesenersesesenersestsenerereeneseneree Section 2 Functionality Wiring Built in I O Wiring the FloBoss and Troupli shoo niho sesen EE E E E E EE 2 1 22 29 2 4 29 2 6 Jal 3 2 3 3 3 4 3 5 3 6 3 7 Section 4 COMMUNICATIONS Car ds c cccccccccccccccccccccccsccccccccccccccccccccccccccsccsscccccces 4 1 4 2 43 4 4 4 5 4 6 4 7 OO IG cctv teres vt cee A E caine A E E A E E E E E savers i i e 0fe 1 epee D Tice PO e A E E E E E oaiae ol 0 8 eich 10 ra T E E T E TTET Connecting the FloBoss407 10 W 10 seereis re n i EE E Troupe noone aad REDI E cren ER E E ETE E E EEA EET FloBoss 407 SPec CAUNO Ses E E E S E E EEE EEEE indl Installation and Seesen EeNNN l Connecting the I O Modules to Wiring o icscscncecccnencotacsencensuenddeansenneasuoesdobansrenansunseeasenesteeaonsenences Pe E E E
100. ard set the jumpers on the card in the proper position as described in Table 4 2 hnd set the output attenuation level as described in Table 4 3 6 Close the door and fasten with the captive screw 7 Refer to Section 4 5 Connecting Communication Cards to Wiring on page 4 13 NOTE If you are installing a Dial up or Leased Line Modem Card it is recommended that you install a telephone style surge protector between the RJ11 jack and the outside line 4 8 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual PHONE JACK COMMUNICATIONS CARD COM2 O O a i te mera 0 i of 48 FJ A P O10 ag di O SS Ls TA IH IH ae O E e m a e a eer ae M S J R2GOG2G00000000009 D A C q 27 S J e DOC0208B aaa aS he O C ta Figure 4 6 Communications Card Location 4 4 2 Setting Modem Card Jumpers The Radio Modem and Leased Line Modem Communications Cards make use of jumpers to select certain operational modes It is
101. at 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 Softpoints A type of FloBoss point with generic parameters that can be configured to hold data as desired by the user SP Setpoint or Static Pressure SPI Slow Pulse Input SPK Speaker SRAM Static Random Access Memory Stores data as long as power is applied and typically backed up by a lithium battery SRBX Spontaneous Report by Exception In a FloBoss it always refers to Spontaneous RBX in which the FloBoss contacts the host to report an alarm condition 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 TXD Transmitted Data communications signal G 6 Glossary Rev Mar 05 FloBoss 407 Instruction Manual INDEX Backup Power for RAM ccceeceeeeeeeeeeeeeeeeeeteeeees 2 4 Numerical Backup Procedur Scaroni avn 2 18 After Installing Components ccccccccsceeeeees 2 19 1985 AGA3 Before Removing POoWe cccccccccccceeeeesseeeeees 2 18 Flow Calculations 0 0 2 6 TB a LAE E E A E theca at den 2 4 2 20 1992 AGA3 Bell and CCITT Standards 200 0 eeeeeeeeeeeeeneeees 4 6 Flow Calculation aorin aa a E 2 6 C
102. by 103 mm W by 135 mm L 1 in H by 4 05 in W by 5 3 in L WEIGHT 80 g 3 oz nominal APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual Radio Modem Specifications OPERATION Mode Full or half duplex direct connection to radio Data Rate Up to 1200 baud asynchronous software selectable Parity None odd or even software selectable Format Asynchronous 7 or 8 bit software selectable Modulation Phase coherent Frequency Shift Keyed FSK Carrier Frequencies Mark 1200 Hz 0 1 Space 2200 Hz 0 1 Input Impedance 20 kQ unbalanced Output Impedance 600 Q balanced RTS to Transmission Delay Configurable in 10 ms increments Sensitivity 35 dBm PTT Signal Isolated solid state switch LED Indicators TXD RXD DTR DCD CTS and RTS POWER REQUIREMENTS 4 75 to 5 25 V dc 0 11 W typical supplied by FloBoss ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity To 95 relative non condensing DIMENSIONS 25 mm H by 103 W mm by 135 mm L 1 in H by 4 05 in W by 5 3 in L WEIGHT 100 g 3 6 oz typical APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Leased Line Modem Specifications OPERATION Mode Full or half duplex on 2 wire or 4 wi
103. cale 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 Calibrate Midpoint 2 such as 50 of range to specify the middle calibration point between the Zero and Span endpoints Midpoint 2 should be the middle value magnitude between Midpoint 1 and Midpoint 3 Calibrate Midpoint 3 such as 75 of range to specify the high calibration point between the Zero and Span endpoints Midpoint 3 should be the high value magnitude above Midpoint 1 and Midpoint 2 29 Press 4 to select APP VALUE and press ENTER Calib Mid Point 1 2 3 ae ee a 30 Key in the lowest Mid point 1 input on the calibrator press App Value DATA PARRAS Cur Value l DATA 31 Press 4 to select SAVE and press ENTER to log the value to bypass SSS the Event Log and continue to the CALIB MORE POINTS ik display Exit 32 Repeat the procedure for Mid points 2 and 3 as required After saving Mid point 3 or selecting EXIT the program returns to SELECT METER INPUT Calibration Step 4 33 Press J to select EXIT from SELECT METER INPUT Save Calib Data Calibration Step 4 and press ENTER 6 34 The Save Calib Data display appears Yeo ee Press J to select YES and press ENTER to log the value to the Leccccns
104. cally come through I O modules installed on the FloBoss The flow calculation is in accordance with AGA Report No 7 2 2 4 Diagnostic Inputs Three diagnostic Analog Inputs monitor input power voltage T voltage and board temperature These values can be observed with ROCLINK configuration software or with the Local Display Panel The diagnostic Analog Inputs are T voltage Point Number E1 Power input voltage Point Number E2 Board temperature Point Number E5 2 2 5 Built in Inputs The on board built in field I O channels provide two Analog Inputs AIs One AI can be configured as a Pulse Input PI These I O channels are suitable for use as flow inputs including flow measurement in the Measurement Canada version of the FloBoss 407 Two plug in terminal blocks provide termination for the built in I O channels Jumper P4 on the termination board provides the input type selection for the AI PI channel With P4 set to PI the channel becomes a Pulse Input The Pulse Input can be connected as either a sourced or an isolated input An LED indicator PI IND shows when the field input to the Pulse Input channel is active 2 2 6 History Points A total of 50 ROCLINK for Windows or 200 ROCLINK 800 history points may be set up and accessed in the FloBoss 407 The first six or eight are pre configured for flow history on Meter Run 1 required for Electronic Flow Metering or Measurement EFM reporting The
105. cessories Instruction Manual Form A4637 The FloBoss has two communication ports built in a local operator interface Local Port and an EIA 232 RS 232 serial port COM1 A variety of optional plug in communication cards are available that allow you to add another communications channel COM2 EIA 232 RS 232 serial E A 422 485 RS 422 485 serial dial up modem radio modem or leased line modem communications 1 3 General Information Rev Mar 05 FloBoss 407 Instruction Manual The FloBoss 407 is housed in a National Electrical Manufacturer s Association NEMA 4X windowed enclosure that can mount on a wall or a 2 inch pipestand The enclosure which protects the electronics from physical damage and harsh environments is fabricated of die cast low copper aluminum alloy It consists of four pieces the body the electronics cover the Keypad cover and the lower cover Silicone rubber gaskets seal the FloBoss when the covers are closed All covers are secured by captive screws Note that for the Measurement Canada version of the FloBoss 407 the electronics cover and the lower cover are secured by special captive screws These screws have holes through the heads for adding security wire seals according to Measurement Industry Canada requirements For the standard version of the FloBoss 407 an optional padlock adapter can be added in the field This adapter is installed on the captive screw that secures the electronics cover With
106. ct them to your local sales representative or contact Emerson Process Management Flow Computer Division Marshalltown IA 50158 U S A x Houston TX 77065 U S A Pickering North Yorkshire UK Y018 7JA EMERSON Website www EmersonProcess com flow l 8 Index Rev Mar 05
107. cting Communication Cards to Wiring 4 6 Troubleshooting and Repair 4 7 Communications Card Specifications 4 2 Product Descriptions The communications cards provide communications between the FloBoss and a host system or external devices The communications card installs directly onto the processor board and activates the COM2 connector when installed The following cards are available EIA 232 RS 232 Serial Communications Card EJA 422 485 RS 422 485 Serial Communications Card e Radio Modem Communications Card Leased Line Modem Communications Card Dial Up Modem Communications Card NOTE Use a standard screwdriver with a slotted flat bladed 1 8 width tip when wiring all terminal blocks 4 1 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 2 1 EIA 232 RS 232 Serial Communications Card The EJA 232 RS 232 communications cards meet all EIA 232 RS 232 specifications for single ended asynchronous data transmission over distances of up to 15 24 meters 50 feet The EIA 232 RS 232 communications cards provide transmit receive and modem control signals Normally not all of the control signals are used for any single application Refer to Figure 4 1 Refer to Section 4 10 Initial Installation and Setup on page 4 10 and Section EIA 232 RS 232 Communications Card Wiring on page 4 14 30 00000000000 00000000000 ETETE s gt 8G0R848 awn PD o LED Indicators Ca
108. d J2 pull the card free from the processor board 6 To reinstall a communications card orient the card with the COM PORTS arrow pointing down Plug the card into its mating connectors and gently press until the connectors firmly seat Install the retaining screw to secure the card 7 Fora Dial up or Leased Line Modem Card connect the phone jack cable to card connector P2 If you are installing a replacement modem card be sure to set the jumpers on the card in the proper position Section 4 4 2 Setting Modem Card Jumpers on page 4 11 and to set the output attenuation level Section 4 4 3 Setting Modem Card Attenuation Levels on page 4 12 9 Close the door and fasten the captive retaining screw 4 18 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 10 Reconnect power to the FloBoss by plugging in the power terminal connector 11 Using ROCLINK configuration software check the configuration data including ROC Displays and FSTs and load or modify them as required 12 Load and start any user programs as needed 13 Verify that the FloBoss performs as required 14 If you changed the configuration save the current configuration data to memory by selecting ROC gt Flags gt Write to EEPROM or Flash Memory Save Configuration as instructed in the applicable ROCLINK configuration software or ROCLINK configuration software 800 configuration software user manual 15 If you changed the configuration incl
109. d count to the FloBoss electronics upon request A 10 ohms scaling resistor R1 is supplied by the factory which accommodates a field device with pulse amplitude V of 11 to 30 volts dc and a Duty Cycle of 50 However it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to amplitudes greater than 30 volts dc The formula for determining the value of R1 displays in Figure 3 17 For optimum efficiency R1 should be scaled for a loop current I of 5 milliamps 3 14 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual SELF POWERED PULSE DEVICE TO OPTIMIZE SCALING RESISTOR R1 Va 1 R1 Ry 2 2K R1 R 2 2K LOOP RESISTANCE 3 4K OHMS LOOP CURRENT 5 mA TYPICAL Ry RESISTANCE OF FIELD WIRING Vo VOLTAGE FROM PULSE DEVICE 11 TO 30 VDC DOC0149A Figure 3 17 Pulse Input Isolated Module Field Wiring 3 4 12 Slow Pulse Input Source Module A schematic representation of the field wiring connections to the input circuit of the Slow Pulse Input Source SPI module 1s shown in Figure 3 18 CAUTION The Slow Pulse Input source module is designed to operate only with non powered devices such as dry relay contacts or isolated solid state switches Use of the module with powered devices may cause improper operation or damage to occur The Slow Pulse Input Source module operates by providing a voltage across terminals
110. d up to 1220 m 4000 ft from the FloBoss 407 unit Terminals A and B for data and for power Polling Period 1 sec max I O MODULES OPTIONAL Four slots provided for optional I O modules Any type and combination of I O modules can be used FRONT PANEL USER INTERFACE Display 2 line by 20 character LCD Overall size is 19 mm by 82 6 mm 0 75 by 3 25 inches Keypad 15 multi function membrane keys Keys allow numerical entries Rev Mar 05 FloBoss 407 Instruction Manual FloBoss 407 Specifications Continued ENVIRONMENTAL ENCLOSURE Operating Temperature 40 to 75 C 40 to 167 F Die cast low copper aluminum alloy with three 4 14 excluding display which is 20 to 70 C 4 to inch NPT holes in bottom Single piece gasketed 158 F doors Coated with ANSI 61 gray polyurethane Storage Temperature 50 to 85 C 58 to 185 F paint Meets CSA Type 4X rating Operating Humidity To 95 non condensing WEIGHT Vibration Less than 0 1 effect on overall accu FloBoss 407 3 2 kg 7 lb racy when tested to SAMA PMC 31 1 Section 5 3 With Integral MVS 7 7 kg 17 Ib Condition 3 EMC Emissions Meets FCC Part 15 Class Aand APPROVALS EN 50022 Level A in accordance with EN50081 2 Standard Version Approved by CSA for 1993 hazardous locations Class I Division 2 Groups A B C and D T4 C US Measurement Canada Version Approved by Measurement Industry Canada for gas cust
111. d with the Analog Input configuration 3 17 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual L2 NOTE The RTD module input can be calibrated before installing it in the field when short wire runs will be used but if the RTD module is used as a temperature input to a flow calculation then the RTD should be calibrated at the same time as the pressure inputs DECADE BOX A4464821 Figure 3 21 Calibration Setup Table 3 1 Calibration Resistance Values ALPHA 50 C 58 F 100 C 212 F 0 00385 80 31 Ohms 138 50 Ohms 0 00392 79 96 Ohms 139 16 Ohms NOTE Resistance values for RTD probes with other alpha values can be found in the temperature to resistance conversion table for that probe 1 Connect the decade box as shown in Figure 3 21 2 Set the decade box to the 50 C 58 F resistance value corresponding to the RTD alpha value in Table 3 1 3 Enter the value displayed for Raw A D Input as the value for Adjusted A D 0 using the Analog Inputs configuration screen for the RTD input Refer to ROCLINK gt Configure gt I O gt AI Points Advanced tab Set the decade box to the 100 C 212 F resistance value given in Tabld 3 1 5 Enter the value displayed for Raw A D Input as the value for Adjusted A D 100 using the Analog Inputs Advanced configuration screen for the RTD input 6 Enter 50 C S8 F for Low Reading EU using the Analog Inputs confi
112. dule to PI Isolated Module C 3 I O Simulation Rev Mar 05 FloBoss 407 Instruction Manual e Cl ie how to use a Discrete Output Isolated module simulate a relay contact to a Pulse Input Source module DOC0184A Figure C 9 DO Isolated Module to PI Source Module C 5 Potentiometer to Analog Inputs Figure shows how to use a potentiometer to simulate a transmitter feeding a 4 to 20 milliamps current signal to an Analog Input Loop module R2 Vs 12 VDC R2 390 OHMS DOC0185A Vs 24 VDC R2 1K OHMS Figure C 10 Potentiometer Input to AI Loop Module Figur C 11 shows how to use a potentiometer and power source to simulate a transmitter feeding a 4 to 20 milliamps current signal to an Analog Input Differential module R1 OPEN Al DIFF AUX PWR OUT 1 AUX PWR 24 VDC R2 20K OHMS Figure C 11 Potentiometer Input to AI Differential Module C 4 I O Simulation Rev Mar 05 FloBoss 407 Instruction Manual C 6 Switch to Discrete Inputs Figure C 12 shows how to use a switch and power source to simulate a device transmitting a discrete voltage level to a Discrete Input Isolated module O SWITCH AUX PWR OUT 1 DOC0187A Figure C 12 Switch Input to DI Isolated Module Figure IC 13 shows how to use a switch to simulate relay contacts to a Discrete Input Source module SWITCH DOC0188A Figure C 13 Switch Input to DI Source Module C 5 I O Simulation Rev Mar 05 FloBoss 407 Instruction
113. e AI Source module normally monitors the voltage output of low voltage transmitters but it can be used for monitoring loop current The module provides source power at terminal A for the loop The Analog Input Source module operates by measuring the voltage across terminals B and C The module accepts a maximum input voltage of 5 volts dc which is the upper operating limit of the module A schematic representation of the field wiring nf Th to the input circuit of the Analog Input Figure 3 7 shows a typical voltage signal input Terminal B 1s the positive signal input and terminal C is the negative signal input These terminals accept a voltage signal in the 0 to 5 volts range Since terminal C connects to common the Analog Input can only be a single ended input Make sure no scaling resistor is installed when wiring the module for a voltage signal Al SRC 10Vdc V SRCIl o ROC POWERED Figure 3 7 AI Source Module Field Wiring for Voltage Devices The AI Source module can be used for monitoring loop current as shown in Figure 3 8 For current loop monitoring scaling resistor R1 generates a voltage across terminals B and C that is proportional to the loop current I 3 8 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual For example a 250 ohms scaling resistor would accommodate either 0 to 20 milliamps or 4 to 20 milliamps current loop transmitters the transmitter must be able to operate on 10 volts dc o
114. e amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SHOCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions 15 mm D by 32 H mm by 43 mm W 0 60 in D by 1 27 in H by 1 69 in W not including pins WEIGHT 37 g 1 3 oz ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual 3 10 Resistance Temperature Detector RTD Input Module Resistance Temperature Detector RTD Input Module Specifications FIELD WIRING TERMINALS A RTD Red Input B RTD White Input C RTD White Input 3 or 4 wire INPUT RTD Type 100 Q platinum with a temperature coefficient of 0 3850 0 3902 0 3916 0 3923 or 0 3926 Q C Temperature Range Fixed at 50 to 100 C 58 to 212 F Excitation Current 0 8 mA Impedance 4 MQ minimum Filter Single pole low pass 4 Hz corner frequency RESOLUTION 12 bits ACCURACY 0 1 of Input Temp Range at Operating Temp from 23 to 27 C 73 to 81 F 0 45 of Input Temp Range at Operating Temp from 0 to 70 C 32 to 158 F 0 8 of Input Temp Range at Operating Temp from
115. e output Status set to On approximately 1 5 volts dc less than the system voltage V 1 5 should be measured across terminals A and B 4 If these values are not measured check to see if the module fuse is open verify the module is wired correctly and verify the load current requirement does not exceed the 57 milliamps current limit value of the module 3 5 6 Discrete Output Isolated Module Equipment Required Multimeter Personal Computer running ROCLINK configuration software 1 Place the Discrete Output in manual mode Scanning Disabled using ROCLINK configuration software 2 Set the output Status to Off and measure the resistance across terminals A and B No continuity should be indicated 3 Set the output Status to On and measure the resistance across terminals A and B A reading of 15 kilohms or less should be obtained 3 24 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 5 7 Discrete Output Relay Module Equipment Required Multimeter Personal Computer running ROCLINK configuration software 1 Place the Discrete Output in manual mode Scanning Disabled using ROCLINK configuration software 2 Set the output Status to Off and measure the resistance across terminals B and C A reading of 0 ohms should be obtained 3 Measure the resistance across terminals A and B No continuity should be indicated 4 Set the output Status to On and measure the resistance across t
116. e pressure Calibration Step 4 device remember to add in the actual atmospheric pressure such as 300 14 73 Static Pressure for Downstream is calibrated the same as for Upstream B 12 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual A different display appears depending upon which input you select DP Reading Calibrate Calibrate the currently selected input Calibrate Exit Press EXIT to return to Step 4 and select another input Exit See SS Zero Shift Effect Set the working pressure for a DP Reading ETET SS SEE Verify Verify the current setting of an input 12 Press 4 to select ZERO SHIFT EFFECT and press ENTER to set the DP Reading 13 Press 4 to select ZERO SHIFT EFFECT and press ENTER to set the DP Reading 14 Key in the working pressure let it stabilize 15 Press 4 to select SAVE and press ENTER Save stores the Zero Shift Data logs the event and returns to Save Calibration Step 5 a Exit discards the data and returns to Calibration Step 5 Adjust Zero Shift 16 Press 4 to select VERIFY in Calibration Step 5 to verify the selected input and press ENTER If the run has been calibrated before verify the calibration at a point in the operating range such as at 0 25 50 75 or 100 percent and Verify Calibration set up the input with the desired applied test value App Value Aao ae a TDATA App Value Applied test value that y
117. e wire or metallic conduit as long as the circuit provides a low impedance ground path With stand alone units a grounding terminal on the outside of the housing allows you to ground the FloBoss 407 directly to an earth ground 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 Lightning Protection Modules LPM are available to provide additional lightning protection for 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 2 12 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 4 2 Connecting Main Power Wiring Equipment Required Small flat blade screwdriver It is important that good wiring practice be used when sizing routing and connecting power wiring All wiring must conform to state local and NEC codes The terminal blocks can accommodate up to 12 AWG wire Use 18 AWG wire or larger for all power wiring Connect power to the FloBoss 407 through the plug in PWR terminal block on the termination board Connect the DC power source to the and terminals Make sure the polarity is correct Figure 2 5 shows the location of the power indicator and the power wiring terminal block POWER INDICATOR POWER TER
118. easures either output voltage Vo or loop current I from externally powered devices only The module operates by measuring the voltage between field wiring terminals B and C The module input is semi isolated from the FloBoss power supply and signal commons When connecting voltage devices the 5 volts input voltage limit of the module must not be exceeded If the output of the field device is in the range of 0 to 5 volts dc do not use a scaling resistor ensure that the supplied 250 ohms scaling resistor is removed Refer to Figure 3 4 for connecting field devices with outputs of 5 volts dc or less The voltage cannot be negative The A to D converter divides the 0 to 5 volts signal into 4095 counts and the last 95 counts being 4001 to 4095 represent overvoltage If you use a 0 to 1 volt input to the converter the resolution is reduced as there are only 800 counts with which to work For field devices with output voltages that exceed 5 volts dc two scaling resistors R1 and R2 are required not supplied Figure 3 5 khows how to connect field devices with outputs exceeding 5 volts dc and where to install scaling resistors at least 1 1 8 watts The equation for determining values of scaling resistors R1 and R2 is given in Figure 3 5 For example if Vo 10 volts and R1 250 ohms then R2 250 ohms Note that R1 must be less than 4 5 kilohms en Al DIFF SELF POWERED ANALOG VOLTAGE DEVICE DOC0155A Vo VOLTAGE FROM ANAL
119. ec 8 ee ee ee ee ee 5 14 SVSCCIM A OLA GC eaa re an ATE 1 10 T MEV OMA EESE E retort release deat eee 2 4 Table 1 1 Power Consumption of the FloBoss 407 and Powered WC VICES esech tose tins namie a ee sedaioeunciceseaeie 1 8 Table 1 2 Power Consumption of the I O Modules seis aa aed A E AA rec teste aa iat crete T alee eae 1 9 Table 2 1 FloBoss 407 Memory Map 00 2 3 Table 2 2 Overload Protection Devices 2 8 Table 2 3 COM Port Signals eeceeeeeeeeee 2 16 Table 2 4 Indicator Functions ccccccceeeeeeeee 2 18 Table 3 1 Calibration Resistance Values 3 18 Table 3 2 Analog Input Module Typical Configuration E UE T EEE AREE EA EET eet 3 22 Table 4 1 Communications Cards LED Indicators E E E A E E AA 4 3 Table 4 2 Jumper Positions for the Leased Line and R dio Vlodem Card essee 4 9 Table 4 3 Leased Line and Radio Modem Card Attenuation Levels cccccccccccccccceceeeeeeeeeeeeeeeeeeees 4 10 Table 4 4 FloBoss 407 Communications Signals a iasaee ead a hats ant eee eee 4 11 Table 5 1 FloBoss 407 Keypad Functions 5 3 Table 5 2 Definition of the Keypad Functions 5 5 Table 5 3 Value Shown on Display 00000000000000 5 9 Tempra E era a 2 6 Rev Mar 05 FloBoss 407 Instruction Manual Termination Board TJS CHIP UON oni oie eee 2 4 FR CG a Seri an ot eee te eae eo les 2 25 Totaling Power Requirements sseeeeeeeees
120. ected from the Keypad The display consists of a 2 line by 20 character LCD display The list of parameters displayed is selected by pressing a key such as 1 0 SUMMARY After pressing the key a predefined list of parameters starts displaying one after another with a three second pause between parameters Figurd 5 4 hows the format of all displays except for those selected with the ALARMS key USER LIST keys MIN MAX key the MINUTE HIST HOUR HIST and DAY HIST keys and the CALIBRATE key Refer to the ROC FloBoss Accessories Instruction Manual Form A4637 for details on the CALIBRATE key displays The other displays that vary from the format shown in Figure 5 4 are next aoe UBC ef js efre jo ETT Figure 5 4 General Display Format On the general display the point tag displays in the first ten characters of the top line of the display and the value of the parameter displays on the remainder of the top line The bottom line has an associated descriptor To advance to another point press the ALT key and then NEXT SET The Normal and ALT Mode columns in Table 5 2 lists the parameters normally displayed when a function is selected with the Keypad liO 5 4 1 1 0 Summary SUMMARY Press the I O SUMMARY key to display a list of all configured I O points a Table 5 3 lists the value type parameter shown on the I O Summary display for the WO DETAIL various point types used by the FloBoss 407 5 8 Display and Keypad Rev Mar 05 FloBos
121. ent The following modules are available Analog Input AI Loop Analog Input AI Differential Analog Input AI Source Analog Output AO Source Discrete Input DI Source Discrete Input DI Isolated Discrete Output DO Source Discrete Output DO Isolated Discrete Output DO Relay Pulse Input PI Source Pulse Input PI Isolated Slow Pulse Input SPI Source Slow Pulse Input SPI Isolated Low Level Pulse Input LLPI Resistance Temperature Detector RTD Input Highway Addressable Remote Transducer HART Interface gt OH oo o DO Below each I O module socket is a plug in terminal block for field wiring connections The plug in terminal blocks permit removal and replacement of the modules without the need to disconnect field wiring I O wiring terminal blocks accept up to 12 gauge American Wire Gauge AWG solid or stranded copper wire Figur shows a typical I O module NOTE Use a standard screwdriver with a slotted flat bladed 1 8 width tip when wiring all terminal blocks 3 1 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual STATIC SENSITIVE DOC0034C Figure 3 1 Typical I O Module 3 2 1 Analog Input Loop and Differential Modules The Analog Input Loop AI Loop and Analog Input Differential AI Differential modules are used for monitoring current loop and voltage output devices Each AI module uses a scaling resistor for scaling loop current to achieve the proper input
122. er operation or damage to occur The Discrete Output Source module provides a switched voltage across terminals B and C that is derived from internal voltage source V A field device such as a relay coil is energized when the FloBoss electronics provides a voltage at terminals B and C When V is switched off by the FloBoss electronics the field device is no longer energized 3 11 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual CAUTION When using the Discrete Output Source module to drive an inductive load such as a relay coil a suppression diode should be placed across the input terminals to the load This protects the module from the reverse Electro Motive Force EMF spike generated when the inductive load is switched off ROC POWERED DISCRETE DEVICE DOC0145A Figure 3 13 Discrete Output Source Module Field Wiring 3 4 8 Discrete Output Isolated Module A schematic representation of the field wiring connections to the output circuit of the Discrete Output Isolated module is shown in Figure 3 14 NOTE The Discrete Output Isolated module is designed to operate only with discrete devices having their own power source The module is inoperative with non powered devices The Discrete Output Isolated module operates by providing a low or high output resistance to a field device When the field device provides a voltage across terminals A and B of the module current either flows or is switched
123. erminals B and C No continuity should be indicated 5 Measure the resistance across terminals A and B A reading of 0 ohms should be obtained 3 5 8 Pulse Input Source and Isolated Modules Equipment Required Pulse Generator Voltage Generator Frequency Counter Jumper wire For both types of modules there are two methods of testing Testing Pulse Input High Speed Operation on page 3 28 Testing Pulse Input Low Speed Operation on page 3 28 NOTE When checking the operation of the Pulse Input Source and Isolated modules ensure the scan rate for the Pulse Input is once every 6 5 seconds or less as set by ROCLINK configuration software 3 5 8 1 Testing Pulse Input High Speed Operation To verify high speed operation 1 Connect a pulse generator having sufficient output to drive the module to terminals B and C 2 Connect a frequency counter across terminals B and C 3 Set the pulse generator to a value equal to or less than 10 kilohertz 4 Set the frequency counter to count pulses 5 Verify the count read by the counter and the total accumulated count Accumulated Pulses read by the FloBoss are the same using ROCLINK configuration software 3 5 8 2 Testing Pulse Input Low Speed Operation To verify low speed operation of the PI Source module 1 Alternately jumper across terminals B and C 2 The module LED should cycle on and off and the total accumulated count Accumulated Pulses should increase 3 25 Input Out
124. es Operational problems will occur if you do not reconfigure the FloBoss 3 6 2 Removing and Installing an I O Module Use the following procedure to remove install an I O module with the FloBoss power off The procedure is performed using ROCLINK configuration software CAUTION There is a possibility of losing the FloBoss configuration and historical data held in RAM while performing the following procedure As a precaution save the current configuration and historical data to permanent memory as instructed in Section 2 T roubleshooting and Repair CAUTION Change components only in an area known to be non hazardous CAUTION Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations CAUTION During this procedure all power will be removed from the FloBoss and devices powered by the FloBoss Ensure that all connected input devices output devices and processes remain in a safe state when power is removed from the FloBoss and when power is restored to the FloBoss 1 Perform a RAM backup as in Section 2 Troubleshooting and Repair 2 Disconnect the input power by unplugging the 5 terminal connector 3 Perform one of the following steps depending on whether the module is to be removed or installed Ifremoving the module loosen the module retaining screw and remove the module
125. es to the ground lead In the event of an I O signal failure verify the signal is not interrupted by the LPM Proceed to the troubleshooting and repair procedures for I O in previous sections of this manual Before removing an LPM make sure all devices and processes remain in a safe state Remove the LPM and disconnect the field wiring Remove any range resistors from the LPM With a digital multimeter verify continuity through each connector socket to the corresponding field wiring terminal If there is no continuity replace the LPM With a digital multimeter check each of the input terminals for continuity to the ground lead If the test shows continuity to the ground lead replace the LPM A 3 Lightning Protection Module Rev Mar 05 FloBoss 407 Instruction Manual A 5 Lightning Protection Module Specifications The following specifications are for the LPM Lightning Protection Module Specifications ELECTRICAL Series Resistance 10 Q from input to output each terminal DC Clamping Voltage 72 to 108 V dc 100 V ms Impulse Clamping Voltage 500 V maximum Clamping Release Voltage 52 V minimum 10 KV us Impulse Clamping Voltage 900 V maximum Surge Life Module can withstand 300 surges of 10 to 1000 us duration at 500 A minimum Insulation Resistance 10 000 MQ minimum Capacitance 1 0 pF maximum 1 MHz each terminal CASE Material ABS polycarbonate thermoplastic Dimensions 17 mm H by 21 mm W by 40 m
126. essential that these jumpers be in their proper position for correct operation of the modem Table 4 2 shows the operating modes and the associated jumper positions for the cards The Leased Line Modem card 1s set by default for 2 wire operation To use it for 4 wire operation jumpers P3 P4 and P5 must be placed in the positions indicated in Tabl 4 2 The Radio Modem card uses jumper P6 to enable power control for keying up a radio The jumper either grounds or isolates the push to talk PTT return line which is used to key up a radio to transmit Jumper P6 has a default setting of GND ground but it can be set to ISO isolated to achieve a floating PTT return if the radio circuitry requires it Table 4 2 Jumper Positions for the Leased Line and Radio Modem Cards Leased Line Modem Jumpers Mode Ratio Modem Jumper _ oe E PTT Grounded default GND PT Isolated so 4 9 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 4 3 Setting Modem Card Attenuation Levels For the Radio Modem and Leased Line Modem Communications Cards the output level is set by default to 0 dB This level can be reduced to better match the modem output to the line or radio The adjustment is made by plugging a resistor into the card at the location labeled R2 rabid 4 3 fis resistor values and the amount of attenuation they provide Table 4 3 Leased Line and Radio Modem Card Attenuation Levels dB Oh
127. eter run Select Meter Run Press EXIT to stop calibration 5 Press ENTER to advance to the Freeze Values Menu Freeze stops the values of the Differential Pressure Low Differential Freeze Values Menu Pressure Static Pressure and Temperature from being updated during verification or calibration This effectively freezes the Calibration Step 2 values used in ongoing processing such as history logging while calibration is being performed 6 Add the desired Freeze Values 7 Press 4 to select an input DP READING PRESS READING TAG OF METER DATA TEMP READING and press ENTER Key in the Freeze Value and press ENTER 9 Repeat for each input 10 Press 4 to select FREEZE THE METER and press ENTER to oe E freeze all inputs at their current or entered values L___ Press EXIT to return to Calibration Step l e 11 Press 4 to select an input DP READING PRESS READING Select Meter Input TEMP READING for calibration and press ENTER DP Reading a DP Reading When the sensor is configured for Downstream ee ee es a sn y Press Reading operation apply the calibrator pressure to the low labeled L side a aaa of the sensor Enter the value as positive even though the Live Temp Reading Reading is a negative value The software automatically lExit ooo compensates SA A i Press Reading For Static Pressure on an absolut
128. face Module 3 5 Troubleshooting and Repair Use troubleshooting and repair to identify and replace faulty modules Faulty modules must be returned to your local sales representative for repair or replacement If an I O point does not function correctly first determine if the problem is with the field device or the I O module as follows Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations 1 Isolate the field device from the FloBoss by disconnecting it at the I O module terminal block 2 Connect the FloBoss to a computer running ROCLINK configuration software 3 Perform the appropriate test procedure described in the following sections A module suspected of being faulty should be checked for a short circuit between its input or output terminals and the ground screw Ifa terminal not directly connected to ground reads zero 0 when measured with an ohmmeter the module is defective and must be replaced 3 21 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 5 1 Analog Input Modules Equipment Required Multimeter To determine if an Analog Input module is operating properly its configuration must first be known Table 3 2 Shows typical configuration values for an Analog Input Table 3 2 Analog Input Module Typical Configuration Values Corresponds To Adjusted A D 0
129. field devices ROC POWERED LOOP DEVICE DOC0158A Modified REMOVE RESISTOR R1 WHEN LOOP RESISTANCE IS LESS THAN 100 OHMS 30 mA MAX Figure 3 9 Analog Output Source Module Field Wiring for Current Loop Devices 3 9 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual ROC POWERED VOLTAGE DEVICE DOC0159A Vo OUTPUT VOLTAGE FROM MODULE 0 TO 5 VDC 5 mA Figure 3 10 Analog Output Source Module Field Wiring for Voltage Devices 3 4 5 Discrete Input Source Module A schematic representation of the field wiring connections to the input circuit of the Discrete Input Source module displays in Figure 3 11 CAUTION The Discrete Input Source module is designed to operate only with non powered discrete devices such as dry relay contacts or isolated solid state switches Use of the module with powered devices may cause improper operation or damage The Discrete Input Source module operates by providing a voltage across terminals B and C that is derived from internal voltage source V When a field device such as a set of relay contacts is connected across terminals B and C the closing of the contacts completes a circuit which causes a flow of current between V and ground at terminal C This current flow is sensed by the DI module which signals the FloBoss electronics that the relay contacts have closed When the contacts open current flow is interrupted and the DI module signals the FloBoss electr
130. guration screen Refer to ROCLINK gt Configure gt I O gt AI Points General tab 7 Enter 100 C 212 F for the High Reading EU using the Analog Inputs configuration screen 8 Click Apply to save the changes 3 18 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 4 15 2 Connecting RTD Module Field Wiring The RTD sensor connects to the RTD module with ordinary copper wire To avoid a loss in accuracy sensor wires should be equal in length of the same material and the same gauge To avoid possible damage to the RTD module from induced voltages sensor wires should be kept as short as possible This is typically 3 35 meters 100 feet or less A schematic representation of the field wiring connections to the input circuit of the RTD input module displays in Figure 3 22 Figure 3 23 Figurd 3 241 and Figure 3 25 25 Two wire RTDs are connected to module terminals A and B Terminal B must be connected to terminal C as shown in Figurg 3 22 RTD ROC POWERED 2 WIRE 100 OHM RTD PROBE DOC4007A Modified Figure 3 22 RTD Input Module Field Wiring for Two Wire RTDs Three wire RTDs have an active element loop and a compensation loop The active element loop connects across terminals A and B The compensation loop connects across B and C The compensation loop helps increase the accuracy of the temperature measurement by allowing the RTD module to compensate for the resistance of hookup wire used bet
131. gure your data NOTE For Measurement Canada units maintenance and resealing of the FloBoss must be performed by authorized personnel only Ensure all input devices output devices and processes remain in a Safe state upon restoring power An unsafe state could result in property damage NOTE Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 or the ROCLINK 800 Configuration Software User Manual Form A6121 for detailed instructions concerning the following procedures 1 Connect the PWR terminal block to restore power NOTE Due to a cut out feature designed to avoid draining the power supply battery the FloBoss normally requires a minimum of 12 5 volts to start up However this feature can be bypassed by depressing the LV START switch while applying power 2 Using the configuration software check the configuration data including ROC Displays and FSTs If the configuration contained in RAM was lost or corrupted the configuration contained in flash memory will automatically be used 3 Load or modify the configuration and FSTs as required 4 Load and start any user programs as needed Reload user programs from their original disk files 5 Verify the FloBoss performs as required 6 If you changed the configuration save the current configuration data to permanent configuration memory by selecting ROC gt Flags gt Write to EEPROM or Flash Memory Save Configuration 7 Save the FSTs t
132. h a 12 volts dc energizing coil and the other with a 24 volts dc energizing coil The DO Relay provides an LED that lights when the input 1s active and functions supported by the module include Latched Discrete Output Toggle Discrete Output Timed Duration Output TDO and TDO Toggle 3 2 7 Pulse Input Source and Isolated Modules The Pulse Input Source PI Source and Pulse Input Isolated PI Isolated modules count pulses from pulse generating devices Each module can accommodate one Pulse Input Both types of modules provide an LED that lights when the input is active Both types of modules use a scaling resistor for scaling the input range Input pulses are counted by a 16 bit counter capable of storing up to 6 5 seconds of pulse counts for a 10 kilohertz input signal Functions supported by both modules include slow counter input slow rate input fast counter input and fast rate input NOTE At the maximum input frequency of 10 kilohertz the input pulses must not exceed 6 5 seconds of pulse counts The PI module limit is 20 seconds of pulse counts at 3 kilohertz maximum input frequency The PI Source module provides a source voltage for dry relay contacts or for an open collector solid state switch The PI Isolated module accepts an external voltage from a powered device and provides electrical isolation from the FloBoss power supplies 3 3 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 2 8 Slow Pulse
133. h field input or output An LPM can be used with any type of input or output as long as the normal operating range of the input or output is less than the clamping release voltage of the LPM therefore the LPM cannot be used with a 120 volts ac signal on a DO Relay Module The LPM is most often used with Analog and Pulse Inputs The LPM has little effect with an RTD module however the LPM protects the I O rack and other modules A 1 Lightning Protection Module Rev Mar 05 FloBoss 407 Instruction Manual A 2 Initial Installation The LPM plugs into any of the field terminal block sockets located on the termination board To add an LPM to protect a built in analog I O channel or an I O module perform the following steps Refer to AAAA ZAA 1 0 Wiring Connect green wire to enclosure ground bar or ground lug LPM407 Figure A 2 Typical Lighting Protection Module Installation Do not use the Lightning Protection Module cannot be used with a 120 volts ac signal on a DO Relay Module ANK AUO If you are installing an LPM on a FloBoss currently in service and there is a field device connected to the I O channel that will receive the LPM make sure the field device will not be left in an undesirable state when it is disconnected from the FloBoss 1 Unplug the field wiring termination block from the socket of the channel for which the LPM is going to be installed A 2 Lightning Protection Module Rev Mar 05 FloBoss 407 Inst
134. he Termination Board on page 2 28 A positive result on the above tests would show that the input is operational Check the field wiring and transmitters for a fault 2 23 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 5 13 Replacing the Processor Board Equipment Required Hex nut driver PC with ROCLINK configuration software installed To replace the FloBoss processor board NOTE For Measurement Canada units maintenance and resealing of the FloBoss must be performed by authorized personnel only When installing devices in a hazardous area make sure each device is labeled for use in such areas Procedures involving switching power on or off or procedures for installing or removing any wiring or components must be performed only when the area is known to be non hazardous Performance of these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working with the FloBoss use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap During this procedure all power will be removed from the FloBoss and devices powered by the FloBoss Ensure 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 1 Perform the RAM backup procedure Refer to Sect
135. he I O Modules to Wiring Each I O module electrically connects to field wiring by a separate plug in terminal block In addition the FloBoss enclosures provide a ground bus bar for terminating the sheath on shielded wiring The following paragraphs provide information on wiring field devices to each type of I O module I O wiring terminal blocks accept up to 12 gauge AWG solid or stranded copper wire CAUTION The sheath surrounding shielded wiring should never be connected to a signal ground terminal or to the common terminal of an I O module Doing so makes the I O module susceptible to static discharge which can permanently damage the module Connect the shielded wiring sheath to a suitable earth ground only 3 5 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 4 1 Analog Input Loop Module The Analog Input Loop module monitors either loop current or output voltage from field devices The module provides source power at terminal A for the loop The AI Loop module operates by measuring the voltage at terminals B and C For current loop monitoring scaling resistor R1 generates a voltage across terminals B and C that is proportional to the loop current I A 250 ohms scaling resistor R1 is supplied by the factory 0 1 1 8 watts to accommodate either 0 to 20 milliamps or 4 to 20 milliamps current loop transmitters This translates to a maximum operating input voltage of 5 volts dc which is the upper limit of the module
136. ications port used for host communications Configuration Refers either to the process of setting up the software for a given system or the result of performing this process The configuration activity includes editing the database building schematic displays and reports and defining user calculations Typically the software setup of a device that can often be defined and changed Can also mean the hardware assembly scheme CPU Central Processing Unit CRC Cyclical Redundancy Check 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 G 1 Glossary Rev Mar 05 FloBoss 407 Instruction Manual DCD Data Carrier Detect modem communications signal Also Discrete Control Device A discrete control device energizes a set of Discrete Outputs for a given setpoint and matches the desired result against a set of Discrete Inputs 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 as 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 Distinct or non
137. icator functions When lit the POWER LED indicates that power is applied to the FloBoss 407 The STATUS LED on the processor board gives a first level indication of the operation of the FloBoss After the power is switched on the STATUS indicator should come on and remain on to indicate normal operation Ifthe STATUS indicator does not remain on check Table 2 4 for possible causes The PI LED located on the termination board shows the state of the Pulse Input channel When the LED is on the PI channel is active PULSE INPUT INDICATOR LV START SWITCH POWER INDICATOR BE J E a E O m g o m 292000 odlooaaooooo a aa aE E x aa o err a6 QOS ooog ooo 222 sooloa oo i z i Q DOC0207A mod STATUS INDICATOR Figure 2 11 FloBoss 407 Indicator Locations 2 17 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 In
138. ing built in inputs main power wiring and troubleshooting For options refer to the remaining sections of this manual Topics covered in this section are Section 2 2 Product Description 2 3 Installing the FloBoss 407 2 4 Connecting the FloBoss 407 to Wiring 2 5 Troubleshooting and Repair 2 6 FloBoss 407 Specifications 2 2 Product Description This section describes the functionality of the FloBoss 407 as well as its processor and termination boards The processor board has the microprocessor memory components the Keypad display interfaces and the connectors for mounting the communications board The termination board has the power supply circuitry the communications ports I O ports and the on board monitoring circuitry Most functions are determined by its firmware and are programmed by the factory into flash memory The features and applications provided by the firmware which must be configured by using ROCLINK configuration software are Either 1985 or 1992 American Gas Association AGA flow calculations for an orifice meter plus AGA7 flow calculations for a turbine meter Archival of data for up to 50 history points Memory logging of 240 alarms and 240 events plus Audit Log events for the Measurement Canada version Logic and sequencing control using a user defined Function Sequence Table FST program Proportional Integral and Derivative PID feedback closed loop control capability Power cycling c
139. io 2 5 2 p AM Backup Procedure Before Removing Power on page 2 21 Disconnect the PWR input connector from the termination board Unplug the processor board power supply cord on the termination board at P1 Disconnect the ribbon cable at P3 on the processor board Disconnect the Keypad ribbon connector at P4 on the processor board un A p N Remove the communications card if present by removing its retaining screw and unplugging the card from its mating connectors Remove the six nuts securing the processor board and lift the board out of the case Remove the LCD from the processor board Install the LCD on the new processor board 10 Place the new processor board in the case Install the screws to secure the board to the case 11 Install the Keypad ribbon connector at P4 on the processor board 12 Install the ribbon cable at P3 on the processor board 13 Install the communications card 1f required 14 Plug the processor board power supply cord into P1 on the termination board 15 Refer to Section 2 5 3 After Installing Components on page 2 22 2 24 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 5 14 Replacing the Termination Board Equipment Required Small Philips screwdriver PC with ROCLINK configuration software installed To replace the termination board When installing devices in a hazardous area make sure each device is labeled for use
140. isolation can be accomplished by using insulating flanges upstream and downstream on the meter run In this case the FloBoss 407 could be flange mounted or saddle clamp mounted directly on the meter run and grounded with a ground rod or grid system Another way of providing electrical isolation would be to mount the FloBoss 407 on a pipestand and use a Remote Multi Variable Sensor installed with non conductive conduit Ground the case of the FloBoss 407 to a ground rod or grid system On pipelines without cathodic protection the pipeline itself may provide an adequate earth ground and the FloBoss 407 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 system All grounding should terminate at a single point If the pipeline to earth impedance is greater than 25 ohms the FloBoss 407 installation should be electrically isolated and a ground rod or grid grounding system installed The FloBoss 407 has a ground bus bar located in the lower section of the enclosure The ground bus bar is electrically bonded to the enclosure and provides space to connect ground wires from I O devices power input and grounding conductors from devices used in the installation For line powered devices the grounding conductor must end at the service disconnect The grounding conductor can b
141. ith ROCLINK configuration software installed If a built in Analog Input does not function correctly first determine if problem is with the field device or the FloBoss 407 I O circuitry 1 2 2 22 Disconnect the I O terminal block to isolate the field device from the FloBoss I O If the FloBoss 407 provides loop power source measure the voltage between terminal T and of the AI channel under test The loop power should be 23 volts dc minimum with jumper P15 in the 24 volts position W1 open or near to input power voltage with jumper P15 in the 12 volts position W1 installed Disconnect power to the FloBoss Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 4 With an ohmmeter check between terminals T and of the AI channel under test If 0 ohms the input has shorted components 5 Replace the termination board if the above tests indicate a fault Refer to Section 2 5 14 Replacing the Termination Board on page 2 28 6 Connect a lead of a 250 ohms resistor and a 5 kilohms potentiometer to the terminal of the AI channel Connect the other resistor lead to terminal and the potentiometer to terminal T of the AI channel under test 7 Connect the FloBoss 407 to a PC running the configuration software Power up the FloBoss 407 8 Turn the potentiometer to vary the input to simulate a transmitter Use
142. ivate them pin 8 4 15 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual Shutdown must be grounded to pin 2 using a jumper This does not affect normal operation All unused signals can be left un terminated P7 Terminal Function oo com 3 i oo ax sR ed 8 on 4 5 5 Dial Up Modem Communications Card Wiring The Dial Up Modem Card interfaces to a PSTN line through the RJ11 jack with two wires The signals present at the RJ11 connector are RJ11 Operating Mode Terminal 2 Wire Tip Figure 4 12 hows the relationship between the dial up modem signals and pin numbers for the RJ11 connector and the COM2 connectors Care should be exercised to avoid shorting the 5 volts dc supply terminal 6 on the COM2 terminal block to common terminal 9 or to any ground when wiring to COM2 Grounding terminal 6 causes the FloBoss to halt operation and data may be lost once a restart is initiated 4 16 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual DIAL UP MODEM CARD RJ11 BLK ry TIP S DE pa te We MODEM a Nc 3H 2 5 5 SPK ae am i COM2 z TERMINAL BLOCK 3V TTL RS232 INTERFACE qo SHUTDOWN RXD TXD DTR DSR RI SPK R O OO O 5V O NNN gt gt gt NNN TONY PON OO a W AODANON AWN gt Figure 4 12 Dial Up Modem Wiring Schematic PSTN TIP RING SPK RXD TXD DTR DSR RI SHUTDOWN 5V COM DOC0216C The following signals output only are a
143. l assis asd ereraa tenes Gaceehs Sone dasaicenvas eens Gasca hice 2 5 Ste Reguitemen a estes ck Saat cad ec ate anes acct ats 1 4 Slow Pulse Inputs DS ONAL CO srce 3 4 Isolated Troubleshooting ccccceeeeseeeeeeees 3 26 TSOlateG WHn eiei oa aah eee nace 3 16 l 6 Index SOULO oes a anata iiemebepseaetoves 3 4 Source Troubleshooting ccccssseseseeeeeeeeeees 3 26 Source Wino sori tiaras cele OR 3 15 Solar Pane snd snns erences treeid istic dates 1 5 Solar POWEE esrar sesso i i a aS 1 6 Specifications Communication Card cccccccccceeeeeeseeeeeeeeeeeeees 4 19 DS PAY a A E E E E AE 2 27 POE OS SO aonn R 2 27 TO Mod le Soinean tac dumtendest 3 30 Keypad ee ee ee aa ne 2 27 Lghtning Protection Module cccccceeeeees A 4 Multi Variable Sensor cccccccccccceceeeeeeeeeeeeees B 16 SECU ents ates ae Ce Rn were Cone OC See tu 1 11 Startup and Operation cccccccceceeeeeeeeeeeeeeeeeeeees 1 10 Sarp SWIM eae a a 1 10 Sa PRES SUPO noceat r e A ER 2 6 Static Random Access Memory SRAM ot ag ela A 2 2 StAtUs ndc arna cece Maseueicied veuroncat emoea aus 2 17 LACUS LE DD 8 sacs neces say saan a saezesodensesseabiugonseat 1 11 Surge Protection sssssssesseeseesseessseesees 1 6 2 5 2 12 Switch Switch to Discrete Inputs cccceseseeeeeeeeeees C 5 Switch to Pulse Inputs cccceeeeesesseeeeseeees C 6 PHO ESA estado E E E E S 1 11 2 19 yS
144. lays in the lower right corner of the screen 2 5 6 Verifying RAM Equipment Required Personal computer with ROCLINK configuration software To detect bad RAM 1 Connect to ROCLINK configuration software 2 Select ROC gt Information gt Other Information tab and verify that RAM Installed is labeled PRESENT 3 The problem could be a bad backup battery or a bad solder joint of the RAM chip 2 5 Verifying Battery Voltage A battery on the processor board B1 or B2 provides power to the real time clock and backup power for the RAM If the battery fails the clock stops running the FloBoss stops operating and the Status LED blinks The battery is a 3 6 volts lithium type and is secured with a hold down clip Under normal usage this battery should last 5 to 10 years However if the FloBoss is powered down for long periods of time battery life will be shortened To check the battery voltage NOTE For Measurement Canada units maintenance and resealing of the FloBoss must be performed by authorized personnel only To avoid circuit damage when working with the FloBoss use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Perform the RAM Backup Procedure previously described in Sectio 2 5 2 RAM Backup Procedure Before Removing Power on page 2 21 if possible 2 Remove the battery from the battery socket typically B1 by sliding the hold down clip to one side and lifting the bat
145. les and 32 HART devices maximum Point to Point Mode Two HART devices per module one per channel Multi drop Mode Up to ten HART devices per module five per channel LOOP POWER Total power supplied through module for HART devices is 20 mA per channel at 10 to 29 V dc Each HART device typically uses 4 mA POWER REQUIREMENTS Loop Source 11 to 30 V dc 40 mA maximum from FloBoss power supply Module 4 9 to 5 1 V dc 17 mA maximum 3 41 Input Output Modules VIBRATION 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SHOCK 1500 Gs 0 5 ms half sine per MIL STD 202 method 213 condition F WEIGHT 48 g 1 7 oz nominal CASE Solvent resistant thermoplastic polyester meets UL94V 0 Dimensions 15 mm D by 51 mm H by 43 mm W 0 60 in D by 2 00 in H by 1 69 in W not including pins ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Surge specifications APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual SECTION 4 COMMUNICATIONS CARDS 4 1 Scope This section describes the communications cards used with the FloBoss 407 Flow Managers This section contains the following information Section 4 2 Product Descriptions 4 4 Initial Installation and Setup 4 5 Conne
146. leshooting ccccceeeeseeeeeeees 3 24 Bolated W 1111105 235 cxacbaadusbatn aac aamiesedaane cts etoseees 3 11 SOUT CO eaan a adnate cosa aah A T 3 3 Source Troubleshooting cccccccccceeeeeeeeeeeeees 3 24 Source Wirin odnese a eee 3 10 Discrete Outputs Discrete Outputs to Discrete Inputs C 3 Discrete Outputs to Pulse Inputs 0008 C 3 Isolated onckeudaneeawsgotiecuan 3 3 Isolated Troubleshooting ccccceeeeseeeeeeees 3 24 Isolated WINE aistocsctstenstarssectadseceastastentedidecanas 3 12 REII o ene E a a 3 3 Relay Troubleshooting ccccccceeeeeeeeeeees 3 25 Relay W WO eec EE Ta 3 13 DS OUNCE osson r 3 3 Source Troubleshooting cceccccccccceeeeeeeeeees 3 24 Source VV 8 5 rigs oe Pa dh A 3 11 DIS LAY cos geste codaete nara evades eso I 5 1 SPECICATION se A 2 27 Display OIL eier ire tacos evessaep asa 5 3 5 15 DIVISION Z oep A 1 5 DOWD ATON eene waseuseacdasstsuariess 5 3 Dry Relay Contacts 2 1 2iisecsvsaisdctestinadevseanschdedivoreoreens 3 3 D Ee E N 4 3 DIR aeea T 2 8 4 3 PDV CNG os ssc cts teceniset a aN 1 7 1 9 E Shel isl Clo eee arene ene E ere 5 2 5 3 FGI NEO GS arein tale tie E AEO 5 4 EEPROM We 10 sence tecosial oc tadesticaicestl as eae enact 2 18 2 19 EIA 232 RS 232 Communications Cards 4 2 NY MII E N ae tte A 4 12 EIA 422 485 RS 422 485 Communications Cards 4 4 WIDE eonan n a A A 4 12 l 2 Inde
147. lti Variable Sensors describes the optional MVS and specifications Appendix CL I O Simulation shows various ways to set up I O simulation for troubleshooting I O components and configurations For more information on software or accessories please refer to the following manuals ROCLINK for Windows Configuration Software User Manual Form A6091 ROCLINK for Windows software Version 1 01 or greater is required for all FloBoss 407 units Version 1 08 or less ROCLINK 800 Configuration Software User Manual Form A6121 ROCLINK 800 Version 1 20 or greater is required for all FloBoss 407 units with Version 1 08 firmware or greater ROC FloBoss Accessories Instruction Manual Form A4637 Provides information concerning accessories such as Resistance Temperature Detector RTD sensors for the Multi Variable Sensor MVS 1 1 General Information Rev Mar 05 FloBoss 407 Instruction Manual 1 2 1 FCC Information This equipment complies with Part 68 of the Federal Communications Commission 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 i
148. ly memory that can be electrically re programmed Itis a form of permanent memory needs no backup power Also called Flash memory G 2 Glossary Rev Mar 05 FloBoss 407 Instruction Manual FloBoss A specialized Remote Operations Controller ROC from the Flow Computer Division of Emerson Process Management a microprocessor based unit that provides remote monitoring and control 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 the Flow Computer Division of Emerson Process Management G GFA Ground Fault Analysis GND Electrical ground such as used by the FloBoss power supply GP Gauge Pressure H HART Highway Addressable Remote Transducer hw Differential pressure J I O Input Output I O Module Module that plugs into an I O slot on a FloBoss 407 to provide an I O channel ID Identification IEC Industrial Electrical Code IMV Integral Multiplier Value IRQ Interrupt Request Hardware address oriented IV Integral Value K Kbytes Kilobytes Also referred to as K kHz Kilohertz L LCD Liquid Crystal Display Display used for reading data LED Light emitting diode LOI Local Operator Interface Local Port Refers to the serial EIA 232 RS 232 port on the FloBoss through which local communications are established typically for configuratio
149. m D 0 65 in H by 0 84 in W by 1 58 in D Length of Ground wire 1 2 m 48 in nominal SURGE WITHSTAND Meets surge requirements IEEEC62 31 ENVIRONMENTAL Meets the Environmental specifications of the FloBoss in which the module is installed including Temperature Humidity and Transient Protection WEIGHT 34 grams 1 2 ounces APPROVALS Approved by CSA for hazardous locations Class I Division 2 Groups A B C and D A 4 Lightning Protection Module Rev Mar 05 FloBoss 407 Instruction Manual APPENDIX B MULTI VARIABLE SENSORS This appendix describes the Multi Variable Sensor MVS devices which provide differential pressure static pressure and temperature inputs to the FloBoss 407 for orifice flow calculation Topics include Section Page B 1 Description B 2 MVS Mounting B 3 MVS Field Wiring B 4 Configuring the MVS B 5 Calibrating the MVS B 6 MVS Troubleshooting and Repair B 7 Miulti Variable Sensor Specifications B 1 Description The MVS205 Multi Variable Sensor provides static pressure differential pressure and process temperature inputs The inputs from the MVS are used in performing orifice flow calculations The MVS8205 operates as a remote or integral unit that communicates via a serial format Functionally the MVS is a sensor device that measures three flow related variables simultaneously These variables are continuously available to the FloBoss that polls the MVS Two versions of the MV
150. m battery provides backup power for the RAM and the real time clock The backup battery mounts on the processor board with a spring clip to hold it in place The processor board has provisions for mounting a second backup battery This provision allows you to replace the battery without losing backup power to the FloBoss 407 The real time clock provides the FloBoss 407 with the time of day date month year and day of the week The time chip automatically switches to battery power when the board loses primary input power An Light Emitting Diode LED Status indicator on the processor board shows the system status Refer to Sectior 2 5 1 LED Indicators on page 2 20 The Reset switch permits a special type of Cold Start from the factory default flash memory configuration rather than from the configuration saved to permanent memory as in a Cold Start Refer to Section 2 5 10 Performing a Reset on page 2 25 2 2 2 Termination Board Description Refer to Figurel2 1 The termination board provides the following functionality to the FloBoss 407 11 to 30 volts dc input power supply External modem port Board temperature and voltage monitor inputs Communications card port 4 Built in field input terminals Multi Variable Sensor MVS port 4 Expansion I O module terminals Operator interface serial port The FloBoss 407 operates with a 12 5 to 30 volts dc power input to the termination board A Power indicator LED light
151. m is resolved 1 3 Product Overview The FloBoss 407 is a microprocessor based flow computer Figure 1 1 that provides functions required for gas flow measurement and custody transfer in accordance with standards such as AGA 1985 or 1992 orifice metering The FloBoss provides on site functionality for applications where there is a need for remote monitoring measurement data archival communications and control The design allows you to configure the FloBoss 407 for specific applications including those requiring calculations logic and sequencing control using Function Sequence Tables FST as well as Proportional Integral and Derivative PID loop control The FloBoss 407 is available in two versions based on the type of approval the standard hazardous area version and the Measurement Industry Canada custody transfer version which includes hazardous area approval These versions have a number of differences both in firmware and hardware Both of these versions are further subdivided by the type of orifice metering calculations either AGA 1992 or AGA 1985 included in the firmware along with AGA7 turbine metering calculations 1 2 General Information Rev Mar 05 FloBoss 407 Instruction Manual Figure l 1 FloBoss 407 Flow Manager Physically the FloBoss 407 consists of two printed circuit cards a Keypad and a display housed in a compact weather tight case The printed circuit cards are the processor board mounted on the door
152. ms dB Ohms 6 ask 6 866K 8 39k _ 8 66k 215K 5 11 K All resistor values are nominal 1 1 4 W resistors are acceptable Attenuation resistors are typically not required for leased line private line operation or fora GE MCS radio Attenuation for a GE TMX radio is typically 20 dB Attenuation for an MDS radio is typically 10 dB 4 10 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 5 Connecting Communication Cards to Wiring Signal wiring connections to the communications cards are made through the COM2 terminal block located on the termination card and through TELCO connectors supplied with certain modem cards Tabld 4 4 khows the communications signal connection pin outs for the COM port and the various communications cards available for the COM2 port on a FloBoss 407 Table 4 4 FloBoss 407 Communications Signals CommCardPin 1 2 3 4 5 6 7 amp 9 COM1 Terminal Block Built in EIA 232 RS 232 RxD TX RTS CTS DCD DTR DSR_ COM _ Communication Cards COM2 Terminal Block EA2232 RS 232 Card DCD DSR RX RTS 1x CTS DIR RI com ElIA 422 485 RS 422 485 sa in RS 422 Mode ElIA 422 485 RS 422 485 eae in RS 485 OUT OUT Mode rRapiomopem _ pr ex pm x com Finis visa on RX TX RX TX 4 wire Private Line DIAL UP MODEM output SHUT only for analyzer DOWN Communicatio
153. n Cards RJ11 Port LEASED LINE MODEM TIP RING RJ11 Port 2 Wire RED GRN LEASED LINE MODEM TIP2 TIP1 RING1 RING2 RJ11 Port 4 Wire BLK RED GRN YEL DIAL UP MODEM RJ11 RING TIP Port RED See Signal is permanently enabled true 4 11 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 5 1 ElA 232 RS 232 Communications Card Wiring Figure 4 7 sl ows the relationship between the EIA 232 RS 232 signals and terminal numbers for the COMZ terminal block EIA 232 CARD COM2 TERMINAL BLOCK FIA 232 1 Merely 9 psr__ gt TRANSMI 24 2 DSR oR Ue o i DIR 25 R j l oe 18 8 RI ces 20 is CTS 22 com 4 PIS 15 9 COM DOC0211B Figure 4 7 EIA 232 RS 232 Wiring Schematic 4 5 2 ElIA 422 485 RS 422 485 Communications Card Wiring Figure 4 8 shows the relationship between the EIA 422 RS 422 signals and terminal numbers for the COM terminal block EIA 422 RS 422 wiring should be twisted pair cable one pair for transmitting and one pair for receiving Jumper P4 in the newer card Jumper P3 in the older card is used to control the RTS transmit function in the E A 422 RS 422 mode This jumper has a default setting of RTS for multi drop communications Placing this jumper in the ON position enables the card to continuously transmit point to point This jumper has no effect when the card is wired for EIA 485 RS 485 operation EIA 422 4
154. n software running on a PC LPM Lighting Protection Module Use this module to provide lightning and power surge protection for FloBoss units LRC Longitudinal Redundancy Checking error checking G 3 Glossary Rev Mar 05 FloBoss 407 Instruction Manual mA Milliamp s one thousandth of an ampere MCU Master Controller Unit Modbus A popular device communications protocol developed by Gould Modicon Modular I O I O channels provided on a FloBoss using I O modules See I O Module MPU Micro processor Unit mW Milliwatts or 0 001 watt mV Millivolts or 0 001 volt MVS Multi Variable Sensor The MVS provides differential pressure static pressure and temperature inputs to the FloBoss 407 for orifice flow calculation N NEC National Electrical Code US NEMA National Electrical Manufacturer s Association US O OH Off Hook modem communications signal Off line Accomplished while the target device is not connected by a communications link For example off line configuration is configuring a FloBoss in a electronic file that is later loaded into the FloBoss Ohms Units of electrical resistance On line Accomplished while connected by a communications link to the target device For example on line configuration is configuring a FloBoss while connected to it so that current parameter values are viewed and new values can be loaded immediately Opcode
155. nation board at P1 Remove the five screws securing the termination board and lift the board out of the case O p N 2 oe Place the new termination board in the case and install the securing screws to the case 10 Connect the ribbon cable at P3 on the processor board 11 Connect the communication card wiring if required 12 Connect the field wiring 13 Connect the operator interface Local Port wiring on the termination board at P2 14 Connect the processor board power connector to the termination board at P1 15 Plug the processor board power supply cord into P1 on the termination board 16 Refer to Sectio 2 5 3 After Installing Components on page 2 22 2 25 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 5 15 Replacing the Flash ROM Equipment Required Flash ROM extractor PC with ROCLINK configuration software installed When installing devices in a hazardous area make sure each device is labeled for use in such areas Procedures involving switching power on or off or procedures for installing or removing any wiring or components must be performed only when the area is known to be non hazardous Performance of these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working with the FloBoss use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap Du
156. nce a unique Address is set for each MVS connect the MVS units as instructed in Section B 3 MVS Field Wiring on page B 6 NOTE Refer to the ROC FloBoss Accessories Instruction Manual Form A4637 ROCLINK for Windows Configuration Software User Manual Form A6091 and ROCLINK 800 Configuration Software User Manual Form A6121 B 5 Calibrating the MVS The Calibration routine provides Verify Calibrate and Zero Shift functions for each input AI MVS and RTD or the meter run 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 To perform initial calibration or recalibration such as after an orifice plate is changed use ROCLINK configuration software or the FloBoss 407 Keypad The following procedure is performed using the Keypad 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 During calibration the Flo
157. ned The padlock shank can be up to 6 35 millimeters 0 25 inches in diameter and the body of the padlock can be up to 38 1 millimeters 1 5 inches wide 2 9 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual To install the padlock adapter 1 Open the main electronics cover of the FloBoss 407 Remove the old retaining washer from the screw and discard the washer Position the screw adapter and new washer as displayed in Figurd 2 3 Thread the screw through the washer and into the enclosure using a screwdriver Rotate the adapter as required using a padlock shank Install the padlock S p a o yN fa PADLOCK a PADLOCK ADAPTOR RETAINING WASHER MAIN COVER SIDE VIEW FRONT VIEW MAIN COVER SHOWN SHOWN WITH ADAPTOR OFFSET FOR CLARITY AND PADLOCK INSTALLED Figure 2 3 Padlock Adapter Installation 2 10 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 4 Connecting the FloBoss 407 to Wiring The following paragraphs describe how to connect the FloBoss 407 to power ground I O devices and communications devices Use the recommendations and procedures described in the following paragraphs to avoid damage to equipment or injury to personnel The FloBoss 407 terminal blocks can accommodate up to 12 American Wire Gauge AWG wire Always turn off the power to the FloBoss
158. nfiguration software to make the changes off line or on line To minimize down time before you replace the module perform changes except for FloBoss Display and FST changes off line by first saving the FloBoss configuration to disk Modify the disk configuration replace the module and then load the configuration file into the FloBoss To make changes on line replace the module proceed directly to the configuration display for the affected point and modify parameters as needed Remember to consider the impact on FSTs and other points that reference the affected point 3 28 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual Any added modules new I O points start up with default configurations Even though adding a module removing a module or moving a module to a new position in the FloBoss does not directly affect the configuration of other I O points it can affect the numbering of I O points of the same type This in turn can impact an FST or higher level point because the referencing of I O points 1s done by a sequence based point number For example if you have AI modules installed in slots A7 A10 and A11 adding another AI module in slot A8 changes the point numbers of the Analog Inputs for modules in slots A10 and A11 CAUTION If one or more FSTs or higher level points such as a PID loop or AGA Flow have been configured in the FloBoss be sure to reconfigure them according to the changes in I O modul
159. nications Card Wiring on page 4 17 R2 Attenuation P3 Jumper P4 Jumper a ae P5 Jumper ejo ree O_o FB4 vas Gt r se ator LED Indicators RTS CTS DCD DTR TXD RXD S OODO0O0O a CR6 CR5 CR4 CR3 CR2 CRI RP2 u4 4 T egzvoowuzuuaouwoos amp C24 C23 Lo p p N 5 A N BiH O o oOpoooooo0oo0o0oo00 y 2 ooopoooo0oo0oo0o0o000O0 30 5 OOO g 1 G OBE OEERBEEHe0HH 2 GOO OEE REO RHO HHH C2 0 RP1 yo N N Q a joo P7 Connector oo S O C27 LEASED LINE RADIO MODEM DOC0246A Figure 4 4 Leased Line Modem Communications Card 4 6 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 3 3 Dial Up Modem Communications Card The Dial up Modem Communications Card supports V 32 bis V 32 V 22 bis V 22 V 21 Bell 212A and 103 communications with auto answer auto dial features The modem card is Federal Communications Commission 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 eliminating the need to adjust pots or move jumpers during installation and setup Refer to Fi gure 4 5 The modem card interfaces to two wire full duplex telephone lines using asynchronous operation at
160. nstruction Manual The Analog Output Source module simulates a transmitter feeding a 0 to 5 volts dc signal to an Analog Input differential module Figure C 3 shows wiring connections R1 OPEN Al DIFF DOC0177A Figure C 3 Voltage Input AO Source Module to AI Differential Module C 2 Analog Outputs to Ammeter or a Volt Meter Figures C 4 and C 5 show how to use a ammeter or a volt meter to check an Analog Output Source module by directly reading the current or voltage from the module R1 0 AO SRC DOC0179A Figure C 4 Current Loop AO Source Module to Ammeter VOLTS es DOC0180A Figure C 5 Voltage Output AO Source to Voltmeter C 2 I O Simulation Rev Mar 05 FloBoss 407 Instruction Manual C 3 Discrete Outputs to Discrete Inputs Figure C 6 shows how to use a Discrete Output Source module to simulate a device transmitting a discrete voltage level to a Discrete Input Isolated module LIMIT DOCO181B Figure C 6 DO Source Module to DI Isolated Module FigurelC 7 shows how to use a Discrete Output Isolated module to simulate relay contacts to a Discrete Input Source module DOC0182A Figure C 7 DO Isolated Module to DI Source Module C 4 Discrete Outputs to Pulse Inputs Figure C 8 bhows how to use a Discrete Output Source module to simulate a device transmitting pulses such as a turbine meter to a Pulse Input Isolated module LIMIT DOC0O183B Figure C 8 DO Source Mo
161. nual Electronics Head SSE Ary Z WARNING EA Sensor Body Coplanar Flange C02278B FRONT VIEW SIDE VIEW Figure B 1 MVS205 Remote Multi Variable Sensor B 2 MVS Mounting MVS mounting depends on whether it is an Integral or Remote MVS The Integral MVS205 is factory mounted directly to the FloBoss 407 enclosure This mounting uses a special coupler to join the threads on the MVS to the center wiring hole in the bottom of the FloBoss 407 enclosure Refer to e which shows outline and mounting dimensions A mounting stiffening plate fastened to the MVS and the FloBoss 407 enclosure provides rigidity to the assembly In this type of mounting the MVS interface circuit is factory installed inside the lower compartment of the FloBoss 407 enclosure B 2 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual 5 12 Mounting Plate LO O N x 8 g De S5 O J H Ss B lt E Q O se Lo aa RTD Cable Connector et oe Figure B 2 FloBoss 407 and Integral MVS Outline and Mounting Dimensions The FloBoss 407 with an Integral MVS can be pipe mounted with the use of mounting blocks and U bolts or it can be panel mounted with 5 16 inch 8 mm bolts When the MVS is pipe or panel mounted the pressure inputs must be piped to the 14 18 NPT connections on the MVS as shown in Figur B 3 The FloBoss 407 with an Integral MVS can also be mounted directly on a manifold valve or an integral orifice assembly
162. o Modem Communications Card Wiring on page 4 16 R2 Attenuation G HO on j gt Yyy yyy DE OG iw a H G Lo ISO 00 2 maena R2 Q POJ T FB3G SO S70 2 pecs m umper E D GNDJDD 4 Z A VR4O O L J B n O k C1 6 O CO VIN W Ti imp 4 armen JDS mM a MY l Ie par T RISO Oma q D S FOOOO R140 o VR6EO O 4 ag WOI O GOIE R C T C a S R15 G Le H Fe T DO O O CRI fa C19 al QO UX OQ c2 J gt D ro bom a Ceo a AK Cl D C10 j 5 OQ P r m US C11 Ps A AY L Np Oxzs 1 VoL ee Th vy oO i a GA G a E 3 O q D tey lt O g D D et te q Pp 7 LAM pa J pal I Re0G 4 O 2 Kl OU me C R2104 be ve 2 z LE d j t AS O TI p U D y Es Rel ie 3 F ae oa SF 4 me 22 OF mO D Indicators aAt U D a pE Poca ree gt pg aw O P ay DT H d e 5 c aA N a B OKON L a D Y as OW O P a q B Sa ORS Te AAO ly oD y2 O J Oe Yay eee w OQ 5 pas R2 O pai fe J a 0 z a ye ie R22 X A le OO Y y OR u gt aAnananaq t as aea C O Oo T cu gt gt l O E G H nae OO E999 JJS g
163. o disk using Utilities gt FST Editor gt FST gt Write function in the FST Editor Refer to the FST Editor in the applicable configuration software user manual 2 5 4 Performing a Warm Start A Warm Start temporarily suspends all input output I O scanning I O processes are restarted from their last calculated values A Warm Start clears and restarts all user enabled flags A Warm Start also starts all FSTs to the first instruction Equipment Required Personal computer with ROCLINK configuration software NOTE If your FloBoss is semi functional refer to Sectio RAM Backup Procedure Before Removing Power on page 2 21 To perform a Warm Start using the configuration software 1 Connect the FloBoss to the PC running ROCLINK configuration software 2 Click ROC gt Flags gt Warm Start and click Apply To perform a Warm Start using the power option 1 Remove power from your FloBoss 2 Reapply power to the FloBoss 2 19 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 5 5 Verifying the FloBoss can Communicate with the PC Equipment Required Personal computer with ROCLINK configuration software To verify that the FloBoss is communicating with the PC running ROCLINK configuration software 1 Connect the FloBoss to the PC running ROCLINK configuration software 2 Ifthe FloBoss is communicating with ROCLINK configuration software COM1 COM2 COMS3 or COM4 disp
164. o 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 407 case ground lug and the earth ground rod or grid The grounding installation method for the FloBoss 407 depends on whether the pipeline has cathodic protection On pipelines with cathodic protection the FloBoss 407 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 407 could be flange mounted or saddle clamp mounted directly on the meter run and grounded with a ground rod or grid system 1 6 General Information Rev Mar 05 FloBoss 407 Instruction Manual Another way of providing electrical isolation would be to mount the FloBoss 407 on a pipestand and use a Remote Multi Variable Sensor installed with non conductive conduit Ground the case of the FloBoss 407 to a ground rod or grid system On pipelines without cathodic protection the pipeline itself may provide an adequate earth ground and the FloBoss 407 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 system All grounding should terminate at a single point If the pipeline to earth impedance 1s grea
165. ody transfer in addition to approval by CSA for hazardous locations see Standard Version Note Overall with Integral MVS 457 mm H by 236 mm that I O Modules must not be used to supply flow W by 130 mm D 18 0 in H by 9 3 in W by 5 1 in inputs to the FloBoss in a Measurement Canada D installation DIMENSIONS Overall FloBoss 407 only 305 mm H by 236 mm W by 112 mm D 12 0 in H by 9 3 in W by 4 4 in D Wall Mounting 71 mm W by 308 mm H 2 8 in W by 12 1 in H between mounting hole centers Mounting hole diameter is 9 4 mm 0 37 in Pipestand Mounting Mounts on 2 inch pipe with U bolt mounting kit included 2 28 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual SECTION 3 INPUT OUTPUT MODULES 3 1 Scope This section describes the Input Output I O Modules used with the FloBoss 407 Flow Manager and includes the following information Section 3 1 Scope 3 2 Product Descriptions 3 3 Initial Installation and Setup 3 4 Connecting the I O Modules to Wiring 3 5 Troubleshooting and Repair 3 6 Removal Addition and Replacement Procedures 3 7 I O Module Specifications 3 2 Product Descriptions The I O modules plug into the FloBoss I O module sockets and accommodate a wide range of process inputs and outputs NOTE FloBoss units used in Measurement Industry Canada installations must not employ I O modules for flow measurem
166. oltage is the input voltage to the FloBoss However it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage The formula for determining the value of R1 is given in Figure 3 16 For optimum efficiency R1 should be scaled for a loop current I of 5 milliamps ROC POWERED PULSE DEVICE TO OPTIMIZE SCALING RESISTOR R1 Vd R1 Ry 2 2K R1 Ry 2 2K LOOP RESISTANCE 3 4K OHMS MAX LOOP CURRENT 5 mA TYPICAL Rw RESISTANCE OF FIELD WIRING Vs SOURCE VOLTAGE FROM MODULE 11 TO 30 VDC Figure 3 16 Pulse Input Source Module Field Wiring 3 4 11 Pulse Input Isolated Module A schematic representation of the field wiring connections to the input circuit of the Pulse Input Isolated module is shown in Figure 3 17 NOTE The Pulse Input Isolated module is designed to operate only with devices having their own power source such as wet relay contacts or two state devices providing an output voltage The module is inoperative with non powered devices The Pulse Input Isolated module operates when a field device provides a voltage across terminals B and C of the module The voltage sets up a flow of current sensed by the module When the field device no longer provides a voltage current stops flowing This interrupted or pulsed current flow is counted and accumulated by the PI module which provides the accumulate
167. onics that the relay contacts have opened A 10 ohms scaling resistor R1 is supplied by the factory and accommodates a source voltage V of 11 to 30 volts dc The source voltage is the input voltage to the FloBoss However it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage The formula for determining the value of R1 is given in el For optimum efficiency R1 should be scaled for a loop current I of 3 milliamps Figure ROC POWERED PULSE DEVICE TO OPTIMIZE SCALING RESISTOR R1 V4 nts naak roche R1 Ry 3 3K LOOP RESISTANCE 4 5K OHMS MAX LOOP CURRENT 3 mA TYPICAL Rw RESISTANCE OF FIELD WIRING Vs SOURCE VOLTAGE FROM MODULE 11 TO 30 VDC Figure 3 11 Discrete Input Source Module Field Wiring 3 10 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 4 6 Discrete Input Isolated Module A schematic representation of the field wiring connections to the input circuit of the Discrete Input Isolated module displays in Figure 3 12 NOTE The Discrete Input Isolated module is designed to operate only with discrete devices having their own power source such as wet relay contacts or two state devices providing an output voltage The module is inoperative with non powered devices The Discrete Input Isolated module operates when a field device provides a voltage across terminals B and C of the
168. onsideration in locating the FloBoss 407 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 to minimize the length of signal and power wiring By code line power wiring must not cross meter runs 1 4 General Information Rev Mar 05 FloBoss 407 Instruction Manual Orient solar panels used with solar powered FloBoss units to face True South not magnetic in Northern hemispheres Orient solar panels used with solar powered FloBoss units to face True North not magnetic in Southern hemispheres Make sure nothing blocks the sunlight from 9 00 AM to 4 00 PM Antennas for FloBoss units equipped for radio communications must be located with an unobstructed signal path If possible locate antennas at the highest point on the site and avoid aiming antennas into storage tanks buildings or other tall structures Allow sufficient overhead clearance to raise the antenna To minimize interference with radio communications locate the FloBoss away from electrical noise sources such as engines large electric motors and utility line transformers Locate the FloBoss away from heavy traffic areas to reduce
169. ontrol for a radio not available in Measurement Canada version Spontaneous Report by Exception SRBX alarming capability Version 1 05 and greater gt gt gt OH Capability to load and run user programs such as the Modbus Protocol Emulation Program 2 1 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 2 1 Processor Board Description The processor board components define the functionality of the FloBoss 407 The processor board provides the following NEC V25 microprocessor Communications card port On board static RAM Real time clock Flash memory for program storage Battery backup power Keypad port Status indicator Display port Reset switch Figurg 2 1 hows a view of the processor board mounted on the door of the FloBoss 407 case and the termination board mounted in the FloBoss 407 case The FloBoss 407 derives processing power from a National Electrical Code NEC V25 microprocessor The NEC V25 is a 16 bit Complementary Metal Oxide Semiconductor CMOS microprocessor featuring dual 16 bit internal data buses and a single 8 bit external data bus The FloBoss can address up to one megabyte of memory and features high speed direct memory access The processor board has 512 kilobytes of Static Random Access Memory SRAM for storing interrupt vectors Function Sequence Tables FSTs custom displays alarms even
170. option HELP ia FST 5 5 Security Security features are implemented through User Lists in ROCLINK configuration software Each user is assigned a 4 digit password Refer to the ROCLINK for Windows Configuration Software User Manual Form A6091 or the ROCLINK 800 Configuration Software User Manual Form A6121 5 5 1 Logging Off the LCD The LCD continues to display the last selected list or value until it is turned off To turn the display off and log off press the ALT and DISPLAY OFF key To restart the Keypad operations press any key and enter your Password DISPLAY OFF PASSWORD Another way to secure the display is to press the ALT key and PASSWORD This logs the current user out of the system To reactivate Keypad operations you must log on with a correct password 5 5 2 Continually Displaying the Last Parameter After logging out using ALT and PASSWORD press the ALT key and the CANCEL key to f cause the LCD to show the last parameter displayed CANCEL For example if at a particular FloBoss 407 installation you wanted to continually monitor a Min Max reading CANCEL 1 Press any key 2 Enter your Password 3 Press the ALT key and MIN MAX 5 14 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual 4 Select the desired history point to display its values 5 Log off with ALT and PASSWORD 6 Press ALT and CANCEL The previously selected values continually displays until someone logs on
171. ou enter ETONE Wee D es EE Cur Value DATA Cur Value Current value 2000 O O Accuracy Accuracy computed as the difference Accuracy DATA 17 Press J to select APP VALUE and press ENTER Log Verif _ a Applied Value is the input desired for the test value and is Exit the actual value expected by the test equipment being SS eS calibrated against For example When calibrating Verify Calibration Display temperature for an RTD input enter the degree value associated with the resistance set up in the decade box B 13 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual Compare this value with the Current Value If the value is too far out of tolerance be sure to perform calibration for the input 18 Key in a test value in engineering units and press ENTER to save the corresponding test value 19 Press 4 to select LOG VERIF and press ENTER to log the last verified value to the Event Log 20 EXIT returns the program to Calibration Step 5 21 Press 4 to select CALIBRATE in Calibration Step 5 to Calib Minimum Scale calibrate the selected input and press ENTER App Value DATA re Use the Calib Minimum Scale display to set the Zero value 0 Of paper 3 range for the in Differential Pressure orifice only Static Pressure ae eee or Temperature This should correspond with the Low Reading Save Timer 0 Count and is the low value for the meter run m
172. p e e Q Q Q O A x Y A gt lt He aa A A oO A Nn He oO N 4 Bad A A ea e N A OD O apo Seu im c2 a c6 3 p uw COM PORTS DOCO369A Figure 4 1 EIA 232 RS 232 Serial Communications Card Newer The EJA 232 RS 233 communications card includes LED indicators along the left hand side that display the status of the RXD TXD DTR DCD CTS and RTS control lines Refer to Tabl 4 1 4 2 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual Table 4 1 Communications Cards LED Indicators Status and Activity The RXD receive data LED blinks when data is being received The LED is on for a space and off for a mark TXD The TXD transmit data LED blinks when data is being transmitted The LED is on for a space and off for a mark DTR The DTR data terminal ready LED lights when the modem is ready to answer an incoming call When DTR goes off a connected modem disconnects The DCD data carrier detect LED lights when a valid carrier tone is detected TRI The Riis the ring indicator LED ig O O O OoOo OoOO S OH The OH is the off hook indicator LED light A dial tone has been detected and the telephone line is in use by your modem NOTE The last three LED indicators are used only on the dial up modem communication card 4 3 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 3 EIA 422 485 RS 422 485 Serial Communications Card The EIA 422 485 R
173. put Modules Rev Mar 05 FloBoss 407 Instruction Manual To verify low speed operation of the PI Isolated module 1 Alternately supply and remove an input voltage across terminals B and C 2 The module LED should cycle on and off and the total accumulated count Accumulated Pulses should increase 3 5 9 Slow Pulse Input Source Module Equipment Required Jumper wire To verify low speed operation of the PI Source module 1 Connect and remove a jumper across terminals B and C several times to simulate slow switching 2 The module LED should cycle on and off and the total accumulated count Accumulated Pulses should increase 3 5 10 Slow Pulse Input Isolated Module Equipment Required Jumper wire To verify low speed operation of the PI Isolated module 1 Alternately supply and remove an input voltage across terminals B and C 2 The module LED should cycle on and off and the total accumulated count Accumulated Pulses should increase 3 5 11 Low Level Pulse Input Module Equipment Required Pulse Generator Frequency Counter Personal Computer running ROCLINK configuration software NOTE When checking the operation of the Low Level Pulse Input module ensure that the Scan Period for the Pulse Input is once every 22 seconds or less as set by ROCLINK configuration software To verify operation 1 Connect a pulse generator with the pulse amplitude set at less than 3 volts to terminals B and C 2 Connect a frequency counte
174. r across terminals B and C Set the pulse generator to a value equal to or less than 3 kilohertz Set the frequency counter to count pulses 4 Verify that the count read by the counter and in the total accumulated count Accumulated Pulses read by the FloBoss are the same using ROCLINK configuration software 3 26 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 5 12 RTD Input Module The RTD module is similar in operation to an AI module and uses the same troubleshooting and repair procedures The RTD module can accommodate two wire three wire or four wire RTDs If two wire RTDs are used terminals B and C must be connected together If any of the input wires are broken or not connected ROCLINK configuration software indicates the Raw A D Input value is either at minimum less than 800 or maximum greater than 4000 as follows An open at terminal A gives a maximum reading An open at terminal B gives a minimum reading An open at terminal C gives a minimum reading To verify the operation of the RTD module 1 Disconnect the RTD and connect a jumper between terminals B and C of the RTD module 2 Connect an accurate resistor or decade resistance box with a value to give a low end reading across terminals A and B The resistance value required can be determined by the temperature to resistance conversion chart for the type of RTD being used 3 Use ROCLINK configuration software to verify that the
175. r be powered from another source This translates to a maximum operating input voltage of 5 volts dc which is the upper limit of the module When using a transmitter with a maximum operating current requirement different from 20 milliamps R1 should be sized to achieve full scale deflection at 5 volts The formula for determining a new value of R1 displays in Figure 3 8 ROC POWERED CURRENT LOOP DEVICE TO SELECT PROPER VALUE OF R1 Vs SOURCE VOLTAGE FROM MODULE 10 Vdc 20 mA MAX _ 5 VOLTS MAXIMUM Figure 3 8 AI Source Module Field Wiring for Current Loop Devices 3 4 4 Analog Output Source Module A schematic representation of the field wiring connections to the output circuit of the Analog Output Source module displays in Figure 3 9 and Figure 3 10 The AO Source module can provide either loop current or output voltage to non powered field devices The Analog Output Source module provides a 0 to 5 5 volts output at terminal A and a 0 to 30 milliamps current source output at terminal B Terminal C is referenced to the FloBoss common Resistor R1 O ohm resistor supplied helps keep the loop resistance within the operating range of the module Remove the 0 ohm resistor when the loop resistance between terminals B and C is less than 100 ohms Terminals A and B are both active at the same time Figure 3 9 shows wiring for a FloBoss powered current loop device and Figure 3 10 shows wiring for an output voltage to non powered
176. ransducer HART eee ee ne eee ee eee 3 4 HON LOT err a naan 2 6 History POMS ea tee Aa a 2 6 Hold Display aosanoranenirea e a 5 3 5 12 HOUT e a E eT nT ne eR 5 8 5 13 Hour History LISCE ximple neira a ATEN 5 13 ERC ONTA Goosen a AN 5 12 NV alye Example saae id rie 5 13 Hourly Historical LOG cccccccccccccecceeceeeeeeeeeeeeees 2 6 VO DD tatoos satan e a NTA 5 5 5 9 VO M d l Sores oe Fee es tet 3 1 Cali Fatt OM esa rn ia wataa tanh d eactdee eee deere 3 5 CONME CLOTS n E i 2 5 oaio a A A A a 3 5 Point Configuration eea 3 28 Removing and Installing cesses 3 29 DPE CEICAIONS eE ated cealuame 3 30 Troubleshooting cccccccccccccccccecceeeeeeeeeeeeeeeeeees 3 21 Ny OAC boat Rea ear reek te eae ane 2 5 WIDE nme eens ere aa ere aE 3 5 4 Index VO Power Requirements s43 3 seine eens 1 7 TOs STAG OM cdi cee eiscene E A ee eae eee C 1 VO SUMMA cesena ciel saree cveceaes 5 5 5 8 I O Wiring Requirements j asch cin cccssacadeneh oocteesctaterebens 1 7 Indicators StS EE D Anne ee anne eee N eRe ee Rete eete ee eee 1 11 Installation FOBOS AO cabanna 2 8 aide INES eena werner tere ene Onnny renter cater ree aoe 1 4 I O Module Power Off ccccccceceeeeeeeeeeeeeees 3 29 VO M dUlE Sennen a a 3 5 17 EEEE E E E E E T A 2 MV See A eget conteeel deteecadsancaaaaaee B 2 Padlock Adapte osinon ii 2 9 re o E E E E E E S EE E 4 9 Bobot oerset n tenes aac wee 1 6 2 12 J Jumpers Po 4 4 4 6 4 9 4 12 4 13
177. rce Current equation to compute other value in alae thermoplastic polyester meets Frequency Response 0 to 10 Hz maximum 50 Dimensions 15 mm D by 32 mm H by 43 mm W pul Cyce 0 6 in D by 1 265 in H by 1 690 in W not Input Filter Debounce 50 ms including pins VIBRATION ENVIRONMENTAL 20 Gs peak or 0 06 in double amplitude Meets the Environmental specifications of the 10 to 2 000 Hz per MIL STD 202 method 204 FloBoss in which the module is installed including condition F Temperature Humidity and Transient Protection MECHANICAL SHOCK APPROVALS 1500 Gs 0 5 ms half sine per MIL STD 202 method Approved by CSA for hazardous locations Class 213 condition F Division 2 Groups A B C and D 3 38 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 9 Pulse Input Module Low Level Pulse Input Module Low Level Specifications MODULE RACK TERMINALS A Not used B Positive Pulse Input C Negative Pulse Input INPUT Type Two state voltage pulse sense Active Range 30 mV minimum to 3 V maximum peak to peak Frequency Response 0 to 3 kHz 50 Duty Cycle Impedance 500 kQ POWER REQUIREMENTS 4 9 to 5 1 V dc 2 mA maximum supplied by FloBoss INPUT ISOLATION Isolation 10 MQ minimum input or output to case Voltage 4 000 V ac RMS minimum input to output Capacitance 6 pF typical input to output 3 39 Input Output Modules VIBRATION 20 Gs peak or 0 06 in doubl
178. rce Module Specifications FIELD WIRING TERMINALS A Not used B Positive to field device C Negative OUTPUT Type Solid state relay current sourced normally open Active Voltage 11 to 30 V dc provided Active Current Limited to 57 mA Inactive Current Less than 100 pA with 30 V dc source Frequency 0 to 10 Hz maximum POWER REQUIREMENTS Output Source 11 to 30 V dc 57 mA maximum from FloBoss power supply Module 4 9 to 5 1 Vdc 1 mA in Off state and 6 mA in On state OUTPUT ISOLATION Not isolated Terminal C tied to power supply common Discrete Output Isolated Module Specifications FIELD WIRING TERMINALS A Positive field device power B Negative C Not Used OUTPUT Type Solid state relay normally open Active Voltage 11 to 30 V dc Active Current Fuse limited to 1 0 A continuous at 75 C 167 F externally supplied Inactive Current Less than 100 pA at 30 V dc Frequency 0 to 10 Hz maximum POWER REQUIREMENTS 4 9 to 5 1 Vdc 1 mA in Off state and 6 mA in On state OUTPUT ISOLATION Isolation 100 MQ minimum input to output and input or output to case Voltage 4 000 V ac RMS minimum input to output Capacitance 6 pF typical input to output Discrete Output Modules Source and Isolated Common Specifications VIBRATION 20 Gs peak or 0 06 in double amplitude 10 to 2 000 Hz per MIL STD 202 method 204 condition F MECHANICAL SH
179. re private channel compatible with Bell 202T Data Rate Up to 1200 baud asynchronous software selectable Parity None odd or even software selectable Format Asynchronous 7 or 8 bit software selectable Modulation Phase coherent Frequency Shift Keyed FSK Carrier Frequencies Mark 1200 Hz 0 1 Space 2200 Hz 0 1 Input Impedance 600 Q balanced transformer input Output Impedance 600 Q balanced transformer output RTS to Transmission Delay Configurable in 10 ms increments Sensitivity 35 dBm Maximum Output Level 0 dBm nominal into 600 Q LED Indicators TXD RXD DTR DCD CTS and RTS Surge Protection Conforms to FCC part 68 4 20 Communications Cards OPERATION CONTINUED Certification FCC Part 68 tested Connector RJ11 type POWER REQUIREMENTS 4 75 to 5 25 V dc 0 11 W typical supplied by FloBoss ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity To 95 relative non condensing DIMENSIONS 25 mm H by 103 mm W by 135 mm L 1 in H by 4 05 in W by 5 3 in L WEIGHT 135 g 4 7 oz typical APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev Mar 05 FloBoss 407 Instruction Manual Dial Up Modem Specifications OPERATION Mode Full duplex 2 wire for dial up PSTN Bell 212 compatible Data Rate Up to
180. re connecting a Remote MVS to the FloBoss 407 remove all power from the MVS by unplugging the power to the FloBoss 407 If you do not remove ALL power electronic components will be damaged Refer to Section 2 Backup Procedure Before Removing Power NOTE For Measurement Canada units maintenance and resealing of the FloBoss must be performed by authorized personnel only NOTE There is a possibility of losing the FloBoss configuration and historical data held in RAM while performing the following procedure As a precaution save the current configuration and historical data to permanent memory 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 B 7 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual To avoid circuit damage when working with the FloBoss use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap During this procedure all power will be removed from the FloBoss and devices powered by the FloBoss Ensure that all connected input devices output devices and processes will remain in a safe state when power is removed and when power is restored 1 Remove power from the FloBoss 2 Run four wires from the Flo
181. re not stored to flash ROM when the Flash Memory Save Configuration or Write to EEPROM function is used in the configuration software The logs have the capacity to store up to 240 logs in a circular fashion with new entries overwriting the oldest entry when the buffer is full In addition to providing functionality for appending new alarms system events and audit events to the logs the logs allow host packages to request the index of the most recent log entry The logs are available internally to the system to external host packages to FSTs and to User C programs Alarm Logs and Event Logs are not stored to the flash ROM during the Flash Memory Save Configuration or Write to EEPROM function in the configuration software The Alarm Log records instances when exceptions from field inputs and calculations occur 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 ASCII character description The Alarm Log provides an audit history trail of past operation and changes The Alarm Log 1s stored separately to prevent recurring alarms from overwriting configuration audit data The Event Log contains a record of past operator changes and system events such as power downs The Event Log is stored separately from the Alarm Log to prevent recurring alarms from overwriting configuration change events The Audit Log
182. re the FloBoss is properly installed Make sure the enclosure has a good earth ground connected to the earth ground bus inside the enclosure Seat and secure all I O modules in their sockets Check the field wiring for proper installation Make sure the input power is fused at the power source Make sure the input power has the correct polarity gt gt gt PH Make sure the input power is at least 12 5 volts unless the LV Start Switch S1 is depressed during power up It is important to check the input power polarity before turning on the power Incorrect polarity can damage the FloBoss CAUTION 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 1 10 General Information Rev Mar 05 FloBoss 407 Instruction Manual 1 6 1 Startup Observe the previous cautions and apply power to the FloBoss 407 After the FloBoss completes start up diagnostics of Random Access Memory RAM and other internal checks the STATUS LED on the processor board turns on This LED should turn on and stay on to show that the FloBoss 407 completed a valid reset sequence If the LED indicator does not come on refer to Section 2 Troubleshooting and Repair for possible causes 1 6 1 1 Performing an LV Start Switch Startup The L
183. rikes install surge suppression devices The following commercially available lightning protection modules have been found to meet requirements Model Number LPC 10643 485 Protects the communication pair A and B terminals Model Number LPC 10643 1 Protects the power and ground pair and terminals These units are available from Lightning Protection Corporation PO Box 6086 Santa Barbara CA 93160 Telephone 1 800 317 4043 http www lightningprotectioncor com B 9 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual B 3 2 RTD Wiring An RTD sensor assembly containing an element with an alpha of 0 00385 is typically used with the MVS8205 sensor Refer to the ROC FloBoss Accessories Instruction Manual Form 44637 for installation information Resistance Temperature Detectors RTD are transducers typically used to sense the temperature of a gas or fluid in a pipe An RTD sensor can provide a signal to an RTD input module in a MVS or to the RTD input of a FloBoss 407 The following RTD assemblies include an RTD element in a protective thermowell and a connection head with screw terminals Model TW25 RTD Element 100 to 400 C 148 to 752 F with 2 5 inch thermowell 4 wire Model TW45 RTD Element 100 to 400 C 148 to 752 F with 4 5 inch thermowell 4 wire These assemblies use a 100 ohms platinum RTD element The spring loaded element has an alpha of 0 00
184. ring this procedure all power will be removed from the FloBoss and devices powered by the FloBoss Ensure 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 NOTE A firmware upgrade can also be performed without removing the flash chip Refer to the Update Firmware procedure described in the ROCLINK for Windows Configuration Software User Manual Form A6091 or the ROCLINK 800 Configuration Software User Manual Form A6121 The Update Firmware method cannot be used for Measurement Canada Authorized personnel must use the Replace the Flash ROM procedure for Measurement Canada To replace the FloBoss 407 flash ROM chip 1 Perform the RAM backup procedure Refer to Section 2 5 2 RAM Backup Procedure Before Removing Power on page 2 21 2 Disconnect the PWR input connector from the processor board 3 Using a Flash ROM Extractor remove the flash ROM chip located at U2 on the termination board 4 Gently press the new flash ROM chip into the socket located at U2 on the termination board The flash ROM chip should fit securely into the socket 5 Connect the PWR input connector to the processor board 6 Refer to Section 2 5 3 After Installing Components on page 2 22 7 Install the updated firmware and user programs into the flash ROM if required 2 5 16 Keypad and Display Replacement To replace a damaged
185. rrent drain on the power supply For an analog I O channel the Duty Cycle 1s approximated by estimating the percentage of time the channel spends in the upper half of its range span of operation For example if an Analog Input wired as a current loop 4 to 20 milliamps device operates in the upper half of its range 75 of the time then 0 75 would be used as the Duty Cycle If the analog channel generally operates around the midpoint of its span use 0 5 as the Duty Cycle 2 To calculate the total power consumed by an I O channel first select either the 12 Volt or 24 Volt column in Table lor Table 1 2 and read the minimum P min and maximum Pmax power consumption value from the table for the desired I O channel 1 7 General Information Rev Mar 05 FloBoss 407 Instruction Manual 3 Calculate the power consumption for a channel with the Duty Cycle using the following equation taken into account Power Pmax X Duty Cycle Pmin 1 Duty Cycle 4 Multiply this value by the quantity QTY of I O channels with the same Duty Cycle and enter the calculated value in the Sub Total column Repeat the procedure for all other I O channels used Total the values in the I O Modules Sub Total column in Table Enter the I O Modules Total value in Tablel 1 1 Calculate the Radio Power Consumption total Refer to Sectio Determining Radio Power Consumption on page 1 9 9 Enter the Radio Power Consumption Total value in Table 1 1 10
186. ruction Manual 2 Plug the LPM into the field wiring terminal block socket located in step 1 Connect the LPM ground wire to the ground bus bar This ground bar must in turn be connected to a good earth ground Do not use the power system ground for this connection 4 Transfer any field wiring from the unplugged termination block to the built in termination block on the LPM A 3 Connecting the LPM to Wiring There is a one to one correspondence between the LPM terminals and the terminals of the I O channel being protected If you are connecting field wiring to the LPM refer to the I O wiring information in Section 3 Input Output Modules NOTE The LPM module provides sockets for a plug in range scaling resistor These sockets which are internally connected to the module s middle and right most screw terminals must be used when installing a range resistor for a built in Analog Input channel For an Analog Input module or any other module using a scaling resistor either the sockets on the I O module or on the LPM may be used for the scaling resistor The LPM module provides a ground wire for connection to the enclosure ground bar or ground lug The enclosure ground bar or ground lug must in turn be connected to a good earth ground Do not use the power system ground for this connection A 4 Troubleshooting and Repair The Lightning Protection Modules function by shunting the high voltage transients through gas discharge tub
187. ry List Example Figurg 5 14 bhows an example of a Minute History List display The minute history scrolls displaying the minute values every three seconds By pressing the HOLD DISPLAY key the minute history stops scrolling and the arrows key can be used to increment the minute values NEXT SET Figure 5 14 Minute History Value Example 5 4 10 Hour History Figure 5 15 shows the general format for the Hour History List display History TYPE PARAMETER Figure 5 15 Hour History List Format The hour history configured points list scrolls when the ALT key and HOUR HIST key 1s pressed Figure 5 16 shows a list display for the MVS 1 point which can be selected with USER the ENTER key from the scrolling list LIST 2 HOUR HIST Figure 5 16 Hour History List Example Figen 17 hows an example of a Hour History List display The hour history scrolls displaying the hour values every three seconds When the HOLD DISPLAY key is pressed the hour history stops scrolling and the arrow keys can be used to increment the hours The date is shown as month day followed by the hour 5 12 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual Figure 5 17 Hour History Value Example 5 4 11 Day History Figurg 5 18 shows the general format for the Day History List display History TYPE PARAMETER Figure 5 18 Day History List Format The day history configured points list scrolls when the ALT key and then DAY HIST key i
188. s pressed Figure 5 19 shows a list display for the MVS 1 point which can then be eres selected with the ENTER key J DAY HIST Figure 5 19 Day History List Example The example shown in Figure 5 20 a Day History value display The date is shown as month day and the time shows the configured beginning hour of the contract day Figure 5 20 Day History Value Example 5 4 12 Control Press the CONTROL key to display the following information concerning the currently Bre selected PID loop Control Type Switch Status Actual Scan Time Pri Setpoint Pri a oe Process Variable Pri Output Pri Proportional Gain Pri Integral Gain Pri Derivative Gain Pri Loop Period Pri Setpoint EU Min Pri Integral Deadband and Pri Scale MIHIMAX Factor 5 13 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual 5 4 13 Comm Ports Press the ALT key and COMM PORTS to display information concerning the currently Rene S selected communications port The LCD displays the communications Port Baud Rate Stop Bits Data Bits Parity Status Mode Key On Delay Key Off Delay Retry a Count and Retry Time COMM PORTS 5 4 14 Sys Param FLOW CORP Press the ALT key and SYS PARAM to display information concerning system parameters The following system parameters display Part Number Address Group 3 Station Name and Contract Hour SYS PARAM 5 4 15 Help Press the HELP key to display help information concerning the currently select
189. s Source and Isolated Slow Pulse Input Source Module Specifications MODULE RACK TERMINALS POWER REQUIREMENTS A Not used Source Input 11 to 30 V dc 9 mA maximum from B Input source voltage FloBoss power supply C Common Module 4 9 to 5 1 V dc 1 mA maximum supplied INPUT by FloBoss Type Contact sense INPUT ISOLATION Range Inactive 0 to 0 5 mA Active 2 to 9 mA Not isolated Terminal C tied to power supply Source Voltage 11 to 30 V dc common Source Current Determined by source voltage Vs loop resistance RI and scaling resistor Rs Vs 1 3 3K RI Rs Slow Pulse Input Isolated Module Specifications FIELD WIRING TERMINALS POWER REQUIREMENTS A Not used 4 9 to 5 1 V dc 1 mA maximum supplied by B Positive input FloBoss C Negative input INPUT ISOLATION INPUT Isolation 100 MQ minimum input to output and Type Two state current sense Input or output to case Range Inactive 0 to 0 5 mA Active 2 to 9 mA Voltage 4 000 V ac RMS minimum input to Current Determined by input volt age Vi loop enue resistance RI and scaling resistor Rs Capacitance 6 pF typical input to output Vi 1 3 3K RI Rs Maximum Voltage 30 V dc forward 5 V dc reverse Slow Pulse Input Modules Source and Isolated Common Specifications INPUT WEIGHT Loop Resistance RI 4 5 kQ maximum for best 37 g 1 3 oz efficiency Scaling Resistor Rs 10 Q supplied see Input aie h lasti i Sou
190. s Part 68 compliant See 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 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 is not 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 2578 If the equipment is causing harm to the telephone network the telephone company may request that you disconnect the equipment until the proble
191. s 3 26 V Gray RA M iy 5 cast ete a epee aust aeeeias 2 20 Verifying the ROC can Communicate with the PC EE A A E E siamo eeeneeaee ee 2 20 T roime Metela naan ocuenrckeatanucaeeaaudaruae C 6 T rbine Meteriht reiini a es 2 6 TA Donon 4 3 U UDARMOW KEV arer E eee aes 5 3 Updating the Firmware ccccccccccceeeeeeeeeeeeeees 2 26 User SISU ane nielecesdescaccsetedncabsaastaanahetane iaevewoscastes 5 8 5 10 V NV Arla Dl SENS OF enra E ATER 2 5 Vernfyine RAM orenen doadeerleternne tadueaeuiaeds 2 20 Verifying the ROC can Communicate with the PC Index NERON anda ees tan cet ehotede ninol Scceateosensae 2 3 VOO Caer oP ea 1 10 Volts and 24i ee epee een eee eee Oe eee ere Ree eee 2 4 W z W JUMP Ch aore ar 2 4 2 22 2 23 WT PANS ete Cele a ded tastes 2 4 WV AEM otak sensecdetacctalseqasiatd siesta tcstadadecetasaigesaadetanaes 2 19 Wiring Analog Input Channels Built in 2 14 Analog Input Differential Module 00 3 7 Aallos Input LoP eaa Gizeehitereeltease 3 6 Analog Input Source eseeoeeneeeneennnnnenenneseeeseseeeeene 3 8 Analog Output SOULCE esssoeoooooeonennesensseseesseeeeeene 3 9 Communications ccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 16 Communications Cards cccccccccceeeeeeeeeeeeeeeeees 4 11 Dial Up Modem Communications Cards 4 16 Discrete Input Isolated 0 cccccccceeeeeeeeees 3 11 Discrete Input SOuUrCE cma cccsnccseseshecsecigeestestsenedeces 3 1
192. s 407 Instruction Manual Table 5 3 Value Shown on Display Pi o Engineering Units DI Not TDI DO TDO Engineering Units DO Not TDO Differential Pressure MVS Static Pressure Temperature 9 4 2 I O Detail I O Detail displays the entire set of parameters for the currently selected I O point To use I O Detail 1 Press O SUMMARY 2 Press EDIT to select a parameter from the I O point list 3 Press ALT and I O DETAIL The values for the selected parameter display 5 4 3 Flow Rates Press the FLOW RATES key to display the flow rate parameters for the first meter run The T and J keys scroll through the parameters for the first meter run To move to the second meter run press ALT and NEXT SET The LCD starts displaying the parameters for the second meter run 5 4 4 Flow Comp Press the FLOW COMP key to display the gas composition parameters for the first meter run The and J keys scroll through the parameters for the first meter run To move to the second meter run press ALT and NEXT SET The LCD starts displaying the parameters for the second meter run 5 4 5 Meter Config Press the METER CONFIG key to display information concerning the selected meter run The LCD displays the pipe diameter orifice diameter latitude elevation calculation method tap type orifice material and DP low flow cutoff for the meter run 5 9 Display and Keypad FLO VW RATES 8 COMM PORTS FLOW COMP 9 SYS PARAM METE
193. s when an input voltage with the proper polarity and level is applied to the power terminal block if the power input fusing protection is operational Refer to Section 1 Performing an LV Start Switch Startup to power up under low voltage conditions The FloBoss 407 power supply circuitry provides supply voltages of 5 5 and 8 5 volts In addition 12 or 24 volts T 1s provided for transmitter power using a switching regulator The T voltage is used by the built in field I O and the plug in I O modules to provide power for loop powered instruments such as transmitters The T voltage depends on the setting of a jumper on the termination board located at P15 or W1 Refer to Figurt 2 1 fon page 2 2 If Jumper P15 is set to 24 volts or if the W1 pins are not connected factory default then the T voltage is 24 volts or greater If the input power voltage to the FloBoss 407 exceeds 24 volts the switching regulator shuts down and the T voltage follows the input voltage If Jumper P15 is set to 12 volts or if the W1 pins are connected supplied jumper plug then the switching regulator no longer operates so that the T voltage is 12 volts provided the input power is 12 volts This setting should only be used when all I O loops for this FloBoss require a 12 volts source 2 4 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual For Revision D or later of the termination
194. se points can be changed if required The time stamp for periodic logging consists of the month day hour and minute The exception is for FST Second logging in which the time stamp consists of the day hour minute and second The FloBoss has a 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 By using the FST Editor utility the period in which the data 1s logged can be placed under program control The FloBoss has a total of 840 Hourly Historical Logs available for every history point The Hourly Historical Log 1s also called the Periodic Log Normally the Hourly Log is recorded every hour at the top of the hour The exception is for FST controlled logging 2 6 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual The FloBoss has a total of 35 Daily Historical Logs for every history point The Daily Historical Log 1s recorded at the configured contract hour every day with a time stamp that is the same as the Hourly Historical Log Each history point has daily historical log entries unless the history point is configured for FST controlled logging 2 2 Alarm Audit and Event Logs Alarm Event and Audit Logs are stored in non volatile RAM in the FloBoss Note that they a
195. seeeeeeeeceeccccnnssseeneeeeececcnnnassseeeeeeeeecccnnaasaaed Event Log and save the calibration values Save Calib Data Press J to select NO and press ENTER to delete the calibration changes restores old calibration data The program proceeds to the SELECT METER RUN display Calibration Step 1 35 Press J to select EXIT and press ENTER from SELECT METER RUN Calibration Step 1 to return to the date and time display and exit the calibration program B 15 Multi Variable Sensors Rev Mar 05 FloBoss 407 Instruction Manual B 6 MVS Troubleshooting and Repair It is very important that the MVS be removed or replaced without power connected CAUTION When replacing an MVS remove all power from the MVS by pulling out the MVS connector plug P8 on the FloBoss 407 If you do not remove ALL power from the MVS electronic components may be damaged If more than one MVS is connected to the FloBoss 407 make sure that each has a unique Address as explained in Section B 4 Configuring the MVS on page B 10 Use ROCLINK configuration software to establish each unique MVS Address If your MVS displays letters such as NANO for any of the input readings there is likely a floating point error in the sensor Attempt to reset the MVS back to factory default settings If you believe an MVS is damaged or faulty contact your local sales representative for repair or replacement If you are having difficulty communicating with an MVS unit
196. ser defined Displays digit 3 on DAY HIST LIST 3 list number 3 LCD for data entry Displays Day History Log ALT Activates Alternate mode the Displays decimal PASSWORD functions labeled in white below each point 2 on LCD for Logs current user off and key For example on the I O data entry prompts for new SUMMARY key I O DETAIL password activates EDIT Activates Edit mode the functions ENTER DISPLAY OFF labeled in red on each key This Validates and saves Logs current user off and includes the numeric digits the an edit or selects a turns off the LCD Press the and the backspace key menu item such as any key to activate the The CANCEL key stops Edit mode during calibration password display 5 7 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual 5 3 4 Arrow Keys The T and J keys are used to scroll through the lists when the Hold Display f t mode is invoked To skip a whole group of parameters select NEXT SET For example the FLOW RATES key normally displays the parameters for the first meter run The T and J keys scroll through the parameters for the first TIME CANCEL meter run To move to the second meter run press ALT and NEXT SET The LCD starts displaying the parameters for the second meter run The arrow keys similarly allows quick access to parameters for control loops and I O points 4 CANCEL 5 4 Display of Parameters The LCD displays various functions when sel
197. sesessessesesesstsesessteees 4 8 Source ceoeenseenecenscensccnnccnacenacennetastnattansennecanetenstanses 3 2 COM T DOE aha 2 5 2 16 4 11 Source Wiring E E E tie aceon eee coast 3 8 COMO PO biceik csc aI an 2 5 2 16 4 11 Testing Built in A AEE AEA E E E tan A 2 22 COMM Port Connector ooccoooocooooooecoooocceceeecc 4 7 Troubleshooting EE aegis ene E 3 22 COMM Potts ooooocoooocooooccocccee 2 16 5 5 5 14 V OHA Se Sonal eneur E 2 14 Communications Wiring Built 1 s cesses eee teseeseeseenes 2 14 CONNECTIONS sessir E 2 4 Analog Outputs Verifying the ROC can Communicate with the PC Analog Outputs to Ammeter or Volt Meter er er eee rs 2 20 Analog Outputs to Analog Inputs C 1 Aig eee Ce eG eee ed 2 16 4 11 Checking Voltage Source Installations 3 23 Communications Cards c cccccssscecesseeeeseseeeseseeeees 4 1 Source ceoteseennceneenecennecnncennecnactnnetinetentennecaneeanetanses 3 2 Attenuation Levels 4 5 4 6 4 10 4 13 4 15 DOULCE WU MG pons ashes ated an hess taap a n 3 9 Dial Up Modem ccccccscssesessssesessesecersesecevsveecevees 4 7 Troubles hoonN onpa 3 22 FIA 232 RS2232 aeaaea leon 4 2 ANEAN a dsoueasras ats dectesas aaasndtosuu saat altve demas 1 5 EIA 422 485 RS 422 485 ccccccccsscsecesesseceseeseeeee 4 4 AP eae re sala Sereda tata a Peace ceehane aba na ck cele Deore 2 5 Leased Line Modem 4 6 4 9 4 15 Arrow E AII A EE P S tae 5 3 PD Td
198. stored after a Reset gt gt gt gt gt OH mm _ O O 0 ate oe oN Device Address and Group Radio Power Control parameters Station Name AGA parameters Number of history points in each module Proportional Integral and Derivative Contract hour PID parameters AI Calibration Configurable Opcode parameters History point configuration FST Tags and Registers I O parameters Softpoint parameters All communication port settings including User program enable flags COM1I power control settings COM2 and USER CALC Perform the RAM Backup Procedure previously described in Section 2 5 2 RAM Backup Procedure Before Removing Power on page 2 21 if possible Remove power from the FloBoss Press the Reset button and hold while returning power to the FloBoss Connect your FloBoss to a computer running ROCLINK configuration software Select Utilities gt Download User Programs or User Program Administration Clear all User Programs Clear All and click OK or Update Select ROC gt Flags Select the Clear EEPROM checkbox or click Flash Memory Clear and click Apply Select the Cold Start checkbox Click the Cold Start Options button Select the Restore Config amp Clear All of the Above Cold Start amp Clear All radio button and click OK 2 5 11 Testing the Built in Analog Input Equipment Required Multimeter 1 kilohm resistor 0 5 kilohms potentiometer PC w
199. struction Manual Table 2 4 Indicator Functions Successful startup and the processor is running STATUS BLINKING Processor is not running and is attempting to restart Can result from bad battery No input power circuit protection devices overloaded insufficient voltage available to power up or input power polarity reversed Power not applied Input active Input not active Power is connected Must be minimum of 12 5 volts unless LV START switch is used 2 5 2 RAM Backup Procedure Before Removing Power Use the following backup procedure when removing or adding FloBoss 407 components Before removing power to the FloBoss for repairs troubleshooting or enhancements perform the backup procedure to avoid losing the FloBoss configuration and other data held in RAM The procedure assumes you are using ROCLINK configuration software User programs cannot be saved out of the FloBoss Reload user programs from their original disk files as instructed in the ROCLINK for Windows Configuration Software User Manual Form A6091 or the ROCLINK 800 Configuration Software User Manual Form A6121 When installing devices in a hazardous area make sure each device is labeled for use in such areas Procedures involving switching power on or off or procedures for installing or removing any wiring or components must be performed only when the area is known to be non hazardous Performance of these procedures in a hazardous area could result in
200. supply and converter accessories to minimize the number of separate power sources required for an installation 1 4 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 407 helps to reduce the effects of electrical noise on the units operation and protects against lightning Lightning Protection Modules LPM are available to provide additional lightning protection for 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 All earth grounds must have an earth t
201. t modes as indicated by the label color Normal operations black label Edit operations red label and Alternate operations white label below key To perform a Normal operation press the desired key neither EDIT or ALT keys are used To perform an Edit operation to key in a value press the EDIT key and then the desired key or keys Press the ENTER key when you are done keying in the value Each time you want to perform an Alternate operation press the ALT key and then the desired key NOTE To make sure that the key you press activates push firmly in the center of the key I O METER SUMMARY CONFIG 7 0 HOLD DISPLAY 4 5 CANCEL CONTROL ALARMS ENTER Figure 5 2 Keypad Layout Figure 5 2 provides a brief description of the Keypad functions and the expected displays To activate the display press any key for example I O SUMMARY This returns a password prompt to the display Enter the numeric password with the Keypad and press ENTER A date and time message shows on the LCD Refer to Section 5 5 Security on page 5 14 concerning password security 5 2 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual Select one of the categories to view from the Keypad The information scrolls on the LCD Press HOLD DISPLAY to stop the list from scrolling on the LCD The FloBoss 407 continuously updates the current display until the HOLD DISPLAY key is pressed to return the list to the scroll mode Table 5
202. ter than 25 ohms the FloBoss 407 installation should be electrically isolated and a ground rod or grid grounding system installed 1 4 6 I O Wiring Requirements I O wiring requirements are site and application dependent Local state or NEC requirements determine the I O wiring installation methods Direct burial cable conduit and cable or overhead cables are options for I O wiring installations Sections 2 nd 3 contain detailed information on connecting I O wiring to the FloBoss 407 1 5 Power Supply Requirements The power consumption of a FloBoss 407 system determines power supply and battery sizing for both line and solar power supplies Table 1 1 hnd Table 1 2 provide information to assist in determining power requirements 1 5 1 Determining I O Channel Power Consumption To determine the I O Channel Power 1 Calculate the Duty Cycle of each I O channel and enter the values in Tabld 1 1 In estimating total I O power requirements the Duty Cycle of each I O channel built in I O or modular I O must be estimated For a non analog I O channel the Duty Cycle is the percentage of time that the I O channel is active maximum power consumption For example if a Discrete Output 1s active for 15 seconds out of every 60 seconds the Duty Cycle 1s Duty Cycle Active time Active time Inactive time 15 sec 60 sec 0 25 NOTE For non analog I O size the I O module scaling resistors for optimal current to minimize cu
203. tery from the board If the clip does not readily rotate you may need to loosen the screw that secures it Be careful not to break or bend the terminal pins 3 Use a multi meter to measure the voltage at the terminals of the battery that has been removed Ifthe voltage of the battery is less than 3 6 volts it is no longer good and must be replaced Ifthe battery is still good re install it into its socket and continue with other troubleshooting procedures 2 20 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 5 8 Replacing the Battery To install a battery into a functioning FloBoss NOTE For Measurement Canada units maintenance and resealing of the FloBoss must be performed by authorized personnel only To avoid circuit damage when working with the FloBoss use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Locate the unused battery socket typically B2 on the processor board Insert the new battery in this position Be careful not to break or bend the terminal pins 2 Remove the old battery from the other battery socket typically B1 by sliding the hold down clip to one side and lifting the battery from the board If the clip does not readily rotate you may need to loosen the screw that secures it Be careful not to break or bend the terminal pins 3 Move the hold down clip to the new battery
204. the correct operation of the AO module by setting the High Reading EU and Low Reading EU values as before Scanning Disabled and observing the field device 3 5 2 2 Check AO Voltage Source Installations Equipment Required Multimeter Personal Computer running ROCLINK configuration software To check operation of the Analog Output module powering a voltage device 1 If the resistance value R of the field device is known measure the voltage drop V across the device and calculate the output EU value using the following formula EU value 1000V R 4 16 x Span Low Reading EU where Span High Reading EU Low Reading EU 2 Compare the computed value to the output EU value measured by the FloBoss with ROCLINK configuration software It is normal for the reading to be several percent off depending on the accuracy tolerance of the device and how rapidly changes occur in the output value Calibrate the Analog Output EU values by increasing or decreasing the Adjusted D A Units 4 Ifthe Analog Output is unable to drive the field device to the 100 value confirm the V 1 to 5 volts voltage is present at the field device Ifthe voltage is present and the device is not at the 100 position the resistance value of the device 1s too large for the V voltage Use a field device with a lower internal resistance Ifthe voltage is not present at the field device but it is present at field wiring terminal B there is
205. the shank up to 6 35 millimeters 0 25 inches diameter of the padlock running through the adapter the screw is inaccessible and the cover cannot be opened 1 4 Installation Guidelines This manual provides generalized guidelines for successful installation and operation of the FloBoss 407 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 407 application while planning an installation NOTE Use a standard screwdriver with a slotted flat bladed 1 8 width tip when wiring all terminal blocks 1 4 1 Environmental Requirements The FloBoss 407 case is classified as a National Electrical Manufacturer s Association NEMA 4X enclosure This provides the level of protection required to keep the FloBoss operating under conditions such as harsh weather and corrosive atmospheres NOTE In salt spray environments it is especially important to ensure that the enclosure is sealed properly including all entry and exit points If salt is allowed to enter it can shorten the life of the lithium battery in the FloBoss and cause the battery to leak corrosive chemicals The FloBoss is designed to operate over a wide range of temperatures as detailed in the Environmental specifications Outside of this range it may be necessary to moderate the temperature in which the FloBoss operates 1 4 2 Site Requirements Careful c
206. tions supported by both modules are Latched Discrete Input Standard Discrete Input and Time Duration Input TDI The DI Source module provides a source voltage for dry relay contacts or for an open collector solid state switch The DI Isolated module accepts an external voltage from a powered two state device and provides electrical isolation from the FloBoss power supplies 3 2 5 Discrete Output Source and Isolated Modules The Discrete Output Source DO Source and Discrete Output Isolated DO Isolated modules provide two state outputs to energize relays and power small electrical loads Each module provides one DO Both types of modules provide an LED that lights when the input is active Both modules are fused for protection against excessive current Functions supported by both modules are Latched Discrete Output Toggle Discrete Output Timed Duration Output TDO and TDO Toggle The DO Source module supplies switched current limited power to small loads The DO Isolated module acts as a solid state normally open switch for activating externally powered devices The solid state switch is optically isolated from the power supplies in the FloBoss 3 2 6 Discrete Output Relay Module The Discrete Output Relay DO Relay module provides two sets of dry relay contacts to switch voltages of up to 250 volts ac One set of contacts is normally open and the other set is normally closed Two types of relay modules are available one wit
207. 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 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 NOTE For a Measurement Canada FloBoss 407 resealing of the case must be performed by authorized personnel only NOTE There is a possibility of losing the FloBoss configuration and historical data held in RAM while performing the following procedure As a precaution save the current configuration and historical data to permanent memory Refer to Section 2 Backup Procedure Before Removing Power 1 To avoid losing data perform backups as explained in Section 2 Backup Procedure Before Removing Power Disconnect power from the FloBoss Loosen the captive screw to open the top door 4 Ifthe communications card is a Dial up or Leased Line Modem Card unplug the telephone jack cable from termination board connector P2 5 Remove the retaining screw from the middle of the communications card Using a rocking motion to disengage the connectors J1 an
208. tor into the card at R2 makes the adjustment Refer to Sectio Setting Modem Card Attenuation Levels on page 4 12 Figure 4 10 shows the relationship between the radio modem signals and terminal numbers for the COM2 terminal block 4 13 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual RADIO MODEM CARD COM2 TERMINAL BLOCK TRANSMIT LEVEL RADIO TXA RXA PTT PTT COM OnRUW N OND RTS RECEIVE LEVEL x q Figure 4 10 Radio Modem Wiring Schematic DOC0232B The following signals used for monitoring or connecting to an analyzer are available at connector P7 located at the bottom edge of the card These signals are normally not active To activate them pin 8 Shutdown must be grounded to pin 2 using a jumper this does not affect normal operation All unused signals can be left unterminated P7 Terminal Function 5 volts dc 8 Shutdown 4 5 4 Leased Line Communications Card Wiring The Leased line Modem Card interfaces to a leased line through the RJ11 jack The terminal functions depend on the mode of operation of the card either 2 wire or 4 wire as follows RJ11 Terminal B Operating Mode Not used 4 14 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual L2 NOTE On the Leased Line Modem Card Tip and Ring is shown reversed to comply with normal telephone signals and functions normally with the two signals reversed The Leased Line Modem Communications
209. transferring stored data 2 2 0 Flow Measurement One of the primary functions of the FloBoss 407 is to measure the flow of natural gas in accordance with the 1985 or 1992 American Petroleum Institute API and American Gas Association AGA standards The FloBoss performs either 1985 or 1992 AGAS3 orifice calculations depending on which was ordered firmware Version 1 04 and earlier contains both In addition all versions of FloBoss 407 firmware contain the AGA7 turbine meter flow calculation function Certain flow calculations may be configured for either Metric or English units 2 5 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual The primary inputs used for the orifice metering flow measurement functions are differential pressure static pressure and temperature Inputs come from the Multi Variable Sensor MVS with the temperature input acquired from an RTD probe whether connected to the MVS or not The 1985 flow calculation is in accordance with AGA Report No 3 1985 and AGA Report No 8 1985 ANSI API 2530 85 and API Chapter 14 2 and API Chapter 21 1 The 1992 flow calculation is in accordance with AGA Report No 3 1992 ANSI API 2530 92 AGA Report No 8 1992 2nd printing 1994 API Chapter 14 2 and API Chapter 21 1 The primary inputs used for the turbine metering flow measurement functions are meter pulse static pressure and temperature These inputs typi
210. ts user program data and history data T POWER SUPPLY JUMPER P15 or W1 COM2 COMM BOARD I O SN SARS AI PI JUMPER P4 ea PI STATUS INDICATOR COMM BOARD CONE TO RJ11 BRACKET BACKUP Pmcs p OPERATOR INTERFACE PORT BATTERY al R g Amman TERMINATION BOARD PROCESSOR ae BOARD I O MODULE CONNECTORS RESET I O MODULE TERMINALS STATUS INDICATOR AI PI ON BOARD I O TERMINAL Al ON BOARD I O TERMINAL MVS PORT POWER INDICATOR POWER CONNECTOR EXTERNAL GROUNDING GROUND BUS BAR TERMINAL ROC407 wmf mod Figure 2 1 Processor and Termination Boards 2 2 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual The processor board has a 512 kilobytes flash memory chip for storing firmware such as the operating system factory code user programs and configuration parameters A protected 64 kilobytes block of flash memory contains the operating system kernel boot block The four different flash chips determine the FloBoss 407 version as follows W68044 Standard AGA92 Version 1 05 or greater W68073 Standard AGA85 Version 1 05 or greater W068057 Measurement Canada AGA92 Version 1 05 or greater W068074 Measurement Canada AGA85 Version 1 05 or greater Tabld 2 1 shows how the FloBoss 407 memory is allocated Each memory location range such as 00000 to OFFFF represents 64 kilobytes of memory Table 2 1 FloBoss 407 Memory Map
211. ts into which I O modules may be plugged A letter physically identifies 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 diagnostic 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 from the Flow Computer Division of Emerson Process Management a microprocessor based unit that provides remote monitoring and control ROCLINK or ROCLINK 800 Configuration software used to configure FloBoss units to gather data as well as most other functions ROM Read only memory Typically used to store firmware Flash memory RTD Resistance Temperature Detector RTS Ready to Send modem communications signal RTU Remote Terminal Unit RTV Room Temperature Vulcanizing typically a sealant or caulk like silicone rubber RXD Received data communications signal G 5 Glossary Rev Mar 05 FloBoss 407 Instruction Manual S SAMA Scientific Apparatus Maker s Association Script A uncompiled text file such as keystrokes for a macro th
212. uding the history database ROC Displays or FSTs save them to disk 4 7 Communications Card Specifications The following tables list the specifications for each type of communications card Serial Communication Cards Specifications EIA 232D RS 232 CARD Meets EIA 232 RS 232 standard for single ended data transmission over distances of up to 15 m 50 ft Data Rate Selectable from 300 to 9600 baud depending on the configuration software used Format Asynchronous 7 or 8 bit software selectable with full handshaking Parity None odd or even software selectable EIA 422 485 RS 422 485 CARD Meets EIA 422 RS 422 and EIA 485 RS 485 standard for differential data transmission over distances of up to 1220 m 4000 ft As many as ten devices can be connected on an EIA 422 RS 422 bus As many as 32 devices can be connected on an EIA 485 RS 485 bus Data Rate Selectable from 300 to 9600 bps Format Asynchronous 7 or 8 bit software selectable Parity None odd or even software selectable Termination Load 140 Q jumper selectable 4 19 Communications Cards LED INDICATORS Individual LEDs for RXD TXD DTR DCD CTS and RTS signals Not all apply to EIA 422 485 RS 422 485 communications POWER REQUIREMENTS 4 75 to 5 25 V dc 0 15 W maximum supplied by FloBoss ENVIRONMENTAL Same as the FloBoss in which the card is installed Refer to the FloBoss specifications DIMENSIONS 25 mm H
213. uration software can be supported by a single FloBoss 3 4 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual 3 3 Initial Installation and Setup Each I O module installs in the FloBoss in the same manner Any I O module can be installed into any I O module socket To install a module on a FloBoss that is not in service perform the following steps For an in service FloBoss refer to Section 3 5 Troubleshooting and Repair on page 3 23 Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations When preparing a unit for installation into a hazardous area change components in an area known to be non hazardous NOTE FloBoss units used in Measurement Industry Canada installations must not employ I O modules for flow measurement 1 Install the I O module by aligning the pins with the desired I O module socket and pressing gently but straight down 2 Tighten the module retaining screw 3 Make sure a field wiring terminal block is installed in the socket adjacent to where the I O module was installed If a Lightning Protection Module is to be installed for this I O channel refer to Appendix A 3 3 1 Calibrating an I O Module After an I O module is installed configure and calibrate the associated I O channel using ROCLINK configuration software 3 4 Connecting t
214. vailable at the COM2 port for wiring to an analyzer or monitor These signals are activated by shorting pin 4 SHUTDOWN to pin 9 COM COM2 i a Ring indicator SHUTDOWN Disable signal lines e esv Bots dc power e Ds Daasetready Common 8 poran 4 6 Troubleshooting and Repair The communications cards have no user serviceable parts If a card appears to be operating improperly verify that the card is set up according to the information contained in Section 4 4 Initial Installation and Setup on page 4 10 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 Follow the procedures below to help ensure data is not lost and equipment is not damaged during replacement of a communications card 4 17 Communications Cards Rev Mar 05 FloBoss 407 Instruction Manual 4 6 1 Replacing a Communications Card If you are installing a communications card for the first time refer to Section 4 4 Initial Installation and Setup on page 4 10 To remove and replace a communications card on an in service FloBoss 407 perform the following procedure Be sure to observe the cautions to avoid losing data and damaging equipment 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
215. ween the probe and RTD module In operation the RTD module subtracts the resistance between terminals B and C from the resistance between terminals A and B The remainder is the resistance of only the active element of the probe This compensation becomes more important as the resistance of the hookup wire increases with distance between the probe and the FloBoss Of course in order to perform properly the compensation loop must use the same type size and length of hookup wire as the active element loop The RTD module is designed for only one compensation loop and this loop is not isolated from the active element loop because terminal B is common to both loops In the 3 wire RTD the wires connect to module terminals A B and C as shown in Figure 3 23 It is important to match the color coding of the RTD probe wires to the proper module terminal because the probe wire colors vary between manufacturers To determine which leads are for the compensation loop and which are for the active element read the resistance across the probe wires with an ohmmeter The compensation loop reads 0 ohms and the RTD element reads a resistance value matching the temperature curve of the RTD RTD 3 WIRE 100 OHM RTD PROBE DOC0161A Modified Figure 3 23 RTD Input Module Field Wiring for Three Wire RTDs 3 19 Input Output Modules Rev Mar 05 FloBoss 407 Instruction Manual RTDs with four wires normally have the compensation loop separate from
216. wer consumption for a particular Duty Cycle Power Prx X Duty Cycle Prx 1 Duty Cycle 3 Determine the power consumption for all radios that use power from the FloBoss and enter the total calculated value in the Sub Total column in Table 1 1 1 9 General Information Rev Mar 05 FloBoss 407 Instruction Manual 1 5 3 Totaling Power Requirements To adequately meet the needs of the FloBoss system it is important to determine the total power consumption to size the solar panel and battery backup requirements accordingly For total power consumption add the device values in Table 1 1 Although Table 1 15 nd Table 1 2 take into account the power supplied by the FloBoss to its connected devices be sure to add the power consumption in mW of any other devices used with the FloBoss in the same power system but not accounted for in the tables Convert the total value in mW to Watts by dividing it by 1000 mW 1000 Watts For selecting an adequate power supply use a safety factor SF of 1 25 to account for losses and other variables not factored into the power consumption calculations To incorporate the safety factor multiply the total power consumption P by 1 25 Psp P x 1 25 Watts To convert Psr to current consumption in amps Isr divide Psp by the system voltage V either 12 volts or 24 volts Isp Psp V _ Amps 1 6 Startup and Operation Before starting the FloBoss perform the following checks to ensu
217. x Electrical isolati Oien etka eeneks 1 6 2 12 IN hc be oe ER cP aT BO Oe err One Eon SEE rede ee 5 2 5 4 Environmental TREGUINCINICILS aerie ii needs eentitedelt eens 1 4 Event LOtu T 2 7 F RA E LE OE EN E E A EEE ONE TE 2 8 FCO INONMA Osia E 1 2 Figure 1 1 FloBoss 407 Flow Managet 1 3 Figure 2 1 Processor and Termination Boards 2 2 Figure 2 2 FloBoss 407 Outline and Mounting DiMenSOn S a e S 2 9 Figure 2 3 Padlock Adapter Installation 2 10 Figure 2 4 Termination Board Wiring Connections EP EAN ERE T E eee ee E E A 2 11 Figure 2 5 Power Wiring Connections 2 13 Figure 2 6 Current Signal on Built in Analog Input APEE LAE AIEI IAEA A AO T E T E ae 2 14 Figure 2 7 Voltage Signal on Built in Analog Input ar E E A G 2 14 Figure 2 8 Externally Powered Built in Pulse Input PA E A EA PELE EE E AE ENO a OE A ANE T 2 15 Figure 2 9 FloBoss Powered Built in Pulse Input E E E E T A E E E 2 15 Figure 2 10 Operator Interface Local Port COM1 and COMPOS eti est uea ee vorcaetiaasducmantes 2 16 Figure 2 11 FloBoss 407 Indicator Locations 2 17 Figure 3 1 Typical I O Module ccccceeeeees 3 2 Figure 3 2 AI Loop Module Field Wiring for Current ZOO DEY ICES reana E 3 6 Figure 3 3 AI Loop Module Field Wiring for Voltage DEVICES eT O O dteineteacsauindsoens 3 6 Figure 3 4 AI Differential Module Field Wiring for Low Voltage DEVICES oaeen a aie 3 7 Figure 3 5 AI
218. y listed in the Edit Mode column of Tabld 5 2 occurs when the EDIT key is first pushed This mode continues until the CANCEL or ENTER key is pressed The ENTER key typically saves the edit to memory Refer to Figure 5 3 DISPLAY OFF 5 3 3 Alt Mode The functions listed in the Alt Mode column of Table 5 2 ar activated by pressing and releasing the ALT key Then press the desired key The ALT key must be pressed each time to activate the ALT mode Refer to Figurd 5 3 PASSWORD Press Specific ie Key SUMMARY Press EDIT T then the Key Press ALT then the Key HO DETAIL Figure 5 3 Operations Key 5 4 Display and Keypad Rev Mar 05 FloBoss 407 Instruction Manual Table 5 2 Definition of the Keypad Functions NORMAL MODE EDIT MODE ALT MODE I O Displays the following for each I O Displays Digit 7 on I O DETAIL SUMMARY point LCD for data entry Displays the entire set of Tag Current Value parameters for the I O Alarm Code point selected FLOW RATES Displays the following for a selected Displays digit 8 on COMM PORTS meter run LCD for data entry Displays the following for MCF Today selected communication MCF Yesterday port MCF Day Current Flow Rate Baud Rate MMBTU Day Current BTU Rate Stop Bits Meter Input Data Bits Static Pressure Parity Temperature Status Mode Key on Delay Key off Delay Retry Count Retry Time Alarm Pointer Recv Counter Copy Retry Counter Valid Receive Ctr
219. z 2 DOC0217A E O O Figure 2 10 Operator Interface Local Port COM1 and COM2 Ports Table 2 3 COMI Port Signals TERMINAL 1 2 3 4 7 5 6 7 6 RXD TXD RTS CTS DCD DSR COM This signal is permanently enabled connected to 10 V dc The COM2 port provides communications access to an optional plug in communications card Section 4 details communications cards and wiring to the COM2 connector 2 16 Functionality Wiring Built in I O Wiring the FloBoss and Troubleshooting Rev Mar 05 FloBoss 407 Instruction Manual 2 4 6 Connecting Multi Variable Sensor Wiring For information on MVS wiring refer to Appendix B and the ROC FloBoss Accessories Instruction Manual Form A4637 2 5 Troubleshooting and Repair Troubleshooting and repair procedures are designed to help identify and replace faulty boards and parts Return faulty boards and parts to your local sales representative for repair or replacement To troubleshoot I O modules refer to Sectiong 3 and for communications cards refer to Sections 4 The following tools are required for troubleshooting IBM compatible Personal Computer ROCLINK configuration software Battery powered digital multi meter Fluke 8060A or equivalent 2 5 1 LED Indicators The FloBoss 407 has three LED indicators to verify operational functionality Figura 2 11 shows the location of the indicators and Table 2 4 p rovides the ind

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