MAN_FloBoss S600_A6115_2001-08_EN

Flow Computer DivisionD301150X012 (loose leaf)

FLOBOSS™ S600 FLOW MANAGER

Instruction Manual

Form A6115

August 2001

FloBoss S600 Instruction Manual

ii 8/01

Revision Tracking Sheet

August 2001

This manual is periodically to incorporate new or updated information. The date revision level of eachpage is indicated at the bottom of the page opposite the page number. A major change in the contentof the manual also changes the date of the manual, which appears on the front cover. Listed below isthe date revision level of each page.

Page RevisionAll Pages 8/01

Daniel and FloBoss are marks of one of the Emerson Process Management companies. The Emerson logo is a trademark and service markof Emerson Electric Co. All other marks are the property of their respective owners. This product may be covered under one or morepatents pending.

Fisher Controls International, Inc. 2001. All rights reserved.

While this information is presented in good faith and believed to be accurate, we do 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 othermatter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. We reserve the right, without notice, toalter or improve the designs or specifications of the products described herein.

Printed in the U.S.A.


8/01 Table of Contents iii

TABLE OF CONTENTS SECTION 1 – OVERVIEW ................................................................................................................1-1

1.1 Section Contents ........................................................................................................................1-11.2 Scope of Manual ........................................................................................................................1-11.3 FloBoss S600 Flow Computer ...................................................................................................1-31.4 IPL 600 ......................................................................................................................................1-61.5 Config 600 Lite ..........................................................................................................................1-61.6 Config 600 Professional.............................................................................................................1-6

SECTION 2 – INSTALLATION........................................................................................................2-12.1 Scope..........................................................................................................................................2-12.2 Section Contents ........................................................................................................................2-12.3 Preparing for Installation ...........................................................................................................2-12.4 Unpacking the FloBoss S600.....................................................................................................2-22.5 Environmental Considerations...................................................................................................2-22.6 Required Tools for Installation ..................................................................................................2-32.7 Installing the FloBoss S600 .......................................................................................................2-3

SECTION 3 – OPERATION ..............................................................................................................3-13.1 Scope..........................................................................................................................................3-13.2 Section Contents ........................................................................................................................3-13.3 Description.................................................................................................................................3-23.4 Keypad .......................................................................................................................................3-3Display .............................................................................................................................................3-63.6 Data Pages..................................................................................................................................3-73.7 Status/ID Line ............................................................................................................................3-73.8 Display Matrix ...........................................................................................................................3-73.9 Using the FloBoss S600.............................................................................................................3-93.10 Entering Data ...........................................................................................................................3-123.11 Alarms......................................................................................................................................3-173.12 Printing.....................................................................................................................................3-193.13 Special Pages ...........................................................................................................................3-213.14 Summary of Operation.............................................................................................................3-22

SECTION 4 – MAINTENANCE........................................................................................................4-14.1 Scope..........................................................................................................................................4-14.2 Section Contents ........................................................................................................................4-14.3 Cold Start Procedure..................................................................................................................4-14.4 Reflash Firmware.......................................................................................................................4-34.5 Network Setup ...........................................................................................................................4-54.6 Factory Setup .............................................................................................................................4-54.7 Troubleshooting .........................................................................................................................4-6

SECTION 5 – SETUP AND WIRING...............................................................................................5-1


iv Table of Contents 8/01

5.1 Scope ......................................................................................................................................... 5-1

5.2 Section Contents........................................................................................................................ 5-15.3 CPU Board ................................................................................................................................ 5-25.4 P144 I/O Board........................................................................................................................ 5-125.5 P154 Prover Board .................................................................................................................. 5-21

SECTION 6 – SOFTWARE INTERFACE ...................................................................................... 6-16.1 Scope ......................................................................................................................................... 6-16.2 Section Contents........................................................................................................................ 6-16.3 System Requirements................................................................................................................ 6-26.4 Software Installation Procedure ................................................................................................ 6-26.5 File Locations............................................................................................................................ 6-36.6 StartUp ...................................................................................................................................... 6-46.7 Connecting to the FloBoss S600 ............................................................................................... 6-4

APPENDIX A – TECHNICAL DATA............................................................................................. A-1A.1 Scope ........................................................................................................................................ A-1A.2 Section Contents....................................................................................................................... A-1A.3 Mechanical and Environmental................................................................................................ A-2A.4 Power Supply ........................................................................................................................... A-3A.5 P152 CPU................................................................................................................................. A-4A.6 P144 I/O ................................................................................................................................... A-7A.7 P154 Prover ............................................................................................................................ A-13A.8 Display-Keypad...................................................................................................................... A-16A.9 Mezzanine Boards .................................................................................................................. A-17

APPENDIX B – ENGINEERING DRAWINGS ..............................................................................B-1B.1 List of Engineering Drawings ...................................................................................................B-1

GLOSSARY........................................................................................................................................ G-1

INDEX...................................................................................................................................................I-1


8/01 Overview 1-1

1

SECTION 1 – OVERVIEW

1.1 Section Contents

This section includes the following information:

Information Section Page NumberSection Contents 1.1 1-1Scope of Manual 1.2 1-1

Organization of Manual 1.2.1 1-1FloBoss S600 Flow Computer 1.3 1-3IPL 600 1.4 1-5Config 600 Lite 1.5 1-6Config 600 Professional 1.6 1-6

1.2 Scope of Manual

This manual introduces the FloBoss S600 Flow Computer, IPL 600 software (used to transferapplication programs to the FloBoss S600), and the CONFIG 600 software (used to develop FloBossS600 applications). This manual describes the installation procedure and shows how to operate thesystem including entering and modifying data. Basic maintenance and troubleshooting information isalso provided.

1.2.1 Organization of ManualThe information in this manual is arranged as follows:

♦ Section 1 – Overview provides an overview of the FloBoss S600, including the IPL 600 andConfig 600 user interfaces.

♦ Section 2 – Installation provides instructions on installing the FloBoss S600 and includesinformation on installation preparation, panel mounting procedures, and the installation andremoval of the plug-in boards and the front panel.

♦ Section 3 – Operation shows how to use the FloBoss S600. This includes keypad functions,screen displays, system initialization, display navigation, data entry, and printing reports.

♦ Section 4 – Maintenance describes how to initiate a cold start and provides maintenance andtroubleshooting information, including the basic board-level test procedures.

♦ Section 5 – Setup and Wiring describes the use of the plug-in connector blocks, field wiringconfiguration, and link and jumper setting for the plug-in board.

♦ Section 6 – Software Interface introduces the FloBoss S600 user interface and lists the systemrequirements, software installation instructions, and file locations on the host PC.


1-2 Overview 8/01

♦ Appendix A – Technical Data contains a complete list of physical, performance, andenvironmental specifications of the FloBoss S600 and add-in boards.

♦ Appendix B – Engineering Drawings includes pertinent installation and wiring drawingsalong with the spare parts list.

♦ Appendix C – Glossary is a glossary of terms and abbreviations used in this manual.

The FloBoss S600 is a compact, microprocessor-based flow computer that has been designed and builtusing proven design techniques and methodologies. The FloBoss S600 can function as a stand-alonesingle/multi-stream flow computer, as a combined meter station and meter stream computer, or as aslave to an external supervisory computer.

The FloBoss S600 is supplied with the IPL 600 program (which allows you to transfer applications tothe flow computer from a host PC), a standard application, and a download cable. Refer to Figure 1-1for an illustration of the FloBoss S600 system, including the optional PC interface cable.

Figure 1-1. The FloBoss S600 System


8/01 Overview 1-3

1.3 FloBoss S600 Flow Computer

The FloBoss S600 accepts process input signals and provides process output and control signals toinstruments used for fiscal metering, custody transfer, batch loading, and meter proving.

The FloBoss S600 provides the following hardware features:♦ Intel 32-bit 80486 DX2 CPU running at 50 MHz with built-in floating point math co-processor.

This configuration is supported by six processors on each I/O board.♦ Capacity, database, and processing capabilities for up to ten mixed metering runs. The CPU can

communicate with up to seven plug-in expansion I/O modules. The panel-mounted case hascapacity for one CPU module and up to three I/O modules.

Figure 1-2. CPU Board

♦ Front panel display and keypad for local system operation and data entry. The FloBoss S600includes a backlit LCD display, 29-button keypad, and an alarm status LED.

♦ The panel case is fabricated from rugged, spot welded zinc coated mild steel with the powersupply backplate mounted inside the case.

♦ Multiple communication interfaces include two RS232 serial ports for connection to a printeror RTU, and three RS422/RS485 serial ports (up to 57.6 kBaud) for connection to a ModbusSCADA data network or the DCS Supervisory System.

♦ Network connectivity through Ethernet 10baseT using FTP and TCP/IP protocols.♦ Dedicated configuration port for connection to the CONFIG 600 user interface.


1-4 Overview 8/01

♦ Functions such as: stream and station totalization batch totalization and correction 3-term PID control flow balancing flow scheduling automatic proving sequence K-factor linearization valve monitor/control sampler control

♦ Prover operations can be configured to include compact, as well as bi-directional provers.♦ Modular Intelligent Input/Output (I/O). The I/O can be configured to match most system

requirements including multiple streams, multiple products, and primary meters.

The I/O card can be configured for the measurement, control, and logic service functions as statedTable 1-1.

Table 1-1. I/O Functions

Number Description12 Analog Inputs4 Analog Outputs1 Raw Pulse Output (Proving)3 4-wire RTDs16 Digital Inputs12 Digital Outputs3 Frequency Inputs2 Dual Pulse Inputs

4 Single Pulse Inputs5 Programmable Pulse Outputs

For more details on the FloBoss S600 hardware, see Appendix A, Technical Data.


8/01 Overview 1-5

Figure 1-3. Intelligent I/O Board

The FloBoss S600 incorporates the following software features:♦ Batches can be programmed using a quantity method, and individual batch-end warning and

end-reached alarms can be configured.♦ Flow and time weighted averages are configurable for all input variables. These averages can

be used to generate correction factors based on daily totals and running batch totals.♦ Supports up to 16 different alarm groups; typically, the three most commonly used are

Computer, System and Process Groups. The current alarm status displays via a single tri-colorLED on the front panel of the FloBoss S600. The alarms in the system can also be viewed andaccepted from the front panel.

♦ Up to 12 user-defined period reports can be configured. Maintenance, batch, and snapshot(current data) reports are also available. Separate report formats are used for gas, liquid, andproving. Reports can be printed locally.

♦ Each user can be allocated a password-enabled security level from a total of 10 security levels. ♦ Current limiting is provided on start-up in order to prevent large in-rush current spikes.♦ PID flow control logic can be configured for each meter run as either flow or pressure control.

1.4 IPL 600

The IPL 600 software is the “Interactive Program Loader” (supplied with the FloBoss S600). The IPL600 software is used to upload and download pre-developed configurations and applications.

Note: The FloBoss S600 will not operate until a configuration file has been downloaded fromthe host PC.


1-6 Overview 8/01

1.5 Config 600 Lite

The Config 600 Lite software (optional) is a subset of the Config 600 Professional software that can beused to upload and download pre-developed configurations and applications.

Note: Config 600 Lite is used to custom configure a new FloBoss S600 during installation.

Config 600 Lite allows you to perform the following functions from the Config 600 Professional list:

♦ Edit process configuration data, including orifice size, analog input scaling, alarm limits, andkeypad values.

♦ Build and customize Modbus slave maps, Modbus master polling sequences, front paneldisplays, and period report formats.

♦ Customize the alarm system, including alarm groups, suppression, text, and inhibits.♦ Configure system security by setting user names and passwords, and assigning access levels for

each data object. ♦ Reflash the CPU module firmware with software upgrades.

1.6 Config 600 Professional

The Config 600 Professional program (optional) allows you to configure the FloBoss S600 from aportable or desktop PC running Windows 95, 98, or NT.

Note: The Config 600 Professional is used to create and develop new FloBoss S600applications.

Config 600 Professional allows you to perform the following functions:

♦ Create a new application from base templates for a gas orifice, gas turbine, gas ultrasonic,liquid turbine, or bi-directional prover system.

♦ Edit process configuration data, including orifice size, analog input scaling, alarm limits, andkeypad values.

♦ Upload data, such as the process configuration data.♦ Build and customize Modbus slave maps, Modbus master polling sequences, front panel

displays, and period report formats.♦ Specify the engineering units and totalization rollover value.♦ Customize the alarm system, including alarm groups, suppression, text, and inhibits.♦ Configure system security by setting user names and passwords, and assigning access levels for

each data object. ♦ Reflash the CPU module firmware with software upgrades.

For more details on using CONFIG 600 Lite and CONFIG 600 Professional software, refer to theonline help file provided with the program.


8/01 Overview 1-7

The online help is content-sensitive and accessible via the F1 key.


1-8 Overview 8/01


8/01 Installation 2-1

2

SECTION 2 – INSTALLATION

2.1 Scope

This section provides instructions on installing the FloBoss S600 including installation preparation,panel mounting procedures, and the installation and removal of the plug-in boards, and the front panel.


This section includes:

Information Section Page NumberScope 2.1 2-1Section Contents 2.2 2-1Preparing for Installation 2.3 2-1Unpacking the FloBoss S600 2.4 2-2Environmental Considerations 2.5 2-2Required Tools for Installation 2.6 2-2Installing the FloBoss S600 2.7 2-2

Removing the Front Panel 2.7.1 2-2Installing the Panel-Mounted Unit 2.7.2 2-2

Installation and Removal of the Boards 2.7.3 2-2Installing Plug-In Boards 2.7.4 2-2

Reinstalling the Front Panel 2.7.5 2-2

2.3 Preparing for Installation

Installation of the FloBoss S600 must conform to all applicable local codes and regulations. Allinstallation procedures should be in accordance with normal practices of good workmanship.Although the FloBoss S600 may not include all of the hardware options described in this manual, theprocedure for the basic installation of the unit remains the same.

Note: It is strongly recommended that you familiarize yourself with the procedures describedin this section before you begin to install the FloBoss S600.

The FloBoss S600 uses a modular design, providing maximum flexibility, and ease of installation. Thebasic panel-mounted version consists of three major components:

♦ Fabricated metal case, complete with pre-installed PSU/backplate and four card slots for theplug-in cards (comprising a dedicated CPU slot and three I/O slots).


2-2 Installation 8/01

♦ Removable front panel comprising the LCD display and keypad assembly.♦ Plug-in boards, one CPU board and one I/O board are supplied for a basic configuration (two

blanking plates are supplied to cover the unused slots).

Figure 2-1 shows the FloBoss S600 system components with the appropriate user-provided tools.

Figure 2-1. All Parts of the Basic FloBoss S600 System

2.4 Unpacking the FloBoss S600

Unpack the FloBoss S600 carefully and inspect all parts for visual damage. All parts should then bechecked off against the purchase order.

Note: Do not discard any packaging material until all pieces of the shipment have beenidentified and you are confident that all parts are working correctly.

2.5 Environmental Considerations

The FloBoss S600 panel mount is designed for use within the control room and should be placed in aposition that provides ease of use, comfort, and safety for operators and maintenance personnel. Theoptimum height for viewing and using the display and keypad is at operator eye level.



CAUTIONWhere one or more units are installed in a confined space or with other heat producingequipment, special attention should be given to the combined heating effect.

This combined heat could increase the environmental temperature beyond its acceptablethreshold impacting performance.

2.6 Required Tools for Installation

Before attempting any installation of the FloBoss S600 hardware, ensure you have the following tools:♦ Small flat-blade screwdriver suitable for the slot headed captive screws on the rear of the case

that secure each plug-in board into the case.♦ 5 mm hex or small adjustable crescent wrench for the front panel bosses.♦ 2.5 mm Allen wrench suitable for the hex cap screw on the front face of the front panel to

secure the front panel molding to the case.

2.7 Installing the FloBoss S600

Refer to the following procedures for installing the various FloBoss S600 components, including thefront panel, panel-mounted unit, and plug-in boards.

2.7.1 Removing the Front PanelTo begin the installation process, first remove the front panel from the FloBoss S600 as follows:

1. Ensure the FloBoss S600 is switched off.

2. Use a 2.5 mm Allen wrench to remove the hex cap screw from the bottom center of thefront panel. Refer to Figure 2-2.



Figure 2-2. Removing the Front Panel

3. Carefully slide the FloBoss S600 face up 4 mm (0.15") to allow it to clear the retaininggroove at the top of the case, and then allow the face to come forwards to clear the panelcase completely. Refer to Figure 2-3.

Figure 2-3. Lift up Panel



4. Disconnect the ribbon cable from the back of the front panel, as it is easier to refit whenreconnecting the front panel. Refer to Figure 2-4.

CAUTIONDo not remove the ribbon cable from the FloBoss S600 board.

Figure 2-4. Remove Connector

5. Remove the top and bottom bosses from the unit using a 5 mm hex wrench.

2.7.2 Installing the Panel-Mounted UnitAfter removing the front panel, you can install the panel-mounted unit as follows:

1. Keeping the environmental considerations in mind, construct the framework of the cubicleto support the operating panel.

Note: A standard 19" rack 12.25" high will accommodate up to five FloBoss S600 flowcomputers.

2. Refer to drawing DE-20438 in Appendix A for position details for two 7 mm (0.276") holesand a cutout. The panel cut out should be rectangular in shape, 150 mm (5.9") vertically by66 mm (2.6") horizontally, for each FloBoss S600 unit. A tolerance of +/- 3 mm (0.12") isallowed on each axis.

DisconnectHere



3. Panel thickness should be at least 3 mm to prevent distortion. Thinner panels can be used,but these require the rear of the case to be supported. Refer to Figure 2-5.

CAUTIONIt is recommended that a rear support or anchor is always used to prevent twisting andother distortion effects during installation and maintenance.

Figure 2-5. Panel Mount

4. Place the front panel case against the rear of the prepared cutout.

5. Reinstall the top and bottom bosses, and tighten with a 5 mm hex wrench.

6. When the rear support is fitted, you should use a self-tapping screw to secure the case to therear support. The maximum depth of the screw inside the case should be 3 mm (0.12").



2.7.3 Installation and Removal of the BoardsThe CPU board is dedicated to the left-most rear slot of the case.

The remaining slots can be populated with plug-in I/O boards, or they can be left blank and coveredwith the blank plates designed for the purpose.

CAUTIONEnsure suitable electrostatic discharge precautions are taken prior to removing any of theplug-in boards.

CAUTIONThe terminals on some boards may be wired to electrical potentials sufficiently high tocause electrical shock and injury. Make sure the power sources of any connected devicesare turned off and discharged before performing any installation or repairs.

Removal of the plug-in boards:

1. Ensure the FloBoss S600 is powered-down before attempting to extract a plug-in board.

2. Unscrew the retention screws before attempting to remove a board to avoid damage to thepull tabs. Refer to Figure 2-6.

Figure 2-6. Unscrewing the Retention Screws



3. Remove the plug-in boards by using the pull-tabs for the appropriate board and pull theboard clear of the case. Some rocking of the board may be required to release theconnector. Refer to Figure 2-7, Figure 2-8, and Figure 2-9.

Figure 2-7. Preparing to use the pull tabs for board release

Figure 2-8. Using the Pull Tabs



Figure 2-9. Board Ready for Removal or Final Insertion

2.7.4 Installing Plug-In Boards1. Install the plug-in boards with care by aligning them in the guides (located at top and

bottom of the case), and gently sliding the board until it mates fully with the appropriateconnector on the power supply backplate.

2. Each plug-in board has two “pull tabs” on the backplate. These should be pressed insecurely on insertion.

CAUTIONThe insertion and location of the plug-in boards along the guides does not requireexcessive force. Take care not to twist or otherwise distort the boards duringinstallation.

3. Secure the board in the case with the retention screws (two per board).

2.7.5 Reinstalling the Front PanelThe final stage of the installation process is to reinstall the front panel on the FloBoss S600 as follows:

1. Connect the ribbon cable (from the front of the case) to the socket on the front panel.



CAUTIONObserve the orientation of the connector with its mating keyway that will preventincorrect insertion. Do not to use excessive force to refit the cable.

2. Place the top of the front panel over the retaining groove on the top boss and slidedownwards.

3. To secure the front panel, place the hex socket screw into its recess in the bottom center ofthe front panel.

4. Use a 2.5 mm Allen wrench to tighten the screw finger-tight.

CAUTIONTake care not to over-tighten the screw; otherwise, damage to the panel face mayoccur.

5. Turn an additional 180 degrees to complete the installation.


8/01 Operation 3-1

SECTION 3 – OPERATION

3.1 Scope

This section shows how to use the FloBoss S600, including keypad functions, screen displays, systeminitialization, data entry, and printing reports. Operation also shows how to navigate the displaymatrix.


Information Section Page NumberScope 3.1 3-1Section Contents 3.2 3-1Description 3.3 3-2Keypad 3.4 3-3

F Keys 3.4.1 3-3Vector and Menu Keys 3.4.2 3-4Alarm Light and Keys 3.4.3 3-4Numeric Keys 3.4.4 3-5Operation Keys 3.4.5 3-5

Display 3.5 3-6Menus 3.5.1 3-6

Data Pages 3.6 3-7Status/ID Line 3.7 3-7Display Matrix 3.8 3-7Using the FloBoss S600 3.9 3-9

Initialization 3.9.1 3-9Navigating the Display 3.9.2 3-11

Entering Data 3.10 3-12Changing a Value 3.10.1 3-12Example Value 3.10.2 3-13Changing Mode 3.10.3 3-14Example Mode 3.10.4 3-15Exponential Format 3.10.5 3-16Security Code 3.10.6 3-16


3-2 Operation 8/01

Alarms 3.11 3-17Alarm Light 3.11.1 3-17View Alarm 3.11.2 3-18Alarm Accept 3.11.3 3-18

Printing 3.12 3-19Special Pages 3.13 3-21Summary of Operation 3.14 3-22

3.3 Description

After the FloBoss S600 has been wired for power and external devices, it may be activated byenergizing the external 24 VDC power supply. When power is first applied, the unit displays themessage RESETTING. Unless LK13 (cold start jumper/link) is installed, the FloBoss S600 displaysthe message RESTARTING. When the unit initializes properly, a menu appears. You may proceedthrough the instructions in this section to gain familiarity with the unit. If the FloBoss S600 does notproperly initialize, proceed to Section 4 for cold start and configuration procedures.

The operation of the FloBoss S600 is through an operator interface comprising an LCD display and akeypad. The layout of the FloBoss S600 front panel is shown in Figure 3-1.


8/01 Operation 3-3

Figure 3-1. Front Panel

3.4 Keypad

The layout of the front panel keypad has been designed to make it easy to use and to reduce thepossibility of error. The keys on the keypad are color-coded by type:

♦ Function – yellow♦ Alarm – dark green♦ Vector/Menu – dark green♦ Numeric – light green♦ Operation – dark green

3.4.1 F KeysThe top of the keypad has four function keys numbered F1 to F4. Each F key can be programmed as ashortcut to a frequently used display page. To program a function key:

1. Go to the required display page.

2. Press the Decimal Point key.

3. Press the desired F key to which the display page is to be assigned.


3-4 Operation 8/01

Once programmed, an F key cannot be unassigned unless the SRAM is cleared or the FloBoss S600 iscold started. Refer to Section 3.9. However, you can reassign an F key to a different display page.

3.4.2 Vector and Menu KeysThe 4-way directional arrow key is located just below the Menu key. The 4-way directional arrow keyallows you to navigate the display matrix and select parameters or data items to view or change.

On a data page, use the or keys to view the previous or next display, respectively. The number ofthe current display is indicated after the decimal point on the Status/ID line.

When the display moves vertically to view another row, the data item shown is always the first displaycell of that row.

The key is also used as the delete/backspace key when entering or changing data.

Press the Menu key to return up one level of the display hierarchy. On a data page, this key returnsyou to the parent menu. By pressing the Menu key followed by the key while on any menu page,you return directly to the Main menu.

3.4.3 Alarm Light and KeysBetween the F keys and the MENU key is the Alarm light and two Alarm keys, View and Accept.

During normal operation, with no alarm activated, the Alarm light is green.

When an alarm is activated, the Alarm light flashes red until the cause for the alarm has been viewedand acknowledged using the View and Accept keys, respectively.

Unacknowledged alarms are initially displayed with the date and time in inverse video. Onceacknowledged, the alarms display in normal video. Multiple alarms display in chronological order.

The Alarm light shows a solid red until the alarm has been cleared. A yellow Alarm light indicateseither a fault with the display or keypad, or alternatively, a communications failure between the frontpanel and the CPU module.


8/01 Operation 3-5

3.4.4 Numeric KeysThe lower part of the keypad houses the numeric keys. The numeric keys offer the full number set (0-9), decimal point (.), and a minus (-) key.

♦ Numeric 0 to 9 – Used to enter or change data and to navigate the display matrix. ♦ Minus – Used to define the default display on the FloBoss S600.

To define the default display:

1. Go to the required data display page.

2. Press the Minus key.

3. Press the Minus key again to confirm.

You cannot unassign a default display for a menu page. To unassign a default display, go to a menupage and repeat steps 2 and 3.

You can also use the minus key to enter negative quantities and the decimal point when enteringfractional quantities. The decimal point is also used to define shortcuts to access frequently useddisplays; see Section 3.4.1.

3.4.5 Operation KeysThe Operation keys are used in conjunction with the Numeric keys to perform a variety of tasks,including:

Exponent – The Expt key is used to enter quantities in scientific notation. Where the value to beentered exceeds the space available on the display (20 characters), it is necessary to express thedata in exponential terms.

Clear – The Clear key is used to cancel or exit from the current operation and return to the previousdata display. Clear is also used to activate the default display.

Display – The Disp key is used to enter the path of a required display. The path is shown on theStatus/ID line at the bottom of every page.

Print – The Print key is used to display the print menu, where commands can be requested for variouspre-configured reports or logs to a printer or computer terminal.


3-6 Operation 8/01

Change – The Chng key is used to edit a displayed database item. Only items marked with an asterisk(*) are changeable. To enter the edit sequence:

1. Press the Chng key. If more than one asterisk is shown on a data display, the FloBoss S600highlights the first object on the page. Use the and keys to move the highlight to therequired point.

2. Press the Chng key again to change the data values. The system automatically determineswhether your assigned security level allows you to change the selected data. In order toprevent accidental re-configuration, certain essential data entry fields require confirmation.

While in Change mode, the key can be used to delete digits or characters by backspacing over thedisplayed data. The Clear key can be pressed at any time to abort the current operation or task.

Enter – Used in combination with the numeric and Chng keys, the key is used to confirm thedata has been entered correctly and complete an operational sequence.

3.5 Display

The LCD display offers eight lines of information displayed as alphanumeric characters. An exampleof a typical display is shown below.

Figure 3-2. LCD Display

3.5.1 MenusAll eight lines of the display are used to show the available menu options, which are arranged in ahierarchical parent menu and sub-menu order. Each menu and associated sub-menu is allocated anumber between 1 to 8 and can be selected using the numeric keys.

If the menu displays more than eight options, press NEXT to display additional items.

The following characters are used after the option number to identify the type of sub-menu or datapage available:

♦ An asterisk (*) signifies a further menu display.♦ A decimal point ( . ) signifies a data display.

1. OVOL FR2. CVOL FR3. MASS FR4. ENERGY


8/01 Operation 3-7

3.6 Data Pages

Generally, each data display shows a single data item along with the associated text, units, anddescription. Prompts and messages also appear when you enter or edit data items. For example, if youpress the Chng key, and are logged in at the required security level, the display prompts you witheither Enter New Value: or displays the available menu options.

Depending on the base configuration, not all data items can be modified. A changeable data item isindicated by an asterisk (*) at the end of the display line.

3.7 Status/ID Line

On the bottom line of every data page is the Status/ID line. Refer to Figure 3-3.

P1.1 <of 2>

Figure 3-3. Status ID Line

On the left-hand side of the Status/ID line is the page reference number. For example, P12.5 followedby the number of associated data pages that can be navigated using the and keys.

In addition, the Status/ID line indicates whether the flow computer is in Prove mode or Maintenancemode by displaying the characters P or M, respectively, on the right-hand side.

3.8 Display Matrix

The FloBoss S600 software system is organized as a structured database of parameters, such asTOTALS, I/O, and CALCULATIONS.

The database groups the parameters logically in a matrix of display cells. For example, most I/Oparameters are grouped in the same area of the matrix. Within these groups, related data items areorganized into rows. For example, for PRT INPUTS, the parameters for Measured, Keypad, andAlarm Limits are all kept in one horizontal row. Refer to Figure 3-4.


3-8 Operation 8/01

PRT Input 1

I/001 PRT 01

In Use Value:30.124 Deg.C

Mode Status:MEASURED *

P55.1 <of4>

PRT Input 1

I/001 PRT 01

Keypad Value:25.000 Deg.C*

Measured Value:30.124 Deg.C

P55.2 <of4>

PRT Input 1

I/001 PRT 01

Limits (HH/H/L/LL):100.000 Deg.C*95.000 Deg.C*5.000 Deg.C*0.000 Deg.C*

P55.3 <of4>

PRT Channel 1

I/001 PRT 01

Resistance:111.72 ohms

P55.4 <of4>

Figure 3-4. Database Matrix

The PRT Input group is shown in Figure 3-4. The first cell in the row (page 1) displays the In UseValue parameter. You can move one cell to the right, using the key, and the associated KeypadValue and Measured Value parameters display. Press the key two further times and the displaychanges to the Resistance parameter.

You can use the Print key and the configuration option to request a display dump of the whole displaymatrix.

Note: The content of the display matrix is application-specific. Although details may varybetween different applications, the principle described is the same. Refer to the ApplicationManual for details of parameters installed in your FloBoss S600.


8/01 Operation 3-9

3.9 Using the FloBoss S600

If you are already familiar with Spectra Flow Computers, you may find it useful to refer to Section3.14, Summary of Operation, on page 3-22.

3.9.1 InitializationThe FloBoss S600 automatically performs an initialization sequence, including a self-test routine,during startup. The startup screen is shown in Figure 3-5.

STARTUP COMPLETED

S/W Version 0.9.0View Angle Setting 8

LCD Back Light ON

Alarm OFF

Figure 3-5. Startup Screen

Depending on the setting of the cold start bit-jumper (link) (LK13), located on the P152 plug in board,and the contents of the SRAM, the FloBoss S600 starts up in one of two modes:

♦ Warm Start – If the FloBoss S600 has been previously configured and the cold start jumper isnot installed, the FloBoss restarts where it left off prior to being powered down. The Mainmenu displays following a successful startup.

♦ Cold Start – If the FloBoss S600 is un-configured, has the cold start jumper installed or aClear SRAM command has been previously issued, the Startup menu displays.

Note: The default setting of the cold start jumper is “open” which results in a warm start.

When the FloBoss S600 is restarted in warm or cold start mode, the firmware is always copied fromFlash to RAM and subsequent operation uses RAM.

During a warm start, the configuration memory (SRAM) is not affected. The FloBoss S600 willcontinue operation using the data stored in the configuration memory just before the restart occurred.Any current accumulated values and online changes that have not been saved will be preserved. Awarm start is generally not required when online parameters are changed and accepted.


3-10 Operation 8/01

During a cold start, the configuration files are copied from Flash and replace any currentlyaccumulated totals, as well as any online changes made to the configuration files since the lastdownload from CONFIG 600. Therefore, a cold start is used to reflash a new configuration or torecover from extreme situations, such as a corrupted database.

Note: When setting the cold start jumper, keep in mind that this setting will also be used whenthe FloBoss S600 self starts for any reason, such as a low-voltage shutdown or recovery from amalfunction. Ensure the cold start jumper setting is removed when not required; otherwise, anunplanned restart could result in lost data.

The following descriptions of FloBoss S600 operations assume a warm start has been performed. Forinformation on operations after a cold start, refer to Section 4.

Following a successful warm start, the Main menu displays as in Figure 3-6.

1* FLOW RATES2* TOTALS3* OPERATOR4* PLANT I/O5* SYSTEM SETTINGS6* TECH/ENGINEER

8* CALCULATIONS

Figure 3-6. Main Menu

The Main menu is the starting point or root of the display matrix. From the Main menu, you cannavigate the sub-menus to access the required data pages.


8/01 Operation 3-11

3.9.2 Navigating the DisplayFrom the Main menu, select the option you require with the appropriate numerical key.

An asterisk (*) before a menu option indicates that further sub-menus are available. A decimal point( . ) before the menu option shows there is no further sub-menu; selecting this option type displays thefirst cell in a row of related parameters within the display matrix.

To navigate the PLANT I/O option, for example, proceed as follows:

1. Select the PLANT I/O option by pressing 4 from the Main menu (Figure 3-6) and theavailable sub- menus display. Refer to Figure 3-7.

1* ANALOG INPUTS2* PRT/RTD INPUTS3* FREQUENCY INPUTS4* PULSE INPUTS5* DIGITAL I/OS6* ANALOG OUTPUTS7* PULSE OUTPUTS

Figure 3-7. Submenu

2. Select the ANALOG INPUTS option by pressing 1, and then select ADC - 06 by pressing 3.Refer to Figure 3-8.

1. ADC 01 -- ADC01

2. ADC 02 -- ACD02

3. ADC 06 -- ACD06

Figure 3-8. Analog Inputs


3-12 Operation 8/01

The data item In Use Value for I/O01 ADC 06 displays, which is the first cell in the row ofrelated analog input parameters.

As the configuration of your FloBoss S600 may differ from this example, try selecting options fromthe menus offered in order to reach the parameter that you require.

The Status/ID line on the bottom of the display changes as you move left or right across the row ofrelated display pages.

An alternative method of selecting the required data page is to enter the unique page address using theDisp key. If you know the location number of the parameter you wish to view, proceed as follows:

1. Press Disp followed by the location number in the format “column.row” such as 1.3.

2. Press Enter.

If you only enter a single number such as the column value, the first cell of the row displays.

To return to the parent menu, press the Menu key located above the arrow key; repeated pressing ofthis key moves you up the display matrix to the Main menu.

Note: If you are on a menu or data page, you can return directly to the Main menu at any time(except during a change sequence) by pressing the Menu key followed by the key.

If you have pressed the Chng key, the Menu key will not respond until either Clear (to abort thechange) or Enter (to complete the change) has been pressed.

3.10 Entering Data

Changing the value or mode of any displayed parameter is straightforward with the FloBoss S600.You can modify both numeric values and calculation modes using the Chng key.

3.10.1 Changing a ValueLocate the parameter to be changed using one of the methods described in section 3.9.2.

If the value is changeable, the data is marked with an asterisk; if there is no asterisk, the data cannot bemodified.

To change the value of a parameter, proceed as follows:

Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required datapage.

1. Press Chng on the required data page.

2. Select the required parameter using the or keys.


8/01 Operation 3-13

3. Press Chng and the prompt ENTER CODE: displays.

4. Key in your Security Code and press Enter (the security code number does not display, buteach digit is indicated by a dot as you key it in).

5. At the prompt ENTER NEW VALUE: key in the new value in integer, numeric, or scientificnotation as appropriate (the current value and any entry limits associated with this parameterare also shown).

6. Press Enter to confirm.

The change mode is automatically exited on accepting or rejecting the mode change if only one dataitem is changeable on the data page.

If necessary, you can edit the new data as you key it in. Enter Change mode and use the key todelete single figures or characters. If you wish to abort the change, press Clear.

Deleting or canceling the change to the parameter should be done before pressing Enter. The Entercommand confirms that you wish the revision to proceed.

3.10.2 Example Value The following example shows how to change the alarm limits for the A/D Converter analog input.

1. Locate the page displaying the alarm limits (HH/H/L/LL) for the Channel 1 I/O01 parameter.The display shows the location number and the asterisk indicates that the values arechangeable. Refer to Figure 3-9.

ADC CHANNEL 1

I/O01 ADC 01

Limits (HH/H/L/LL)

1000.000 barg*

95.000 barg*

5.000 barg*

0.0 barg*

1.0

P52.3 <of5>

Figure 3-9. Alarm Limits


3-14 Operation 8/01

2. Press Chng and highlight the HH value.

♦ Press Chng again and the display responds with the prompt ENTER CODE:. ♦ Key in your Security Code and press Enter. ♦ At the prompt ENTER NEW VALUE: key in the new value 100 and verify this on the

display.3. Once you have verified the data, press Enter to confirm. The value in the display changes to

the new data and recalculates any linked parameters.

4. Repeat the above process for the H, L, and LL limits.

3.10.3 Changing ModeTo select a new calculation mode, the key sequence is similar to changing a value.

Locate the parameter to be changed using one of the methods described under Section 3.9.2

If the mode is changeable, the mode is marked with an asterisk; if there is no asterisk, the mode cannotbe modified.

Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required datapage.

1. Press Chng on the required data page.

2. Select the required parameter using the or keys.

3. Press Chng and the prompt ENTER CODE: displays.

4. Key in your Security Code and press Enter (the security code number does not display buteach digit is indicated by a dot as you key it in).

5. At the prompt, select the required mode by using the appropriate numerical key (1 to 8).

6. A second mode change window displays asking for confirmation. Press 1 to accept or 2 toreject the mode change.

The change mode is automatically exited on accepting or rejecting the mode change if only one dataitem is changeable on the data page.

The Clear key enables you to cancel the mode change to the parameter, if necessary.


8/01 Operation 3-15

3.10.4 Example ModeThe following example shows how to change the standard density parameter to a calculated value froma keypad-entered value.

1. Locate the page displaying the STR01 STANDARD DENS mode status. Refer to Figure 3-10.

STR01 STANDARD DENS

In Use Value:

10.000000 kg/m3

Mode Status:

KEYPAD *

P32.10 <of 21>

Figure 3-10. Standard DENS

2. Press Chng, key in your Security Code and press Enter.

3. Press 1 to select CALCULATED. Refer to Figure 3-11.

1. CALCULATED

2. KEYPAD

Figure 3-11. Calculated


3-16 Operation 8/01

Confirm

SET TO:CALCULATED

1. YES2. NO

Figure 3-12. Confirm

4. Press 1 to confirm. The display indicates the revised operational mode. Refer to Figure 3-12.

Note: If the change is not allowed, ‘Denied’ displays on the line you are changing and thechange is not implemented.

3.10.5 Exponential FormatThe Expt key allows you to enter parameters in scientific notation. Where a value is smaller than0.00000001 or greater than 10000000 (8 significant figures), you must use the Expt key to express thevalue in exponential terms.

You can also use the exponential notation for entering numbers that are within the range of 8significant figures; but the displayed value will be shown as a normal number.

To enter an exponential value:

1. Key in the value.

2. Press the Expt key (an E appears on the display) and then enter the required power.

3. Press the Enter key.

For example, to enter the figure 0.00000009 as an exponential value: Key in 9.0, press Expt, enter -8to represent the power and press Enter to confirm.

3.10.6 Security CodeThe security system allows up to 50 unique users. Each user is allocated two individual passwords;one is numeric for access to the FloBoss S600 and the other is alphanumeric for access to the CONFIG600 Software. In addition, each user is allocated a security level between 0 (highest) and 9 (lowest).

Note: Each user should have a unique FloBoss S600 security code and username. Level 0cannot be set as a login level as it is used for totalizer values, measured values, and such.


8/01 Operation 3-17

The configuration parameters are assigned in predefined groups with common minimum-security level.The security level can be modified for each user application from within CONFIG 600.

Please refer to your System Administrator for further information on your password settings andsecurity levels.

3.11 Alarms

The default alarm system installed in the FloBoss S600 is a latching, manual, common-accept system.

Alarms are triggered when measurements exceed the pre-set limits for a parameter or if there is amalfunction. The alarm may be relayed to a terminal or siren (klaxon) in the Control Room. On thepanel of the FloBoss S600, a light indicates an alarm and the source of the alarm is shown on thedisplay.

3.11.1 Alarm LightDuring normal operation, with no alarms present, the Alarm light is a constant green. When an alarmis activated, the light flashes red until the cause for the alarm has been viewed and the Accept key hasbeen pressed. Refer to Section 3.11.3, Alarm Accept, on page 3-18.

Once acknowledged, the light shows a constant red until the alarm condition has been cleared.


3-18 Operation 8/01

3.11.2 View AlarmPress the View key to display the parameters that have triggered the alarm.

The first line of the alarm display indicates the date and time of the alarm. While the alarm remainsunaccepted, this line is shown in inverse video. The second and third lines are used to describe wherethe alarm has been activated and its nature. The total number of alarms, accepted and unaccepted, isshown on the bottom line. Refer to Figure 3-13.

09/11/1999 13:05:00STR01 CHROM MODETELEM

Alarm 1 of 9

Figure 3-13. Alarm Display

When there is more than one alarm to be viewed, the display can be cycled around all the alarms usingthe or keys.

3.11.3 Alarm AcceptPress the Accept key to notify the FloBoss S600 that you have viewed all the alarms and are preparedto acknowledge them all together. The inverse time and date on all the alarms then returns to normalvideo.

Once an alarm condition is cleared, its alarm prompt is automatically cleared from the display. Whenall the alarms in the system have cleared, the Alarm light resets to a constant green.


8/01 Operation 3-19

3.12 Printing

By default the FloBoss S600 is configured to output reports to a serial printer or a terminal. The Printkey is used to generate either a constant log or pre-configured reports.

The Print menu is Figure 3-14.

PRINT OPTIONS

1. HELP2* CONFIGURATION3* REPORTS4* COMMUNICATIONS5. CURRENT ALARMS

Figure 3-14. Print Options

Pressing 1 or 5 performs the action; 2, 3, or 4 go to the following submenus:

PRINT OPTIONS

1. CONSTANTS LOG2. DISPLAY DUMP3. SECURITY DUMP4. ALL ALARMS

Figure 3-15. Print Options 2


3-20 Operation 8/01

PRINT OPTIONS

1. CURRENT REPORT2. CONFIG REPORT3. ARCHIVED REPORTS


Pressing 3 in the menu displayed in Figure 3-16 takes you to a submenu listing the reports that aresetup to archive reports. Choosing any of those will then display the available reports to print.

PRINT OPTIONS

1. MODBUS MAPS


The following reports can be requested:

Constants Log – Lists all the constant parameters and the in-use values that are available for changefrom the display.

Display Dump – Lists the whole display matrix.

Security Dump – Lists the current security levels assigned to data items.

All Alarms – Lists all possible alarms that can be generated by the alarm system.

Current Report – Lists the meter run totals.


8/01 Operation 3-21

Config Report – Lists the configuration parameters, including the installed calculation sets.

Archived Reports – Includes all archived reports listed by time and date.

Current Alarms – Lists all the acknowledged and un-acknowledged alarms currently set in the flowcomputer in separate chronological lists.

Modbus Maps – Lists the Modbus maps stored in the FloBoss S600 that are assigned to a telemetrylink.

3.13 Special Pages

The FloBoss S600 includes display pages to perform specific functions, which are located under theTECH-ENGINEER/DISPLAY SETUP menu. Refer to Figure 3-18.

1. DISPLAY SETUP2. CONTRAST3. DATE & TIME4. DISPLAY TEST5. SECURITY6. COMMUNICATIONS

Figure 3-18. Display Setup Menu

Display Setup – Includes the parameters associated with the display setup.♦ Display T/O – The display timeout is the period of non-use before the default display is shown

(default 300sec).♦ Logout T/O – The logout timeout is the period of non-use in change mode before the current

user is automatically logged out (default 20sec). ♦ Ident T/O – This is the timeout period of non-use in change mode before the display mode is

activated (default 120sec).♦ Contrast – Used to set the LCD viewing angle.

Note: Some models have automatic temperature correction of viewing angle with nomanual adjustment provided.

Date & Time – Used to set the current date and time.


3-22 Operation 8/01

Display Test – Used to turn all the pixels on and off.

Security – Used to enable/disable keypad access and file transfer from the host PC.

Communications – Used to display the available COM ports and link status, and define the serial portsettings.

3.14 Summary of Operation

The following is a summary of the operational features available on the FloBoss S600.

Display Matrix – Data items are arranged logically in groups and are placed in cells and rows within adisplay matrix. See your Application Manual for details of the parameters installed on yourFloBoss S600.

View Parameter – First, use the numerical keys to select the relevant menu and sub-menu option, andthen use the and keys to display the required parameter in the matrix row. Alternatively,press the Disp key, enter the location number (row.column), and press Enter.

Return to Main menu – Press the Menu key to view the parent menu. Repeated pressing of this keymoves you to the Main menu. Alternatively, press the Menu key followed by the key whileviewing a menu or data display (but not during a change sequence) to return directly to the Mainmenu.

Change Value – Select the display cell of the parameter to be changed. An asterisk indicates that thevalue is changeable. Press Chng, enter Security Code, press Enter, enter new value, and pressEnter to confirm.

Change Mode – Select the display cell of parameter to be changed. An asterisk indicates that thevalue is changeable. Press Chng, enter Security Code, press Enter, select the required mode fromoption list, and press 1 to confirm.

Clear – Press Clear to abort the change sequence.

Scientific Notation – Use the Exponent key when a value exceeds 8 significant figures. Key in thenew value, press Expt, enter required power, and then press Enter to convert value to exponentialformat.

Alarm – Alarms are indicated by a flashing red light. Display alarm details by pressing the View key.Accept each alarm as it displays by pressing the Accept key. Once the fault conditions areremoved, the Alarm Light shows a constant green.

Print – Press the Print key to print a constant log or generate a report.


8/01 Operation 3-23

Default Display – Select data display page to be used as default, press the Minus key, and press theMinus key again to confirm. Note you cannot assign a default display for a data entry or menupage.

To select a different page to be used as the default, go to the desired page, press the Minus key,and press the Minus key again to confirm.

To clear the default page function, go to any menu page, press the Minus key, and press the Minuskey again to confirm.

Program Function Keys – Go to the required display page, press the Decimal Point key, and thenpress the required F key to which the display page is to be assigned.


3-24 Operation 8/01


8/01 Maintenance 4-1

1

SECTION 4 – MAINTENANCE

4.1 Scope

This section describes the procedure for initiating a Cold Start on the FloBoss S600. Maintenance alsoprovides instructions for maintaining and troubleshooting the FloBoss S600.


This section includes:

Information Section Page NumberScope 4.1 4-1Section Contents 4.2 4-1Cold Start Procedure 4.3 4-1

Run Mode 4.3.1 4-2Reflash Firmware 4.4 4-2

Download and Reflash Config File 4.4.1 4-2Cold Start 4.4.2 4-2

Network Setup 4.5 4-2Factory Setup 4.6 4-2

Clear SRAM 4.6.1 4-2RAM Disc Start 4.6.2 4-2Format Flash 4.6.3 4-2

Troubleshooting 4.7 4-2Initial Checks 4.7.1 4-2Removing and Replacing Plug-in Boards 4.7.2 4-2Changing the Fuse 4.7.3 4-2Startup List 4.7.4 4-2

4.3 Cold Start Procedure

Normally, the FloBoss S600 would be requested to Warm Start. The FloBoss S600 will be unable toWarm Start if:

♦ The FloBoss S600 has not been previously configured.♦ The Cold Start jumper (LK13) installed.♦ A Clear SRAM command has been issued.


4-2 Maintenance 8/01

CAUTIONOnly a suitably qualified person should perform reprogramming of the FloBoss S600.

4.3.1 Run ModeOn a running FloBoss S600, prior to programming the Flash memory with the FloBoss S600 operatingsystem firmware, you must set the run mode to Cold Start, as follows:

1. Go to the SYSTEM SETTINGS menu.

2. Select the SYSTEM STATUS sub-menu.

Note: The sequence of keys to access the SYSTEM STATUS page may vary on customizeddisplays. This may also be true for any page in a customized system.

3. Press Chng and the prompt Enter Code: displays.

4. Key in your Security Code.

5. Press 1 to select Cold Start, and press 1 again to confirm.

6. Reboot the FloBoss S600 (power down, wait a minimum of five seconds, and then repower).

Once the FloBoss S600 has completed its start-up initialization sequence, the FloBoss S600 Startup menudisplays. Refer to Figure 4-1.

1. WARM START

2. COLD START

3. NETWORK SETUP

4. REFLASH FIRMWARE

5. REFLASH CONFIG

6.

7.

8. FACTORY SETUP

Figure 4-1. Startup Menu

The FloBoss S600 Startup menu options include:♦ Warm Start – This selection restarts a previously configured FloBoss S600 where it left off prior

to being powered down.♦ Cold Start – This is used to build a new metering database on the FloBoss S600 using the

configuration files stored in Flash memory.♦ Network Setup – This is used to configure the TCP/IP, Gateway and Modbus addresses. If the

Modbus address has been changed, restart the FloBoss S600 for the change to take place.



♦ Reflash Firmware – This is used to reprogram the FloBoss S600 operating system firmwarestored in Flash memory.

♦ Reflash Config – This is used to copy the configuration files into Flash memory from the volatileRAM disk.

♦ Factory Setup – This is used to perform a RAM Disc Start, Clear SRAM, and Format Flash.

4.4 Reflash Firmware

The Reflash Firmware option allows you to reprogram the Flash memory with new values for theoperating system components and the application firmware.

This option requires you to download a binary file from CONFIG 600 into the volatile RAM disk on theFloBoss S600 prior to erasing and reprogramming the Flash memory. Refer to Section 5, PC Setup, forPC software setup and use.

CAUTIONUnder no circumstances should you allow the FloBoss S600 to be turned off while it is erasingor reprogramming the Flash memory; otherwise, the FloBoss S600 will be renderedunusable. Should this occur, the FloBoss S600 must be returned to the factory for systemreprogramming.

To reprogram the Flash memory:

1. Select the REFLASH FIRMWARE command from the FloBoss S600 Startup menu.

2. Press 1 to confirm, and the following message displays:

PERFORM CONFIG 600 FLASH COMMAND NOW

3. From CONFIG 600, enter the Transfer program, select the required vxworks.bin file and click onSend Now to download it to the FloBoss S600.

4. The following message displays on the FloBoss S600:RECEIVING BINARY FILE

Once the file has been successfully downloaded, the FloBoss S600 displays the message:RECEIVED OK

Note: Do not proceed if the message FLASH FAILED displays. Remove the power connector for5 seconds and the FloBoss S600 will Cold Start.

5. The FloBoss S600 proceeds to erase and reprogram the Flash memory, and displays the followingmessage:

RESETTING - PLEASE WAIT

The FloBoss S600 then restarts; if the FloBoss S600 has not restarted after 30 seconds, remove thepower connector for 5 seconds to initiate a Cold Start.



4.4.1 Download and Reflash Config FileTo allow the FloBoss S600 to retain the configuration data indefinitely following a download fromCONFIG 600, the Reflash Config option is used to copy the configuration file into Flash memory fromthe volatile RAM disc.

To reflash the configuration data from the RAM disc:

1. From the Config 600 software, select the Transfer Data option.

2. Choose the Com port connected to the FloBoss S600. Default parameters are 38,400 KB, 8 databits, 1 stop bit, and no parity.

Note: Configurations can also be transferred via Ethernet, as well as by the serialcommunications port.

3. Select the configuration you require, then select the sections you desire to transfer to the FloBossS600.

4. Click on Send Now to download to the FloBoss S600.

5. Select the REFLASH CONFIG command from the FloBoss S600 Startup menu.

6. Press 1 to confirm, and the following message displays:

SAVING CONFIGURATION TO FLASH

Once completed, the FloBoss S600 Startup menu displays.

For further configurations, the data is automatically stored to flash memory when it has been transferred.The user is not required to manually reflash the configuration.

4.4.2 Cold StartOnce the configuration file has been downloaded from the host PC, you can select the Cold Start optionto build a new metering database using the configuration data stored in the Flash memory of the FloBossS600.

Prior to any network communications, the necessary network settings should also be set. Theseparameters can only be viewed or changed via the FloBoss S600 Startup menu. Refer to Network Setup,Section 4.5.

To initiate a Cold Start of the FloBoss S600:

1. Select the COLD START command from the FloBoss S600 Startup menu.

2. Press 1 to confirm and the following message displays:

CONFIGURING - PLEASE WAIT

3. A new database is then built using the configuration files held in the Flash memory.

Once completed, the FloBoss S600 Main menu displays.



4.5 Network Setup

The Network Setup option allows you to define the TCP/IP Ethernet, Gateway, and Modbus networkaddresses.

When any Modbus slave configuration builder has an address of zero specified, the Modbus port will beconfigured with the address entered here. This is typically used when the same configuration file is loadedinto multiple FloBoss S600 flow computers on the same Modbus network; thus, giving each FloBoss S600a unique node address.

These settings are kept in a separate area of the SRAM database and will be retained following aconfiguration download.

These parameters can only be viewed or changed via the FloBoss S600 Startup menu.

To define the network addresses:

1. Select NETWORK SETUP from the FloBoss S600 Startup menu.

2. Select the required address option.

3. Enter the address value (for an Enron Modbus link, a maximum value of 247 is permitted).

4.6 Factory Setup

The Factory Setup options include RAM Disc Start, Clear SRAM, and Format Flash. These options,with the exception of Clear SRAM, should only be used by factory personnel in the event of a problem.

4.6.1 Clear SRAMThe Clear SRAM option is used to clear out the FloBoss S600 by overwriting the SRAM area. Allbattery-backed configuration data will be lost, including system configuration data, process configurationdata, metering totalizers, and network settings.

Generally, Clear SRAM is only used prior to a new application being downloaded to the FloBoss S600.

Following a Clear SRAM command, the FloBoss S600 will not be able to warm start again until a fullconfiguration download from PC Setup has been completed.

To clear the SRAM:

1. Select FACTORY SETUP from the FloBoss S600 Startup menu.

2. Select the CLEAR SRAM command.

3. Press 1 to confirm and the following message displays:

COMMUNICATIONS LINK FAILURE



4. Reboot the FloBoss S600 (power down, wait five seconds, and then repower). Once completed,the FloBoss S600 Startup menu displays.

4.6.2 RAM Disc StartThe RAM Disc Start option provides an alternative means of creating a new metering database on theFloBoss S600 via FTP transfer. Do not use this option. This option should only be used by factorypersonnel.

To initiate a RAM Disc Start:


2. Select the RAM DISC START command.

3. Press 1 to confirm.

4. The existing SRAM database, including the totals, is deleted. A new database is then built usingthe configuration files held on the SRAM disk. The following message displays:

CONFIGURING - PLEASE WAIT

Note: The RAM disk contents are volatile. Use the REFLASH CONFIG command to ensure thenew configuration is permanently saved.


4.6.3 Format FlashThe Format Flash option is used to reformat the Flash memory. Any data stored in Flash will be lost,including the configuration data, report formats, display setting, and Modbus addresses. This optionshould only be used by Flow Computer Division (Daniel) personnel.

To initiate a reformat of the Flash memory:


2. Select the FORMAT FLASH command.

3. Press 1 to confirm.


4.7 Troubleshooting

The troubleshooting techniques described here allow you to determine the nature of a problem and applythe most applicable solution.



4.7.1 Initial ChecksBefore contacting your sales/support agent with a problem, first check the following:

♦ Check that all the plug-in boards are seated correctly and the retaining screws are fastened. ♦ Check that all the field wiring is properly connected.♦ Check the supply voltage.

If the power supply seems to be working correctly, but the startup routine does not appear on the display,check the fuse for damage.

If the problem persists, and none of the checks appear to solve the problem, please contact your local salesrepresentative to return the unit.

Note: The whole machine, including the case, should be returned. On no account should thecircuit boards be extracted and returned separately.

4.7.2 Removing and Replacing Plug-in BoardsTo remove or install a plug-in board from the FloBoss S600, refer to Section 2, Installation, for detailedprocedures.

4.7.3 Changing the FuseThe fuse is located in a clip-in type holder on the CPU module.



FUSE

Figure 4-2. Fuse Location

To change a suspect fuse, proceed as follows:

1. Switch off power.

2. Unscrew and remove the CPU module.

3. Use only light pressure to extract the fuse.

4. Check the fuse and, if necessary, replace it with a 20 mm x 5 mm 2.5 Amp anti-surge fuse only.The use of a fuse with a higher current rating invalidates the warranty on the FloBoss S600.

5. Replace the fuse and check it is secure before replacing the CPU module into the case.

6. Replace the plug connectors.

7. Switch on the power supply.

4.7.4 Startup ListThe following table provides a list of possible solutions to problems that may be encountered during thestartup sequence.



Table 4-1. Startup List

Symptom Possible SolutionNo Power Check fuse.No Initial I/O Red Led After Power On Power down, remove and reseat I/O board, reapply power.No Front Panel Backlight Check connector (J2) between front panel and main board.Front Panel Led Is Permanently Orange Reboot the FloBoss S600; if problem remains, return FloBoss

S600 to factory.No I/O Red Led Showing Depower, remove and reseat I/O board, reapply power.Cold Start Menu Is Displayed Instead OfExpected Warm Start Menu

Check if cold start jumper (link) is fitted. Download configurationfile.

I/O Fail Message Is Displayed Check I/O links (refer to Section 5, Setup and Wiring).


8/01 Setup and Wiring 5-1

1

SECTION 5 – SETUP AND WIRING

5.1 Scope

This section includes information on plug-in connector blocks, field wiring configurations (ANIN,PRT, and DPR signals), and link/jumper settings for the plug-in boards.

It is recommended that all wiring be made with stranded wire that is no larger than 16 AWG.

For the communication ports, wiring of 18 to 22 AWG is recommended. Power wiring isrecommended to be 16 AWG.

All local wiring practices and regulations should be observed.

CAUTIONDo not use a Megger or similar instrument to check for isolation or continuity betweensignals on any of the connectors of the FloBoss S600. These instruments produce voltagesfar in excess of design parameters and damage may occur. If any such instrument is used,the warranty on the FloBoss S600 will be invalidated.



Information Section Page NumberScope 5.1 5-1Section Contents 5.2 5-1CPU Board 5.3 5-2

Power Supply 5.3.1 5-3Watchdog Relay 5.3.2 5-3RS232 Modem Port 5.3.3 5-3RS422/485 Multidrop Port 5.3.4 5-3Ethernet LAN Port 5.3.6 5-3Front Panel Port 5.3.6 5-3On-Board Battery Backup 5.3.7 5-3Remote Display or PC 5.3.8 5-3P152 CPU On-board Connectors 5.3.9 5-3P152 CPU Berg Jumpers (Links) 5.3.10 5-3

P144 I/O Board 5.4 5-3Analog Inputs 5.4.1 5-3Digital Inputs 5.4.2 5-3


5-2 Setup and Wiring 8/01

Turbine Pulse Inputs 5.4.3 5-3Frequency Inputs 5.4.4 5-3PRT/RTD Inputs 5.4.5 5-3Analog Outputs 5.4.6 5-3Digital Outputs 5.4.7 5-3Pulse Outputs 5.4.8 5-3P144 I/O Berg Jumpers (Links) 5.4.9 5-3

P154 Prover Board 5.5 5-3Digital Inputs 5.5.1 5-3Turbine Pulse Inputs 5.5.2 5-3Frequency Inputs 5.5.3 5-3Digital Outputs 5.5.4 5-3Pulse Outputs 5.5.5 5-3P154 Prover Berg Jumpers (Links) 5.5.6 5-3

5.3 CPU Board

The P152 CPU board contains the host processor and associated peripherals, which form the heart ofthe system.

Various plug-in connections are provided on the rear backplate of the CPU board. Additionalconnectors and jumpers (links) are also used on the board, which are set at the factory prior toshipping.

Refer to Figure 5-1 for a detailed illustration of the CPU board backplate.



TB-1

COM 1-2

REMOTE I/O

TB-2

NETWORK

COM 4

COM 3

POWER

COM 5, 6, 7RS 232/485

Figure 5-1. CPU Backplate

5.3.1 Power SupplyPower is supplied to the FloBoss S600 via the P152 CPU board. Connection is made by a plug-in,standard 5-mm pitch screw terminal. The power supply connector is labeled TB-1.

The FloBoss S600 should be powered by a nominal 24 VDC power source capable of supplying 2amps. The unit will operate between 20 and 32 VDC.

The startup in-rush current may draw 6 amps for approximately 100 milliseconds. This in-rushbecomes significant when multiple flow computers are connected to the same power supply.

An on-board anti-surge fuse (2.5 amp rating) protects the supply line should a fault occur within theunit.

Fully regulated 15 and 24 VDC supplies are also available for applications such as powering loops orpre-amplifiers. These outputs are protected by resettable thermal fuses.

The TB-1 pin connections are shown in Table 5-1.



Table 5-1. TB-1 Pin Connections

Pin Function1 +24 VDC-INPUT2 0 V (Return)-INPUT3 +24 VDC-OUTPUT (500 mA)4 +15 VDC-OUTPUT (100 mA)5 0 V (Return)-OUTPUT

5.3.2 Watchdog RelayA single pole, double throw relay with Normally Open or Normally Closed terminals provides thewatchdog status from pins 6, 7, and 8 of TB-1. A CPU failure causes the relay to de-energize.Connection is made by a plug-in, standard 5 mm-pitch screw terminals.

Note: Contact is rated at 1A, 30 volts DC and 30 volts AC, and is a Form “C” contact.

The TB-1 pin connections display in Table 5-2.

Table 5-2. TB-1 Pin Connections

Pin Function6 Normally Closed7 Common8 Normally Open

The relay is energized during normal operation.



5.3.3 RS232 Modem PortTwo RS232D communications ports are provided on the backplate of the CPU board. The ports useFCC-68 RJ45 connectors and are labeled COM3 and COM4. Converters are commercially availableto configure either 9-way D type or 25-way D type connection.

The COM3 and COM4 pin connections are shown in Table 5-3.

Table 5-3. COM3 and COM4 Pin Connections

Pin Function1 GND2 DTR3 RTS4 TX5 RX6 CTS7 DSR8 DCD

Figure 5-2. Pin Connections

Maximum cable length is a function of the baud rate and quality of cable used. For example, amaximum length of 15 m (50 feet) should be used at 19.2 kBaud using unscreened cable.

The ports should be connected to the peripheral devices using multi-conductor, shielded cable. It isrecommended that the cable screen be connected to protective earth, keeping signal ground separate,particularly in noisy environments.



5.3.4 RS422/485 Multidrop PortThree RS422/RS485 ports are located on the backplate of the CPU board and provide high speed/longdistance links of up to 57.6 kBaud and 1200 meters (4000 feet). The ports use the connector labeledTB-2.

Note: For two-wire RS422/ RS485 installations, jumper TX+ to RX+ and TX- to RX- on P152CPU board TB-2.

The COM5, COM6, and COM7 pin connections is shown in Table 5-4.

Table 5-4. COM5, COM6, and COM7 Pin Connections

Pin Port Function1 COM5 RX-2 COM5 RX+3 COM5 TX-4 COM5 TX+5 COM6 RX-6 COM6 RX+7 COM6 TX-8 COM6 TX+9 COM7 RX-10 COM7 RX+11 COM7 TX-12 COM7 TX+13 COMPUTER

GROUNDGND

5.3.5 Ethernet LAN PortThis port is for high-speed communications using an Ethernet local area network architecture. Thespeed of data transfer is 10Mb/sec using a 10baseT twisted pair.

The port uses a FCC-68 RJ45 connector labeled Network on the backplate of the CPU.



5.3.6 Front Panel PortThis is an alternative connection for COM2 and is used with the CONFIG 600 program to transferconfiguration files.

Pinouts display in Table 5-5.

Table 5-5. COM2 Alternative Connections

Pin Function1 RTS2 TX3 GND4 GND5 RX6 CTS

Figure 5-3. COM2 Alternative Connections

5.3.7 On-Board Battery BackupTwo battery options are available. A simple check should be made to ensure which type has beensupplied:

♦ Rechargeable, board mounted, nickel metal hydride cell.♦ Non-rechargeable, intrinsically safe cell.

Note: The status of this battery is monitored by a voltage sensing circuit. An alarm is raised ifthe battery voltage drops below the predefined limit.

This is a factory-fitted option. Only one type of battery can be installed. Once the IS or 1/2AA cell isinstalled, without line power to the FloBoss S600 unit, the battery life will become exhausted.



5.3.8 Remote Display or PCThe connector labeled COM1-2 on the backplate of the CPU board is used to connect the FloBossS600 to a remote display (COM1) or the host PC (COM2).

CAUTIONDo not reconfigure Com1 and Com2. They are for internal use only.

The COM1-2 pin connections display in Table 5-6.

Table 5-6. COM1-2 Pin Connections

Pin Function1 GND2 TX to R. Display3 GND4 SPEAKER OUT5 N/C6 TX to PC7 RTS to PC8 GND9 RX from R. Display10 CTS to R. Display11 GND12 N/C13 N/C14 RX from PC15 CTS to PC

The COM1-2 port uses a standard 15-way D-type female connector.

Only shielded, multi-conductor cable should be used to connect to the COM1-2 port. It isrecommended, particularly in noisy environments, that the cable shield is connected to earth ground,ensuring the signal ground is separate.

Note: The cable length should not exceed 15 meters (49 feet).



5.3.9 P152 CPU On-board ConnectorsThe miscellaneous device connectors provided on the P152 CPU module are shown in Table 5-7. Thisinformation is for identification purposes only.

Table 5-7. Miscellaneous Device Connectors for the P152 CPU Module

Socket DescriptionJ2 CPU cooling fan molex (12 VDC)J3 PC/104 expansion bus (16- bit)J4 Additional plug-in battery molex 3.6 VDCJ5 IDE Hard disk pin header J6 Altera serial programming pin header (factory use only)J7 Keyboard and mouse pin headerJ8 Security bit linkJ9 Optional communications LED backplate pin header



5.3.10 P152 CPU Berg Jumpers (Links)The entries shown in boldface are the default configuration settings; however, these may not apply toyour specific configuration.

Table 5-8. Default Configuration Settings for the P152 CPU Berg Jumpers (Links)

Jumper (Link) Position DescriptionCPU & RADISYS

LK3 ON 3 volt operationOFF

LK4 ON Internal RTC enabledOFF

LK5 ON Internal keyboard & mouse enabledOFF Enabled

LK6 ON 8 bit BIOSOFF

LK7 ON 7 DMA channel operationOFF

LK8 ON All interrupts available via MUXOFF

LK9 ON EIDE supportedOFF

LK10 ON CS_USR1# supportedOFF

LK11 ON COM1, COM2 supported: data & RTS/CTS onlyOFF

LK12 ON COMCLK enabledOFF

LK13 ON Cold Start forced on power upOFF

LK14 ON BIOS Monitor start enabledOFF

FlashLK15 1-2 Write Prohibited - Block 0 - 1M

2-3 Write EnabledLK16 1-2 Write Prohibited - Block 1 - 2M



2-3 Write Enabled



Clock MultiplyLK19 ON DX2: Off

OFF DX4: On = Clk x3, Off = Clk x2586: On = Clk x4, Off = Clk x3

BIOS ROM SizeLK20 1-2 1M EPROM

2-3 4M EPROMSQFP 486 CPULK21 ON Link to upgrade SQFP 486 CPU

OFFEthernetLK24 ON ENEEP

OFFLK25 ON IOS 2

OFFLK26 ON IOS 1

OFFLK27 ON IOS 0

OFFCache SelectLK28 ON Non-Enhanced = Off

OFF EnhancedOn = WritethroughOff = Writeback

LK29 ON Link when write-back processor fittedOFF

Table 5-9. Clock Speed Selection

Clock Speed Link 22 Link 2333 MHz OFF OFF40 MHz ON OFF50 MHz ON ON66 MHz OFF ON



5.4 P144 I/O Board

The P144 I/O board measures process signals used by the CPU while running the flow computerfunctions.

The backplate has three low density D-type connectors for field wiring. These connectors are labeledSKT-A, SKT-B, and SKT-C. There is also a version available with standard plug-in screw terminalblocks.

SKT-A

SKT-B

SKT-C

ANIN 1-10ANOUT 1-4

ANIN 11 - 12DIGIN 1-6DIGOUT 1 - 2Freq InputsPulse Outputs

DIGIN 7-16DIGOUT 3-12Turbine Inputs

Figure 5-4. I/O Backplate

5.4.1 Analog InputsThere are two fully floating A/D converters per I/O board, each measuring five single-ended analoginput (ANIN) channels. There are also two current-only inputs (ANIN 11 and 12). This provides atotal of 12 analog inputs.

The ANIN channels use the connectors labeled SKT-A and SKT-B, which are located on the backplateof the P144 board.

Channels CH1 to CH10 are located on connector SKT-A and channels CH11 and CH12 are located onconnector SKT-B.

The primary measurement for ANIN 1-10 is voltage, which is compared to a stable reference source.



Each channel (ANIN 1-10) is configurable as a 0 to 5.25V or 0 to 22mA input range using a jumper(link) on the board to place a high accuracy calibrated shunt resistor in parallel with the input.

Note: The channels for each A/D converter should be similarly configured to guaranteeaccuracy.

The ANIN pin connections are shown in Table 5-10 and Table 5-11.

Table 5-10. ANIN Pin Connections for SKT-A

Pin Function8 ANIN-CH121 ANIN-CH29 ANIN-CH322 ANIN-CH410 ANIN-CH520 RETURN CH1-511 ANIN-CH624 ANIN-CH712 ANIN-CH825 ANIN-CH913 ANIN-CH1023 RETURN CH6-10

Table 5-11. ANIN Pin Connections for SKT-B

Pin Function7 ANIN-CH12 (current)8 ANIN-CH11 (current)20 GND

5.4.2 Digital InputsThere are 16 optically-isolated digital inputs (DIGIN) per plug-in board.

The digital inputs have been grouped into four banks of 4-off single ended inputs with a commonreturn to reduce the termination count.

The DIGIN channels use the connectors labeled SKT-B and SKT-C, which are located on thebackplate of the P144 board. Channels CH1 to CH6 are located on connector SKT-B, and channelsCH7 through CH16 are located on connector SKT-C.

The sample period is 500 milliseconds.



Note: The return lines (Ex. pin 17 on SKT-B) must be connected to a 24VDC source such asprovided by the external termination board, while the DIGIN lines (Ex. pin 13 on SKT-B)expect typical “open collector” (referenced to GND) connections.

The DIGIN pin connections are in Table 5-12 and Table 5-13.

Table 5-12. DIGIN Pin Connections for SKT-B

Pin Function13 DIGIN-CH114 DIGIN-CH215 DIGIN-CH316 DIGIN-CH417 RETURN CH1-418 DIGIN-CH519 DIGIN-CH6

Table 5-13. DIGIN Pin Connections for SKT-C

Pin Function19 DIGIN-CH718 DIGIN-CH817 RETURN CH5-816 DIGIN-CH915 DIGIN-CH1014 DIGIN-CH1113 DIGIN-CH1212 RETURN CH9-1211 DIGIN-CH1310 DIGIN-CH149 DIGIN-CH158 DIGIN-CH167 RETURN CH13-16

5.4.3 Turbine Pulse InputsThe four pulse inputs may be used either independently or in pairs of two. Generally, they are used fordual pulse measurement, such as turbine applications.

In dual pulse mode, level A or B pulse checking can be enabled.

Each input has an input range of 1 to 10,000 Hz. Each channel has live integrity checking. A circuitfail alarm is activated if cabling faults develop or the pre-amp power fails.



The electrical connection of these inputs is dependent on which DPR mezzanine is fitted to the P144I/O module. For example, a P148 Mezzanine is suitable for Spectra-Tek pre-amp signals.

The dual-pulse input channels use the connector labeled SKT-C, which is located on the backplate ofthe P144 board.

The dual-pulse input pin connections are shown in Table 5-14.

Table 5-14. Dual-pulse Input Pin Connections for SKT-C

Pin Function4 SINGLE/DUAL PULSE-CH1+23 SINGLE/DUAL PULSE-CH1-3 SINGLE/DUAL PULSE-CH2+22 SINGLE/DUAL PULSE-CH2-2 SINGLE/DUAL PULSE-CH3+21 SINGLE/DUAL PULSE-CH3-1 SINGLE/DUAL PULSE-CH4+20 SINGLE/DUAL PULSE-CH4-

5.4.4 Frequency InputsThe three frequency inputs are typically used for density transducer signals. Each input has a an inputrange of 0 to 10,000 Hz. The frequency input channels use the connector labeled SKT-B, which islocated on the backplate of the P144 board.

The frequency input pin connections are shown in Table 5-15.

Table 5-15. Frequency Input Pin Connections for SKT-B

Pin Function9 FREQUENCY-CH1+27 FREQUENCY-CH1-10 FREQUENCY-CH2+28 FREQUENCY-CH2-11 FREQUENCY-CH3+29 FREQUENCY-CH3-

5.4.5 PRT/RTD InputsThere are three Platinum Resistance Thermometer (PRT)/Resistance Temperature Detector (RTD)inputs.

The PRT inputs are suitable for Class A, 4-wire PRT devices that conform to the BS EN 60751:1996standard. In CONFIG 600 there are two options:



♦ DIN (coefficient of 0.00385 ohm/ohms degrees Celsius).♦ AMERICAN (coefficient of 0.003926 ohm/ohms degrees Celsius).

The “DIN” 43760 selection is typical in Europe and common in the United States, while the“AMERICAN” STANDARD coefficient (alpha) is still common for circumstances where a slightlymore pure Platinum is used to effect a higher absolute accuracy.

The temperature measurement range is -100 to +200° C (-148 to +392° F).

The PRT input channels use the connector labeled SKT-B, which is located on the backplate of theP144 board.

The PRT input pin connections are shown in Table 5-16.

Table 5-16. PRT Input Pin Connections for SKT-B

Pin Function4 PRT-CH1 I+1 PRT-CH1 V+21 PRT-CH1 V-24 PRT-CH1 I-5 PRT-CH2 I+2 PRT-CH2 V+22 PRT-CH2 V-25 PRT-CH2 I-6 PRT-CH3 I+3 PRT-CH3 V+23 PRT-CH3 V-26 PRT-CH3 I-

5.4.6 Analog OutputsThere are four analog outputs (D/A Converter). Each D/A Converter channel is fully floating andprovides its own floating supply. Loads up to a 650-ohm loop impedance can be connected directly.

The D/A Converter output channels use the connector labeled SKT-A, which is located on thebackplate of the P144 board.

The D/A Converter output pin connections on the back of the I/O card are shown in Table 5-17. Theunit can be used in either source or sink configuration.



Table 5-17. D/A Converter Output Pin Connections for SKT-A

Pin Function1 DAC-CH1 +15 V SOURCE14 DAC-CH1 SINK2 DAC-CH1 0 VDC15 DAC-CH2 +15 V SOURCE3 DAC-CH2 SINK16 DAC-CH2 0 VDC4 DAC-CH3 +15 V SOURCE17 DAC-CH3 SINK5 DAC-CH3 0 VDC18 DAC-CH4 +15 V SOURCE6 DAC-CH4 SINK19 DAC-CH4 0 VDC

Figure 5-5 shows an example of how Channel 1 would be used in the source or sink configuration. Seedrawing DE-20400 Field Wiring Model FloBoss S600 for external terminal board connectionassignments.

Figure 5-5. Analog Output Channel 1 as a Source or Sink



5.4.7 Digital OutputsThere are 12 digital output channels. The DC polarity must be carefully checked. Use an external DCsupply in series with the load. When using inductive loads, such as relay coils, place a diode across theload.

The digital outputs (DIGOUT) are high current, open collector type. The maximum current rating is100 mA at 24 VDC. Output frequencies up to 0.5 Hz are possible.

The DIGOUT channels use the connectors labeled SKT-B and SKT-C, which are located on thebackplate of the P144 board. Channels CH1 to CH2 are located on connector SKT-B and channelsCH3 and CH12 are located on connector SKT-C.

The DIGOUT pin connections are shown in Table 5-18 and Table 5-19.

Table 5-18. DIGOUT Pin Connections for SKT-B

Pin Function36 DIGOUT-CH137 DIGOUT-CH2

Table 5-19. DIGOUT Pin Connections for SKT-C

Pin Function37 DIGOUT-CH336 DIGOUT-CH435 RETURN CH1-434 DIGOUT-CH533 DIGOUT-CH632 DIGOUT-CH731 DIGOUT-CH830 RETURN CH5-829 DIGOUT-CH928 DIGOUT-CH1027 DIGOUT-CH1126 DIGOUT-CH1225 RETURN CH9-12



5.4.8 Pulse OutputsThere are five programmable pulse outputs, typically used for electronic counters or sampler control.The pulse output channels (PULSEOUT) use the connector labeled SKT-B, which is located on thebackplate of the P144 board.

The PULSEOUT pin connections are shown in Table 5-20.

Table 5-20. PULSEOUT Pin Connections for SKT-B

Pin Function30 PULSEOUT-CH131 PULSEOUT-CH232 PULSEOUT-CH333 PULSEOUT-CH435 RETURN CH1-434 PULSEOUT-CH512 RETURN CH5

5.4.9 P144 I/O Berg Jumpers (Links)The entries shown in boldface are the default configuration settings; these may not apply to yourspecific configuration. Refer to Table 5-21, Table 5-22, and Table 5-23.

Table 5-21. Flash Link Setting

Jumper (Link) Position DescriptionLK1 ON Write Enable

OFF Write ProtectedLK2 ON Point to Point mode enabled

OFF Point to Point mode off



Table 5-22. P144 I/O Berg Links

MUX Address: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15LK3 LK4 LK5 LK6 LK7 LK8 LK9 LK10 1-2

2-3 LK12LK13-15

Note: A/D Converter Shunts are configured in groups of five and must be used together ascurrent OR voltage.

Table 5-23. A/D Converter Shunt Mode

A/D ShuntsLK16 ON Current Mode ADC-CH1

OFF Voltage ModeLK17 ON Current Mode ADC-CH2




OFF Voltage Mode**LK16-19 should be fitted as a setLK21 ON Current Mode ADC-CH6





OFF Voltage Mode**LK21-25 should be fitted as a set



5.5 P154 Prover Board

The P154 is a dedicated prover interface card that has been designed to work with compact ormicroprover, unidirectional and bi-directional provers, with 2 or 4 detector switches. In addition, itcontains high resolution timing circuits so that dual chronometry methods can be utilized to increasethe apparent resolution for instances when insufficient turbine pulses are present with the provervolume available. The prover can also be used in master meter proving and supplies 32 digital inputs,12 digital outputs, 2 frequency (density) inputs, and 4 hardware-assisted pulse outputs. There are noanalog functions on the prover board.

The backplate has three low density D-type connectors for field wiring. These connectors are labeledSKT-D, SKT-E, and SKT-F. There is also a version available with standard plug-in screw terminalblocks.

SKT-D

SKT-F

RAW IN 1-3DENSITY 1-2

SKT-EDIGIN 1-6 AND 17-32DIGOUT 1-2Pulse Outputs 1-4

DIGIN 7-16DIGOUT 3-12DUAL PULSE 1-4

SPHERE SWITCH 1-4PLLINRAW OUT

PLLOUT

Figure 5-6. Prover I/O Backplate

5.5.1 Digital InputsThere are 32 optically-isolated digital inputs (DIGIN) per plug-in board. The digital inputs have beengrouped into four banks of 4-off single ended inputs with a common return to reduce the terminationcount.



The DIGIN channels use the connectors labeled SKT-E and SKT-F, which are located on the backplateof the P154 board. Channels CH1 to CH6 are located on connector SKT-E, and channels CH7 throughCH16 are located on connector SKT-F.

The sample period is 500 milliseconds.

Note: The return lines (Ex. pin 17 on SKT-E) must be connected to a 24VDC source such asprovided by the external termination board, while the DIGIN lines (Ex. pin 13 on SKT-E)expect typical “open collector” (referenced to GND) connections.

The DIGIN pin connections are shown in Table 5-24 and Table 5-25.

Table 5-24. DIGIN Pin Connections for SKT-E

Pin Function13 DIGIN-CH114 DIGIN-CH215 DIGIN-CH316 DIGIN-CH417 RETURN CH1-418 DIGIN-CH519 DIGIN-CH61 DIGIN CH-172 DIGIN CH-183 DIGIN CH-194 DIGIN CH-205 RETURN CH-17-206 DIGIN CH-217 DIGIN CH-228 DIGIN CH-239 DIGIN CH-2410 RETURN CH 21-2420 DIGIN CH-2521 DIGIN CH-2622 DIGIN CH-2723 DIGIN CH-2824 RETURN CH 25-2825 DIGIN CH-2926 DIGIN CH-3027 DIGIN CH-3128 DIGIN CH-3229 RETURN CH 29-32



Table 5-25. DIGIN Pin Connections for SKT-F

Pin Function19 DIGIN-CH718 DIGIN-CH817 RETURN CH5-816 DIGIN-CH915 DIGIN-CH1014 DIGIN-CH1113 DIGIN-CH1212 RETURN CH9-1211 DIGIN-CH1310 DIGIN-CH149 DIGIN-CH158 DIGIN-CH167 RETURN CH13-16

5.5.2 Turbine Pulse InputsThe four pulse inputs may be used either independently or in pairs of two. Generally, they are used fordual pulse measurement, such as turbine applications.

In dual pulse mode, level A or B pulse checking can be enabled. The dual-pulse input channels use theconnector labeled SKT-F, which is located on the backplate of the P154 board.

Each input has an input range of 1 to 10,000 Hz. Each channel has live integrity checking. A circuitfail alarm is activated if cabling faults develop or the pre-amp power fails.

The electrical connection of these inputs is dependent on which DPR mezzanine is fitted to the P144I/O module. For example, a P148 Mezzanine is suitable for Spectra-Tek pre-amp signals.

The dual-pulse input pin connections are shown in Table 5-26.

Table 5-26. Dual-pulse Input Pin Connections for SKT-F

Pin Function4 DUAL PULSE-CH1+23 DUAL PULSE-CH1-3 DUAL PULSE-CH2+22 DUAL PULSE-CH2-2 DUAL PULSE-CH3+21 DUAL PULSE-CH3-1 DUAL PULSE-CH4+20 DUAL PULSE-CH4-



5.5.3 Frequency InputsThere are two frequency inputs, typically used for density transducer signals. Each input has an inputrange of 0 to 10,000 Hz.

The frequency input channels use the connector labeled SKT-D, which is located on the backplate ofthe P154 board.

The frequency input pin connections are shown in Table 5-27.

Table 5-27. Frequency Input Pin Connections for SKT-D

Pin Function9 FREQUENCY-CH1+21 FREQUENCY-CH1-10 FREQUENCY-CH2+22 FREQUENCY-CH2-

5.5.4 Digital OutputsThere are 12 digital output channels. The DC polarity must be carefully checked. Use an external DCsupply in series with the load. When using inductive loads, such as relay coils, place a diode across theload.

The digital outputs (DIGOUT) are high current, open collector type. The maximum current rating is100 mA at 24 VDC. Output frequencies up to 0.5 Hz are possible.

The DIGOUT channels use the connectors labeled SKT-E and SKT-F, which are located on thebackplate of the P154 board. Channels CH1 to CH2 are located on connector SKT-E and channelsCH3 and CH12 are located on connector SKT-F.

The DIGOUT pin connections are shown Table 5-28 and Table 5-29.

Table 5-28. DIGOUT Pin Connections for SKT-E

Pin Function36 DIGOUT-CH137 DIGOUT-CH2



Table 5-29. DIGOUT Pin Connections for SKT-F

Pin Function37 DIGOUT-CH336 DIGOUT-CH435 RETURN CH1-434 DIGOUT-CH533 DIGOUT-CH632 DIGOUT-CH731 DIGOUT-CH830 RETURN CH5-829 DIGOUT-CH928 DIGOUT-CH1027 DIGOUT-CH1126 DIGOUT-CH1225 RETURN CH9-12

5.5.5 Pulse OutputsThere are five programmable pulse outputs, typically used for electronic counters or sampler control.The pulse output channels (PULSEOUT) use the connector labeled SKT-E, which is located on thebackplate of the P154 board.

The PULSEOUT pin connections are shown Table 5-30.

Table 5-30. PULSEOUT Pin Connections for SKT-E

Pin Function31 PULSEOUT-CH132 PULSEOUT-CH233 PULSEOUT-CH334 PULSEOUT-CH435 RETURN CH1-4



5.5.6 P154 Prover Berg Jumpers (Links)The entries shown in boldface in Table 5-31 are the default configuration settings; these may not applyto your specific configuration.

Table 5-31. P154 Prover Berg Jumpers (Links)

Link Position DescriptionsFlashLK1 ON Write Enable

OFF Write ProtectedNode Address (see Table 5-32)LK2 ON

OFF Multiplexed mode (MUX)LK11 ON

OFF Multiplexed mode (MUX)MUX Address: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15LK3 LK4 LK5 LK6 LK7 LK8 LK9 LK10 1-2

2-3 Altera VoltageLK12 1-2 3.465V

2-3 5V - VccRaw Pulse Output ModeLK13/14 1-2 RS422 differential driver

2-3 Open collectorRaw Pulse Input #3 – Line DeterminationLK15/16 ON Line determination resistors connected: +ve pulled up to Vcc and –ve down

to 0VOFF Lines undetermined



Table 5-32. Node Addressing: Communications Mode Selection

Node Addressing: Communications Mode SelectionMode Link 2 Link 11 Link 3-10

Point-to-point ON OFF IGNOREDMulti-dropped ON ON IGNORED

Multiplexed (MUX) OFF OFF ADDRESS


8/01 Software Interface 6-1

SECTION 6 – SOFTWARE INTERFACE

6.1 Scope

This section introduces the FloBoss S600 user interface and lists the system requirements, softwareinstallation instructions, and file locations on the host PC.

Information on using the FloBoss S600 software is only provided via the online help files.

The following sections apply to IPL 600, Config 600 Lite and Config 600 Professional, except wherenoted.



Information Section Page NumberScope 6.1 6-1Section Contents 6.2 6-1System Requirements 6.3 6-2System Requirements 6.3 6-2Software Installation Procedure 6.4 6-2File Locations 6.5 6-3StartUp 6.6 6-4Connecting to the FloBoss S600 6.7 6-4


6-2 Software Interface 8/01

6.3 System Requirements

The FloBoss S600 optional software is supplied on CD-ROM. The software is a Windows-basedprogram package. To install and operate the FloBoss S600 software, you require either a portable ordesktop PC that meets the following minimum requirements:

Table 6-1. System Requirements

Component Required Minimum SuggestedCPU Pentium 133 MHz Pentium 233 MHzMemory Windows 95: 16MB

Windows NT: 32 MB> 32 MB of RAM

Free Disk Space 50MB 100MBOperating System Windows 95 Windows 95 with Internet Explorer 4CD-ROM 2x speed 16x speedSerial Port 1 No. (38400 Baud) 1 No. (38400 Baud)Display Resolution Super VGA: 800x600 with 256

colorsSuper VGA: 1024 x 768 with 256 colors orgreater

Selection Device Pointing device compatible withWindows operating systems

Mouse recommended

6.4 Software Installation Procedure

If you are installing the software from a remote CD-ROM drive, ensure you map a network drive letterto the path of the CD-ROM drive before you begin installation.

To install on a Windows 95/98 or NT 4.0 operating system:

1. Insert the FloBoss S600 software disc into your CD-ROM drive. The CD should “autorun”.However, if this does not occur, continue with the following steps.

2. Click the Start button on the Task bar.

3. Click the Run button and the Run Window displays. Refer Figure 6-1.

Figure 6-1. Run Dialog


8/01 Software Interface 6-3

4. Type x:\Setup (where x is your designated CD-ROM drive) in the Open field and thenclick OK.

5. Windows opens the setup file and the Installation Wizard begins. Follow the instructionsprovided on each screen.

6.5 File Locations

All files associated with the FloBoss S600 software are located in the respective default directory pathsnoted:

Config Pro=C:\Program Files\Daniel Ltd\Config Pro

Config Lite=C:\Program Files\Daniel Ltd\Config Lite

IPL600=C:\Program Files\Daniel Ltd\IPL600, unless you specified a differentdrive or directory during installation.

The configuration files containing the settings that appear in the database manager window are locatedin the Configs directory. A separate sub-directory is then used for each configuration.

When you receive new configuration files, they are typically in the form of a self-executing .exe file.Place this file in the Configs directory. Run (execute) the file. Running the executable files creates aunique new subdirectory within the Configs directory that contains all of the required directories,.txt, .pcs, .1c and .cfg files for the new configuration.

The files that define the report format are located in the Reports directory, and the files specifying theModbus settings are located in the Modbus directory.

The following files are downloaded to the FloBoss S600 during the configuration process:

vxworks.bin.x.x.x.x. – the operating system and task firmware binary file (where x.x.x.x.is the version number of the vxworks file).

s600conf.cfg – the main configuration file for the metering database and all the initializationvalues.

display.txt – the configuration file for the display menus and data pages.

Mbxx.txt – the Modbus configuration files including Slave register maps and Master pollingsequences (where xx indicates the file name is application-specific).

Mbpseq.txt – the prover sequence configuration file.

Repxx.txt – the report format configuration files (where xx indicates the file name isapplication-specific).


6-4 Software Interface 8/01

6.6 StartUp

After the FloBoss S600 software as been successfully installed, use Start > Programs to start theprogram.

Note: Refer to the online help for detailed instructions on using CONFIG 600.

To start the program directly from the executable file, use the directory path you specified wheninstalling the software. The default setting is:

C:\Program Files\Daniel Ltd\Config Pro\ Config 600 Pro.exe

C:\Program Files\Daniel Ltd\Config Lite\Config 600 Lite.exe

C:\Program Files\Daniel Ltd\IPL600\IPL600.exe

6.7 Connecting to the FloBoss S600

A special serial cable is required to connect the host PC to the FloBoss S600 unit. A ready-made linkcable is available for a PC with a 9-pin serial port.

Alternatively, you may fabricate your own link cable using the wiring details in Figure 6-2.

Note: Due to the high baud rate used for the communications between the host PC and theFloBoss S600, it is recommended that the maximum cable length be restricted to 5 meters (15feet).

Figure 6-2. Link Cable


8/01 Technical Data A-1

APPENDIX A – TECHNICAL DATA

A.1 Scope

This appendix contains a complete list of physical, performance, and environmental specifications ofthe FloBoss S600 and its plug-in boards.

The FloBoss S600 unit consists of an 80486 microprocessor-controlled CPU board, an I/O board, and apower supply back-plane, all fitted inside a zinc-coated pressed mild steel case with a display andkeypad in the front panel of the unit.

A.2 Section Contents


Information Section Page NumberScope A.1 A-1Section Contents A.2 A-1Mechanical and Environmental A.3 A-2Power Supply A.4 A-3P152 CPU A.5 A-4

Battery Backup A.5.1 A-4Communications A.5.2 A-5Other Peripherals A.5.3 A-6Watchdog Relay A.5.4 A-7

P144 I/O A.6 A-7Analog Inputs (voltage or current type) A.6.1 A-8PRT Inputs A.6.2 A-9Frequency/Density Inputs A.6.3 A-9Turbine Pulse Inputs A.6.4 A-10Digital Status Inputs A.6.5 A-10Analog Outputs A.6.6 A-11Digital Outputs A.6.7 A-11Pulse Outputs A.6.8 A-12Raw Pulse Outputs A.6.9 A-12

P154 Prover A.7 A-13Frequency/Density Inputs A.7.1 A-13Turbine Pulse Inputs A.7.2 A-14Digital Status Inputs A.7.3 A-14Digital Outputs A.7.4 A-15


A-2 Technical Data 8/01

Pulse Outputs A.7.5 A-15Raw Pulse Outputs A.7.6 A-16

Display-Keypad A.8 A-16Mezzanine Boards A.9 A-16

Spectra-Tek DPR Mezzanine A.9.1 A-16Daniel Mezzanine A.9.2 A-16

A.3 Mechanical and Environmental

Table A-1 and Table A-2 display the computer case and mounting specifications.

Table A-1. Computer Case and Mounting

Display Keypad Moulding 85 mm (3.35") width x 269 mm (10.59") height x 28 mm (1.10") deepCase 84.5 mm (3.327") width x 270 mm (10.63") height x 303.8 mm (11.94") deepPanel Cutout 66 mm (2.6") width x 150 mm (5.9") height (both with ±1 mm tolerance)Pitch Between Cases 110 mm (4.33") giving 25 mm (0.98") air gapMax Panel Thickness 10 mm (0.39")Weight 4.3 kg (9.48 lb) approx. with a single I/O board space configurationStructure Painted, welded steel outer case with plastic front panelCircuit Boards Eurocard-compatible which slide in and out from the rearAccess Allow 300 mm (11.81") clearance directly behind case for maintenance

Table A-2. Environmental Conditions

Operating Temperature 0° C to +60° C (32° F to 140° F)Storage Temperature -40° F to 158° F (-40° C to +70° C)Relative Humidity 90% non-condensingSafety Classification For use in a classified safe electrical areaEMC Complies with European Union EMC regulations



A.4 Power Supply

Table A-3 details power inputs.

Table A-3. Power Inputs

Supply Voltage 20-32VDC, 24W nominal, 48W maximum; typically 18W with single I/O boardInrush Current Thermistor protection providing 6A at 25° CSupply Isolation Three-way, galvanically isolated from input to computer, supply and earthHold-up Period 4 ms after power fail flagInput Fuse 2.5A anti-surge 20 mmMaximum Input Ripple 2V pk-pkDC Input Power Fail Flag 17-19V

Table A-4. Power Outputs - 24 Volts

Regulation Fully regulated 24VOutput Current 500mAOutput Protection Resettable fuse and electronic current limitIsolation Level 50VDCIsolation Type Isolated from both the input 24VDC and the computer 0V, but shared with 15V output

Table A-5. Power Outputs - 15 Volts

Regulation Full linear regulationOutput Current 100mAOutput Protection Resettable fuse and electronic current limitIsolation Level 50VDCIsolation Type Isolated from both the input 24VDC and the computer 0V, but shared with 24V output



A.5 P152 CPU

The CPU module is based on a PC-compatible architecture. The P152 CPU contains a complete set ofPC peripherals, such as interrupt controllers (PICs), timer (PIT) DMA controllers, RTC, and PC104(ISA compatible) expansion bus.

Table A-6. CPU Module Components

Processor Intel 50 MHz 80486 DX2/50 (208 Pin SQFP) with built-in floating point mathsco-processor

DRAM Memory 16MByte standard, with 32-bit data path using 2 off 64Mbit 3V EDO expandableup to 32MByte max

SRAM Memory 1MByte standard, optional 2 MByte on 16-bit wide ISA bus. Battery backedFlash Memory 4MByte standard on 16-bit ISA bus, write protected in 1MByte blocksMonitor/BIOS 128KByte on 8-bit ISA busReal Time Clock Battery supported calendar clock chip, maintains system time during power lossExpansion Bus PC/104 format; power restrictions - contact factory for details

A.5.1 Battery BackupThe battery backup is used to retain the contents of the SRAM on the CPU, the PC compatible BIOSCMOS memory area and the calendar clock. The standard battery is a Ni-MH rechargeable 3.6V,140mAh unit. To ensure that the battery is fully functional, a regular load test is performed on the unit.

Table A-7. Standard Ni-MH Rechargeable

Charging Time (20%-80%) 48 hoursHold-up Time (without recharge) 3 months at 20° C (68° F), 1 month at 40° C (104° F)Battery Life (Typical) 5-7 yearsBattery Backup Holdup Time (after battery has failedits load test)

2 weeks at 20° C (68° F)



A.5.2 Communications The following tables detail communications ports.

Note: Ports 3 through 7 are configurable for remote communications by the customer.

Table A-8. In Total

Port Type LocationTotal Number of Serial Ports 8

RS232 Ports 2 uncommitted + front panel + configuration portRS422 Ports 3 uncommitted

Dedicated Port Link to I/O / RIO boardsPort Number Location

Port 1 KeypadPort 2 PC downloadPort 3 RS 232Port 4 RS 232Port 5 RS 422/485Port 6 RS 422/485Port 7 RS 422/485Port 8 I/O Remote Connection

Table A-9. Front Panel Port

Connector Type 20-pin IDC headerCommunication Standard RS232DSignals Supplied Tx, Rx, CTS, Enter Interlock Control, GNDBaud Rate 9600 BaudFormat 8 bit data, 1 stop bit, odd parity

Note: Located on the back side of the front panel, and connects to a dedicated 20-pin connectoron the P155 power supply, and routes the configuration port to a bottom mounted RJ12.

Table A-10. Configuration Port (bottom side of front panel)

Connector Type 6 pin RJ12Communication Standard RS232DSignals Supplied Tx, Rx, RTS, CTS, GNDBaud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400Format Config 600 protocol



Table A-11. RS232 Ports

Connector Type FCC-68 RJ45Communication Standard RS232DSignals Supplied Tx, Rx, RTS, CTS, DTR, DSR, GND, DCDBaud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400 Format Software configurableData Protocol ASCII, MODBUS (ASCII, RTU)

Table A-12. RS422/RS485 Ports

Connector Type standard screw terminals, 3.5 mm pitch, 13-pinCommunications RS422 - point-to-point - 4 wire

RS422 – Multidrop (RS485 4 wire) - 4 wireRS485 - Multimaster - 2 wire

Signals Supplied Tx+, Tx-, Rx+, Rx-, Common ShieldBaud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600Format Software controlled on each channelData Protocol ASCII, MODBUS (ASCII, RTU)

A.5.3 Other PeripheralsThe following tables detail other peripherals.

Table A-13. Ethernet

Speed 10 Mbit/secondMedia Connectivity 10baseT, twisted pair utilizing standard RJ45

Table A-14. Clock Facilities

Time Battery-supported calendar clockClock Accuracy(battery supported)

10 seconds per day

Clock Accuracy (powered on) 0.5 seconds per dayWatchdog Period 2.5 seconds maximum



A.5.4 Watchdog RelayTable A-15 details the watchdog relay.

Table A-15. Watchdog Relay

Contact Form Change-over contactsMax Current 1AMax Voltage 50VDCMaximum Power 30VAControl Released on de-power, or watchdog restart, or software controlled

A.6 P144 I/O

The P144 Intelligent I/O board is the data gathering component in a hierarchical flow computer. Up toseven P144 I/O boards, or other expansion boards, can be addressed by a single P152 486 processorboard. The P144 can be case or rack mounted.

Table A-16. P144 I/O

I/O Connection Qty DescriptionAnalog Inputs 12 Single-ended, 1-5V or 4- 20mA DC type. Two of these are current onlyANINS 2 Current onlyAnalog Outputs 4 4-20mA DC typeDigital Inputs 16 Voltage sensingDigital Outputs 12 Open collector typeDual Pulse Inputs 2 Turbine inputs, 0 to 10,000HzFrequency Inputs 3 Density period / frequency 0 to 10,000HzPRT Inputs 3 4-wire RTD (IEC 751)Pulse Outputs 5 Programmable DC to 100HzRaw Pulse Output 1 Raw pulse output for proving: DC to 5 kHz



A.6.1 Analog Inputs (voltage or current type)The following tables detail the AI voltage and AI current types.

Table A-17. Analog Inputs

Type of Inputs Two groups of 5 single-ended voltage or current inputs, each groupsharing a common return; channels 11 and 12 are current input only

Scan Rate All channels can be acquired in under 1 secondConversion Method Integrating charge - balanceEffective Resolution More than 16 bits, auto zero, auto calibrateConversion Time Less than 100ms per channelSeries Mode Rejection >100dB at 50Hz and 60HzVoltage Common Mode Range ±50V as a group relative to computer groundCommon Mode Rejection >100dB at 50Hz and 60HzSignal Level 0 to 5.125V or 0 to 22mAInput Impedance >10M-Ohms (voltage mode), approx 250 Ohms (current mode)Temperature Drift <100 ms per channel, all channels 500 msCalibration Period 2 years to 0.005% of voltage

5 years to 0.01% of voltage

Table A-18. A/D Converter Inputs Voltage Mode

Type of Inputs Single-ended voltage inputsInput Range 0 to 5.2VAccuracy ±0.005% of FSD at 23° C (73° F)Ambient Temperature Effect ± 7 ppm/°C (± 4 ppm/° F) from 23°C (73° F) in the range 0 to 45° C

(32 to 113° F)

Table A-19. A/D Converter Inputs Current Mode

Type of Inputs Single-ended current inputsInput Range 0 to 22mAAccuracy ± 0.02% of FSD at 23°C (73°F)Ambient Temperature Effect ± 10 ppm/° C (± 5.5 ppm/° F) from 23° C in the range 0 to 45° C

(32 to 113° F)Common Mode Range Not Applicable



A.6.2 PRT InputsTable A-20 details PRT inputs.

Table A-20. PRT Inputs

Type of Input 4 wire connection using Pt 100 transducersPRT Resistance 100 Ohms (Pt 100 to IEC 751)Excitation Current 1mA nominalMeasuring Range 60 to 216 Ohms (-100° C to +300° C) (-148° F to +572° F)Resolution 0.01° C (0.018° F)Accuracy -100° C to 200° C (-148° F to 392° F) ± 0.01%

-200° C to 300° C (392° F to 572° F) ± 0.02%PRT Cables Core resistance up to 600 OhmsBarriers 9V, 100 Ohms are satisfactorySecurity Continuous cable/PRT integrity tests for earths/open circuits

A.6.3 Frequency/Density InputsTable A-21 details frequency and density inputs.

Table A-21. Frequency/Density Inputs

Configuration DC coupled, galvanically isolatedNumber of Inputs 3Signal Level 3V min pk-pkMaximum Input Voltage 12V pk-pkCurrent Limit Internally limited to 3mAFrequency Range DC to 10kHzAccuracy of Frequency Measurement 10 ppmResolution 5 nanoseconds



A.6.4 Turbine Pulse Inputs Table A-22 details turbine pulse inputs.

Table A-22. Turbine Pulse Inputs

Number of Inputs 2 dual pulse stream or 4 single pulse streamsInput Type Spectra-Tek differential or Daniel preamp mode depending on mezzanine type fittedSignal Level Dependent on mezzanine fittedFrequency Range DC to 10kHzSecurity Monitoring IP 252/76 (ISO 6551), level A or B

Note: Refer to Section A.9, Mezzanine Boards, on page A-16 for mezzanine details.

A.6.5 Digital Status InputsTable A-23 describes the digital status inputs.

Table A-23. Digital Status Inputs

Configuration 16 opto-isolated inputs, arranged in 4 groups of 4 with common positiveconnection to allow simple interface to Open Collector outputs

Max Input Voltage 30V Min Input On Voltage 12VMax Input Off Voltage 3.0VInput Impedance 2-2.5k Ohms typicalProtection Reverse voltage protection



A.6.6 Analog OutputsTable A-24 describes analog outputs.

Table A-24. Analog Output

Type of Input Four galvanically-isolated 4 to 21 mA outputsResolution 12 bit minimumAccuracy ± 0.1% at 23° C (73° F)Temperature Coefficient 20ppm/° C (11ppm/° F)Load Loop Resistance 650 Ohms maximum when powered by local isolated source, 470W -

1000W when powered from +24V external supplyMaximum External Supply 32VOutput Form Controlled active current sink to ground return of local floating supplyNumber of Field Connections 3 terminals per channelUpdate Time 100ms to within 1%

A.6.7 Digital OutputsTable A-25 describes digital outputs.

Table A-25. Digital Outputs

Configuration Galvanically isolated in 3 groups of 4 with common negativeNumber of Outputs 12Frequency Range DC to 0.5 HzMax Output SaturationVoltage 1.5V @ 100mALow current SaturationVoltage 600mV @ 1mA to suit TTL style input, with 4.7kΩ pull up to 5 VMax Output StandoffVoltage 42V limited by TransorbMax Output Current 100mAReset/Power on State All digital outputs - OFF



A.6.8 Pulse OutputsTable A-26 details pulse outputs.

Table A-26. Pulse Outputs

Number of Outputs 5 driven from TPU channelsConfiguration Opto-isolated open collectors in a group of 4 and one singleFrequency Range DC to 100Hz Max Output Current 100mAMax Output Saturation Voltage 1.5V @ 100mALow Current Saturation Voltage 600mV @ 1mA to suit TTL style inputMax Output Standoff Voltage 42V limited by Transorb

A.6.9 Raw Pulse OutputsTable A-27 details raw pulse outputs.

Table A-27. Raw Pulse Outputs

Configuration Digital ground referenced open collectorGating Software controlledMax Output Saturation 1.5VMax Output Standoff Voltage 26V (limited by Transorb)Max Output Current 100mAFrequency Range DC to 5kHzMinimum On Period 100µs (microsecond)Use To bus together several streams to a common prover computer



A.7 P154 Prover

The P154 is a dedicated prover interface board that has been designed to work with compact ormicroprover, unidirectional and bi-directional provers with 2 or 4 sphere switches.

Table A-28. P154 Prover

I/O Connection Qty DescriptionDigital Inputs 32 Voltage sensingDigital Outputs 12 Open collector typeDual Pulse Inputs 2 Turbine inputs, 0 to 10,000HzFrequency Inputs 2 Density period / frequency 0 to 10,000HzPulse Outputs 4 Programmable DC to 100HzRaw Pulse Output 1 Raw pulse output for proving: DC to 5 kHzRaw Pulse Input 3Phase Loop LockInput

2

Switch Detect 4

A.7.1 Frequency/Density InputsTable A-29 details Frequency/Density Inputs.

Table A-29. Frequency/Density Inputs

Configuration DC coupled, galvanically isolatedNumber of Inputs 3Signal Level 3V min pk-pkMaximum Input Voltage 12V pk-pkCurrent Limit Internally limited to 3mAFrequency Range DC to 10kHzAccuracy of Frequency Measurement 10 ppmResolution 5 nanoseconds



A.7.2 Turbine Pulse InputsTable A-30 describes Turbine Pulse Inputs.

Table A-30. Turbine Pulse Inputs

Number of Inputs 2 dual pulse stream or 4 single pulse streamsInput Type Spectra-Tek differential or Daniel preamp mode depending on mezzanine type fittedSignal Level Dependent on mezzanine fittedFrequency Range DC to 10kHzSecurity Monitoring IP 252/76 (ISO 6551), level A or B

Note: Refer to Section A.9, Mezzanine Boards, on page A-16 for mezzanine details.

A.7.3 Digital Status InputsTable A-31 describes Digital Status Inputs.

Table A-31. Digital Status Inputs

Configuration 16 opto-isolated inputs, arranged in 4 groups of 4 with commonpositive connection to allow simple interface to Open Collector outputs

Max Input Voltage 30V Min Input On Voltage 12VMax Input Off Voltage 3.0VInput Impedance 2-2.5k Ohms typicalProtection Reverse voltage protection



A.7.4 Digital OutputsTable A-32 details Digital Outputs.

Table A-32. Digital Outputs

Configuration Galvanically isolated in 3 groups of 4 with common negativeNumber of Outputs 12Frequency Range DC to 0.5 HzMax Output SaturationVoltage 1.5V @ 100mALow current SaturationVoltage 600mV @ 1mA to suit TTL style input, with 4.7kΩ pull up to 5 VMax Output StandoffVoltage 42V limited by TransorbMax Output Current 100mAReset/Power on State All digital outputs - OFF

A.7.5 Pulse OutputsTable A-33 details pulse outputs.

Table A-33. Pulse Outputs

Number of Outputs 5 driven from TPU channelsConfiguration Opto-isolated open collectors in a group of 4 and one singleFrequency Range DC to 100Hz Max Output Current 100mAMax Output Saturation Voltage 1.5V @ 100mALow Current Saturation Voltage 600mV @ 1mA to suit TTL style inputMax Output Standoff Voltage 42V limited by Transorb



A.7.6 Raw Pulse OutputsTable A-34 details the Raw Pulse Output.

Table A-34. Raw Pulse Outputs

Configuration Digital ground referenced open collectorGating Software controlledMax Output Saturation 1.5VMax Output Standoff Voltage 26V (limited by Transorb)Max Output Current 100mAFrequency Range DC to 5kHzMinimum On Period 100µs (microsecond)Use To bus together several streams to a common prover computer

A.8 Display-Keypad

Table A-35 details the Display and Keypad.

Table A-35. Display-Keypad

Graphics Display LCD 128 x 64 pixel (8 lines of 20 alpha-characters) withLED backlight, using a Toshiba T6963 LCD controller

Alarm/Status 3 color LED: green, amber, redKeyboard 29 self-colored silicon rubber keys with tactile feelConfiguration Port RJ12 connector for the CONFIG 600 package on the

bottom face of the front panel mouldingConnectivity Watchdog Front panel signals the user if no update or poll occurs

after the time-out periodWatchdog Time-out Period 10 secondsConnection to FloBoss S600 20-pin ribbon cableCommunications to FloBoss S600 9600 baud, 8 bit, odd parityDisplay Test User initiated



A.9 Mezzanine Boards

The following sections detail the mezzanine boards.

A.9.1 Spectra-Tek DPR MezzanineTable A-36 details the Spectra-Tek DPR Mezzanine board.

Table A-36. P148 Spectra - Tek Pre-amp Mezzanine

Configuration Opto-coupled inputsInput Signal Levels +/- 3.5V to +/- 12VInput Current Minimum 5mAFrequency Range DC to 10kHzLine Integrity Dual back-to-back optos, allowing full quiescent line and electronic

integrity testing, when used with S-Tek pre-amps and pulsersDual Pulse Compliance IP 252/76 level A or B

A.9.2 Daniel MezzanineThis section details the Daniel Mezzanine board.

Table A-37. P148 US Version Mezzanine

Configuration Opto-coupled inputsInput Signal Levels +/- 10V to +/- 24VInput Current Minimum 5mAFrequency Range DC to 10kHzLine Integrity Dual back-to-back optos, allowing full quiescent line and electronic

integrity testing, when used with S-Tek pre-amps and pulsersDual Pulse Compliance IP 252/76 level A or B


8/01 Engineering Drawings B-1

APPENDIX B – ENGINEERING DRAWINGS

B.1 List of Engineering Drawings

♦ DE-20400 Field Wiring Diagram Model DS600 (Sheets 1-3)♦ DE-20438 Outline and Dimensional and Mounting Instructions S600 (Sheets 1-2)♦ DE-20472 CPU Remote Terminal Board Layout (Optional)♦ DE-20473 Intelligent I/O Remote Terminal Board Layout (Optional)♦ DE-20474 P152 CPU Board S600 Connection Diagram♦ DE-20475 P144 I/O Board S600 Connection Diagram♦ DE-20476 P154 Prover Board S600 Connection Diagram♦ BE-20477 Template Panel Cutout S600


8/01 Glossary G-1

GLOSSARY

Glossary for the FloBoss S600

AADC – Analog to Digital Converter, also known as A/D Converter.

ADDRESS – A character, or group of characters, used in order to identify a particular item, e.g.particular area of memory or particular computer on a communication link with many computers.

AGA – American Gas Association.

ALPHANUMERIC – Consisting of only the letters A to Z and the numerals 0 to 9.

ANALOG – A signal that has no defined steps, its value being determined by its size.

ANIN – Analog input, also known as AI.

ANOUT – Analog output, also known as AO.

API – American Petroleum Institute.

ASCII – American Standard Code (for) Information Interchange. The representation of alphanumericcharacters and control codes as a single byte within the range 0 to 127.

ASTM – American Society for Testing and Materials.

BBAUD – Refers to the rate of serial data transfer, e.g. baud rate of 10 = 10 bits per second.

BINARY – Numbers in base 2, i.e. only numbers 0 and 1 are used.

BIT – A binary digit.

BITSWITCH – Switches that represent data bits by on or off state.

BTU – British Thermal Unit.

BUFFER – A device inserted between devices to match impedance, equipment speeds or to supplyadditional drive capability.

BUS – One or more conductors used as a path over which information is transmitted.

BYTE – Block of 8 bits, can define 256 states (0 thru 255).


G-2 Glossary 8/01

CCOMPRESS – Compressibility calculated using AGA8.

CONFIG 600 LITE – Tool for configuring the FloBoss S600.

CONFIG 600 PROFESSIONAL – Tool for creating new applications.

CONSTANTS – Numbers which are only infrequently changed.

CONTROL BUS – Bus Connections for Control Signals, e.g. Read/Write.

CPU – P152 Central Processing Unit module.

CTS – Clear to Send.

CURRENT LOOP – Serial Communication Technique (0mA/20mA).

CV – Calorific Value calculated using AGA5 or ISO6976.

DDAC – Digital to Analog Converter, also known as D/A Converter.

DATABUS – A group of bi-directional lines capable of transferring data to and from the CPU storageand peripheral devices.

DCU – Data Concentrator Unit.

DI – Digital input.

DIGITAL – A signal that has only two states e.g. On/Off 1/0 5V/0V.

DO – Digital output.

DP – Differential Pressure.

DPR – Dual Pulse Receiver or turbine input.

DRAM – Dynamic Random Access Memory. Volatile storage memory used by the FloBoss S600.When power is removed from the FloBoss S600, the contents of the DRAM memory are assumedto be lost.

DSR – Data Set Request.

DTR –Data Terminal Ready.

EEEPROM – Electrically Erasable Programmable Read Only Memory.


8/01 Glossary G-3

EEROM – Electrically Erasable Read Only Memory.

E-FORMAT – Mathematical notation where the mantissa is between 1 and 9 and the exponent is themultiplier.

ETHERNET – Network hardware connection.

EXPONENT – Base 10 Multiplier.

FFCU – Flow computer unit.

FLASH MEMORY – Non-volatile storage memory. Although slower to access than SRAM andDRAM, once its contents have been programmed, it requires no further attention to support thatdata. The configuration files and operating system are kept here. Write protect jumpers are used toprevent accidental programming of this memory.

FRQ – Frequency or period input.

FTP – File transfer protocol. Used to copy a file or multiple files from one computer to another.

HHEX – Numbers in base 16, i.e. numbers 0 to 9 and letters A to F are used.

I, J, KINTEGER – A whole number.

INTELLIGENT I/O – P144 Intelligent Input Output module, also known as IIO.

I/O – Input and Output.

IP – Institute of Petroleum.

IP – Ingress protection standard, refer to British standard 5420 or International Electro-Technicalcommission standard 144.

IPL 600 – Interactive program loader tool for transferring application programs from the PC to theFloBoss S600.

IS – Intrinsically safe to CENELEC standard EN50020.

LLED – Light Emitting Diode (an indicator).


G-4 Glossary 8/01

MMANTISSA – Numerically significant part of a floating point number.

MICRO – Microcomputer is the complete microprocessor based instrument.

MNEMONIC – Grouping of characters used to aid memory.

MODBUS – Modbus is the communication protocol utilized on the station supervisory computer datalink.

MODEM – Modulator Demodulator.

MODULATE – The superimposing of one signal upon another.

MULTIPLEXOR – Multiple Input Selector.

NNOISE – Random Electrical Interference.

NON-VOLATILE – Memory type that retains data when the power supply is disconnected.

OOCTAL – Numbers in base 8, i.e. numbers 0 to 7 are used.

OPEN COLLECTOR – Digital output that is driven by a transistor and requires external power.

OPTO-ISOLATOR – Optical Device for connecting signals while maintaining electrical isolation.

OVERRANGE – Over the present current limit for ADC.

P, QPCB – Printed Circuit Board.

PERIPHERAL – Equipment connected outside the main processor.

PID – Three term control action. Using Proportional, Integral and Derivative components to modify acontrol output, with the goal of achieving a measured process variable at a set point.

PORT – A group of inputs or outputs to the computer.

PROGRAM – Series of instructions.

PROM – Programmable ROM.

PROTOCOL – Precise description of data interchange over a telemetry link.


8/01 Glossary G-5

PRT – Platinum Resistance Thermometer.

PSU – Power Supply Unit.

RROM – Read Only Memory (fixed storage).

RS232 – Voltage standard for serial data transmission.

RTD – Resistance Thermometer Device.

RTS – Request to Send.

RTU – Remote Terminal Unit.

RX – Received information.

SSECURITY CODE – Security Codes are used to limit access by operators to parameters retained in

the micro memory.

SRAM – Static Random Access Memory (battery backed).

S600 –FloBoss S600 Flow Computer.

TTAGNAME – Alphanumeric string of up to twelve characters used to associate data with I/O points.

TCP/IP – Transfer Control Program/Internet Protocol.

TOTALIZER – Area of RAM for integrating totals.

TRANSDUCER – Device which converts energy from one form to another.

TRI-REG – Triple Register - area of RAM where data is stored in triplicate.

TX – Transmitted information.

UUNDERRANGE – Under preset current limit for A/D Converter.

VVARIABLES – Changeable values.


G-6 Glossary 8/01

VOLATILE – Memory - unstable in the absence of power.

VDU – Visual Display Unit.

W, X, Y, ZWATCHDOG – A hardware circuit that monitors correct program operation and causes program

restart in the event of malfunction.


8/01 Index I-1

INDEX

AA/D Converter Inputs Current Mode.......................... A-8A/D Converter Inputs Voltage Mode ......................... A-8Accept

Alarm.................................................................... 3-18Alarm......................................................................... 3-22

Accept................................................................... 3-18Alarm Light............................................................... 3-17Alarm Light and Keys ................................................. 3-4Alarms ....................................................................... 3-17

View ..................................................................... 3-17All Alarms................................................................. 3-20AMERICAN ............................................................. 5-16Analog Inputs ............................................................ 3-11

(voltage or current type) ........................................ A-8ANIN.................................................................... 5-12

Analog Outputs ............................................... 5-16, A-11Archived Reports....................................................... 3-20Asterisk ....................................................................... 3-6

BBackup

Battery ................................................................... A-4On-Board Battery ................................................... 5-7

Battery Backup........................................................... A-4On-Board ................................................................ 5-7

BoardsRemoving and Replacing Plug-in........................... 4-7

CCable ........................................................................... 5-5Calculations................................................................. 3-7Change ........................................................................ 3-6Change Mode ............................................................ 3-22Change Value ............................................................ 3-22Changing a Value ...................................................... 3-12Changing Mode......................................................... 3-14Changing the Fuse....................................................... 4-7Chng ............................................................................ 3-6Clear ................................................................... 3-5, 3-22Clear SRAM................................................................ 4-5Clock Facilities........................................................... A-6Cold Start .............................................. 3-9, 4-1, 4-2, 4-4COM1.......................................................................... 5-8COM2................................................................... 5-7, 5-8Communications................................................ 3-21, A-5Config 600 Lite ........................................................... 1-6Config 600 Professional .............................................. 1-6

Config Report ............................................................ 3-20Configuration Port ...................................................... A-5Constants Log............................................................ 3-20Contrast ..................................................................... 3-21CPU

P152 ....................................................................... A-4CPU Board .................................................................. 5-2CPU On-board Connectors

P152 ........................................................................ 5-9Current Alarms .......................................................... 3-20Current Report ........................................................... 3-20

DDaniel Mezzanine..................................................... A-17Data

Entering ................................................................ 3-12Data Pages ................................................................... 3-7Date & Time .............................................................. 3-21Decimal Point .............................................................. 3-6Default Display.......................................................... 3-22Density Inputs................................................... A-9, A-13Digital Inputs

DIGIN................................................................... 5-21DIGIN................................................................... 5-13

Digital Outputs ............................................... A-11, A-15DIGOUT......................................................5-18, 5-24

Digital Status Inputs ....................................... A-10, A-14DIN............................................................................ 5-16Disp ....................................................................3-5, 3-12Display......................................................................... 3-5

LCD ........................................................................ 3-6Navigating ............................................................ 3-11

Display Dump............................................................ 3-20Display Matrix....................................................3-7, 3-21Display Setup............................................................. 3-21Display T/O ............................................................... 3-21Display Test............................................................... 3-21display.txt .................................................................... 6-3Display-Keypad........................................................ A-16Download and Reflash Config File ............................. 4-4

EEnter ............................................................................ 3-6Entering Data............................................................. 3-12Environmental

Specifications......................................................... A-2Environmental Considerations..................................... 2-2Ethernet ...................................................................... A-6Ethernet LAN Port....................................................... 5-6


I-2 Index 8/01

ExampleMode Change ........................................................3-15Value Change ........................................................3-13

Exponent ..................................................................... 3-5Exponential Format....................................................3-16Expt .................................................................... 3-5, 3-16

FF Keys ......................................................................... 3-3Factory Setup ....................................................... 4-3, 4-5Figure 1-1. The FloBoss S600 System....................... 1-2Figure 1-2. CPU Board .............................................. 1-3Figure 1-3. Intelligent I/O Board................................ 1-5Figure 2-1. All Parts of the Basic FloBoss S600 System................................................................................... 2-2

Figure 2-2. Removing the Front Panel ....................... 2-4Figure 2-3. Lift up Panel ............................................ 2-4Figure 2-4. Remove Connector .................................. 2-5Figure 2-5. Panel Mount ............................................ 2-6Figure 2-6. Unscrewing the Retention Screws........... 2-7Figure 2-7. Preparing to use the pull tabs for boardrelease........................................................................ 2-8

Figure 2-8. Using the Pull Tabs ................................. 2-8Figure 2-9. Board Ready for Removal or Final Insertion................................................................................... 2-9

Figure 3-1. Front Panel .............................................. 3-3Figure 3-10. Standard DENS ....................................3-15Figure 3-11. Calculated.............................................3-15Figure 3-12. Confirm ................................................3-16Figure 3-13. Alarm Display ......................................3-17Figure 3-14. Print Options.........................................3-18Figure 3-15. Print Options 2......................................3-19Figure 3-16. Print Options 3......................................3-19Figure 3-17. Print Options 4......................................3-20Figure 3-18. Display Setup Menu .............................3-21Figure 3-2. LCD Display............................................ 3-6Figure 3-3. Status ID Line.......................................... 3-7Figure 3-4. Database Matrix....................................... 3-8Figure 3-5. Startup Screen.......................................... 3-9Figure 3-6. Main Menu .............................................3-10Figure 3-7. Submenu.................................................3-11Figure 3-8. Analog Inputs .........................................3-11Figure 3-9. Alarm Limits ..........................................3-13Figure 4-1. Startup Menu ........................................... 4-2Figure 4-2.................................................................... 4-8Figure 5-1. CPU Backplate ........................................ 5-3Figure 5-2. Pin Connections....................................... 5-5Figure 5-3. COM2 Alternative Connections .............. 5-7Figure 5-4. I/O Backplate..........................................5-12Figure 5-5. Analog Output Channel 1 as a Source orSink ..........................................................................5-17

Figure 5-6. Prover I/O Backplate ..............................5-21Figure 6-1. Run Dialog .............................................. 6-2Figure 6-2. Link Cable ............................................... 6-4File Locations.............................................................. 6-3Flash..................................................................... 3-9, 4-3

Format..................................................................... 4-6Reflash.................................................................... 4-4

Flash Failed ................................................................. 4-3FloBoss S600 Flow Computer..............................1-1, 1-3Format Flash................................................................ 4-6Frequency Inputs .............................................. 5-15, 5-24Frequency/Density Inputs................................. A-9, A-13Front Panel .................................................................. 2-3

Reinstalling............................................................. 2-9Front Panel Port................................................... 5-7, A-5Function Keys

Program ................................................................ 3-22Fuse

Changing................................................................. 4-7

II/O ............................................................................... 3-7Ident T/O ................................................................... 3-21Initial Checks............................................................... 4-7Initialization ................................................................ 3-9Installation................................................................... 2-3

Boards..................................................................... 2-7Panel-Mounted Unit ............................................... 2-5Plug-In Boards........................................................ 2-9Preparing................................................................. 2-1Reinstalling the Front Panel.................................... 2-9Removing the Front Panel ...................................... 2-3Software.................................................................. 6-2Tools ....................................................................... 2-3Unpacking............................................................... 2-2

IPL 600........................................................................ 1-6

KKeypad .......................................................3-2, 3-3, A-16

LLAN Port

Ethernet................................................................... 5-6LCD Display ........................................................3-2, 3-6

Navigating ............................................................ 3-11Logout T/O................................................................ 3-21

MMain Menu

Return ................................................................... 3-22Maintenance ................................................................ 4-1Matrix

Display.................................................................... 3-7Mbpseq.txt................................................................... 6-3Mbxx.txt ...................................................................... 6-3Mechanical and Environmental .................................. A-2Menu Keys .................................................................. 3-4Menus .......................................................................... 3-6


8/01 Index I-3

Mezzanine Boards .................................................... A-17Modbus Maps............................................................ 3-20Mode

Change Example................................................... 3-15Changing .............................................................. 3-14

Modem Port................................................................. 5-5Multidrop Port

RS422/485 .............................................................. 5-6

NNetwork Setup...................................................... 4-2, 4-5Numeric Keys.............................................................. 3-5

OOn-Board Battery Backup ........................................... 5-7Operation..................................................................... 3-1Overview..................................................................... 1-1

PP144 I/O Berg Jumpers (Links)................................. 5-19P144 I/O Board ................................................. 5-12, A-7P152 CPU................................................................... A-4P152 CPU Berg Jumpers (Links) .............................. 5-10P152 CPU Board ......................................................... 5-2P152 CPU On-board Connectors ................................ 5-9P154 Prover.............................................................. A-13P154 Prover Berg Jumpers (Links) ........................... 5-26P154 Prover Board .................................................... 5-21Panel-Mounted Unit

Installation .............................................................. 2-5Peripherals.................................................................. A-6Plant I/O .................................................................... 3-11Plug-in Boards

Removing and Replacing........................................ 4-7Plug-In Boards

Installation .............................................................. 2-9Power Inputs............................................................... A-3Power Outputs - 15 Volts ........................................... A-3Power Outputs - 24 Volts ........................................... A-3Power Supply ...................................................... 5-3, A-3Print ....................................................3-5, 3-8, 3-18, 3-22Program Function Keys............................................. 3-22Prover

P154..................................................................... A-13Prover Board

P154...................................................................... 5-21PRT Input .................................................................... 3-8PRT Inputs ................................................................. A-9PRT/RTD Inputs ....................................................... 5-16Pulse Inputs

Turbine ....................................5-14, 5-23, A-10, A-14Pulse Outputs ................................................. A-12, A-15

PULSEOUT................................................. 5-19, 5-25

RRAM............................................................................ 3-9RAM Disc Start ........................................................... 4-6Raw Pulse Outputs ......................................... A-12, A-16Reflash Config............................................................. 4-3Reflash Config File...................................................... 4-4Reflash Firmware ........................................................ 4-3Reinstalling the Front Panel ........................................ 2-9Remote Display or PC ................................................. 5-8Removal of the Boards ................................................ 2-7Removing and Replacing Plug-in Boards.................... 4-7Repxx.txt ..................................................................... 6-3Requirements

System .................................................................... 6-2Return to Main Menu ................................................ 3-22RS232 Modem Port ..................................................... 5-5RS232 Ports ................................................................ A-6RS422/485 Multidrop Port .......................................... 5-6RS422/RS485 Ports .................................................... A-6RTD Inputs ................................................................ 5-16Run Mode .................................................................... 4-2

Ss600conf.cfg ................................................................ 6-3Scientific Notation..................................................... 3-22Security...................................................................... 3-21Security Code ............................................................ 3-16Security Dump........................................................... 3-20Setup

Factory .................................................................... 4-5Setup and Wiring......................................................... 5-1Software....................................................................... 1-5

Config 600 Lite....................................................... 1-6Config 600 Professional.......................................... 1-6Installation .............................................................. 6-2IPL 600 ................................................................... 1-6

Special Pages ............................................................. 3-20Spectra-Tek DPR Mezzanine ................................... A-17SRAM.......................................................................... 3-9

Clear........................................................................ 4-5StartUp......................................................................... 6-4Startup List .................................................................. 4-8Status/ID Line.......................................................3-4, 3-7Summary of Operation .............................................. 3-21System Requirements .................................................. 6-2

TTable 1-1. I/O Functions............................................. 1-4Table 4-1. Startup List ................................................ 4-9Table 5-1. TB-1 Pin Connections ............................... 5-4Table 5-10. ANIN Pin Connections for SKT-A ....... 5-13Table 5-11. ANIN Pin Connections for SKT-B........ 5-13Table 5-12. DIGIN Pin Connections for SKT-B ...... 5-14Table 5-13. DIGIN Pin Connections for SKT-C ...... 5-14


I-4 Index 8/01

Table 5-14. Dual-pulse Input Pin Connections for SKT-C ...............................................................................5-15

Table 5-15. Frequency Input Pin Connections for SKT-B ...............................................................................5-15

Table 5-16. PRT Input Pin Connections for SKT-B .5-16Table 5-17. D/A Converter Output Pin Connections forSKT-A......................................................................5-17

Table 5-18. DIGOUT Pin Connections for SKT-B...5-18Table 5-19. DIGOUT Pin Connections for SKT-C...5-18Table 5-2. TB-1 Pin Connections............................... 5-4Table 5-20. PULSEOUT Pin Connections for SKT-B.......................................................................................5-19

Table 5-21. Flash Link Setting..................................5-19Table 5-22. P144 I/O Berg Links ..............................5-20Table 5-23. A/D Converter Shunt Mode ...................5-20Table 5-24. DIGIN Pin Connections for SKT-E.......5-22Table 5-25. DIGIN Pin Connections for SKT-F .......5-23Table 5-26. Dual-pulse Input Pin Connections for SKT-F ...............................................................................5-23

Table 5-27. Frequency Input Pin Connections for SKT-D...............................................................................5-24

Table 5-28. DIGOUT Pin Connections for SKT-E. ..5-24Table 5-29. DIGOUT Pin Connections for SKT-F ...5-25Table 5-3. COM3 and COM4 Pin Connections ......... 5-5Table 5-30. PULSEOUT Pin Connections for SKT-E5-25

Table 5-31. P154 Prover Berg Jumpers (Links)........5-26Table 5-32. Node Addressing

Communications Mode Selection..........................5-27Table 5-4. COM5, COM6, and COM7 Pin Connections................................................................................... 5-6

Table 5-5. COM2 Alternative Connections ............... 5-7Table 5-6. COM1-2 Pin Connections......................... 5-8Table 5-7. Miscellaneous Device Connectors for theP152 CPU Module .................................................... 5-9

Table 5-8. Default Configuration Settings for the P152CPU Berg Jumpers (Links) ......................................5-10

Table 5-9. Clock Speed Selection .............................5-11Table 6-1. System Requirements ................................ 6-2Table A-1. Computer Case and Mounting .................A-2Table A-10. Configuration Port (bottom side of frontpanel).........................................................................A-5

Table A-11. RS232 Ports ...........................................A-6Table A-12. RS422/RS485 Ports ...............................A-6Table A-13. Ethernet..................................................A-6Table A-14. Clock Facilities ......................................A-6Table A-15. Watchdog Relay.....................................A-7Table A-16. P144 I/O.................................................A-7Table A-17. Analog Inputs.........................................A-8Table A-18. A/D Converter Inputs Voltage Mode.....A-8Table A-19. A/D Converter Inputs Current Mode .....A-8Table A-2. Environmental Conditions .......................A-2Table A-20. PRT Inputs .............................................A-9

Table A-21. Frequency/Density Inputs ..................... A-9Table A-22. Turbine Pulse Inputs............................ A-10Table A-23. Digital Status Inputs ............................ A-10Table A-24. Analog Output..................................... A-11Table A-25. Digital Outputs .................................... A-11Table A-26. Pulse Outputs ...................................... A-12Table A-27. Raw Pulse Outputs .............................. A-12Table A-28. P154 Prover......................................... A-13Table A-29. Frequency/Density Inputs ................... A-13Table A-3. Power Inputs............................................ A-3Table A-30. Turbine Pulse Inputs............................ A-14Table A-31. Digital Status Inputs ............................ A-14Table A-32. Digital Outputs .................................... A-15Table A-33. Pulse Outputs ...................................... A-15Table A-34. Raw Pulse Outputs .............................. A-16Table A-35. Display-Keypad................................... A-16Table A-36. P148 Spectra - Tek Pre-amp MezzanineA-17

Table A-37. P148 US Version Mezzanine .............. A-17Table A-4. Power Outputs - 24 Volts ........................ A-3Table A-5. Power Outputs - 15 Volts ........................ A-3Table A-6. CPU Module Components ...................... A-4Table A-7. Standard Ni-MH Rechargeable ............... A-4Table A-8. In Total .................................................... A-5Table A-9. Front Panel Port....................................... A-5Technical Data............................................................ A-1Tools............................................................................ 2-3Totals........................................................................... 3-7Troubleshooting........................................................... 4-6

Flash Failed ............................................................ 4-3Startup List ............................................................. 4-8

Turbine Pulse Inputs.....................5-14, 5-23, A-10, A-14

UUnpack ........................................................................ 2-2

VValue

Changing............................................................... 3-12Changing Example ............................................... 3-13

Vector and Menu Keys................................................ 3-4View Alarm ............................................................... 3-17View Parameter ......................................................... 3-22vxworks.bin.x.x.x.x ..................................................... 6-3

WWarm Start ...........................................................3-9, 4-2Watchdog Relay .................................................. 5-4, A-7Wiring.......................................................................... 5-1


8/01 Index I-5


I-6 Index 8/01

For information, contact your local sales representative or:Emerson Process ManagementFlow Computer DivisionMarshalltown, Iowa 50158 U.S.A.Website: www.EmersonProcess.com/flow

MAN_FloBoss S600_A6115_2001-08_EN

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