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FLOBOSS S600 Daniel Flow Computer
FLOBOSS S600 Daniel Flow Computer
FLOBOSS S600 Daniel Flow Computer
This manual is revised periodically to incorporate new or updated information. The date revision level of
each page is indicated at the bottom of the page opposite the page number. A major change in the content
of the manual also changes the date of the manual, which appears on the front cover. Listed below is the
date revision level of each page.
Page Revision
FloBoss and ROCLINK are marks of one of the Emerson Process Management companies. The Emerson logo is a trademark
and service mark of Emerson Electric Co. All other marks are the property of their respective owners.
While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory
results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express
or implied, regarding the performance, merchantability, fitness or any other matter with respect to the products, nor as a
recommendation to use any product or process in conflict with any patent. Fisher Controls reserves the right, without notice, to
alter or improve the designs or specifications of the products described herein.
ii Rev Sep/04
FloBoss S600 Instruction Manual
TABLE OF CONTENTS
INDEX................................................................................................................................................... I-1
The FloBoss S600 Flow Manager is designed for use either as a stand-alone flow computer or as a system
component. The intelligent I/O boards fit both gas and liquid applications and support two streams and a
header. Adding I/O boards (maximum 3) allows you to configure up to six streams and two headers.
Orifice, ultrasonic, turbine, positive displacement, Coriolis, annubar & V-Cone flow meter types are all
supported.
The analog performance of the FloBoss S600 is of the highest order, allowing longer intervals between
calibration checks.
♦ One LAN port for Ethernet 10 baseT connectivity (using FTP and TCP/IP protocols). An optional
second Ethernet port can be added if required.
♦ HART communication is facilitated by way of a 12 channel I/O board. Point to point and multi-drop
architectures are supported (up to 50 Transmitters).
♦ An embedded web-server allows remote access to the flow computer. Security is provided by way of
user name and password protection with a detailed event log for audit purposes (supports Windows®
Internet Explorer® version 6 or greater).
♦ Three EIA-422/485 (RS-422/RS485) serial ports (up to 38400 bps baud) for connection to a Modbus
SCADA data network or DCS Supervisory System.
♦ One dedicated configuration port for connection to the Config 600 Software.
The FloBoss S600 uses distributed processing to achieve maximum performance. The main CPU
incorporates a hardware floating point processor. Each additional card also has local processing to convert
inputs and output from engineering units to field values and vice-versa, as well as running background tests
and PID loops.
All metering calculations are performed using 64 bit (double) precision floating point numbers for the
highest accuracy. Cumulative totals are stored in three separate memory locations (Tri-reg format) for
maximum integrity. The user language Logicalc™ also allows double precision mathematical functions to
be performed on the database objects.
Configuration can be set through the front panel interface, the Config 600 Lite software interface, or the
Config 600 Pro software interface. The IPL600, Config 600 Lite and Config 600 Pro interfaces allow both
sending (download) of new or modified configurations and receiving (upload) of existing configuration
from the FloBoss S600. The front panel interface consists of a backlit LCD display, 29-button keypad, and
an alarm status LED.
The FloBoss S600 Flow Manager provides the following functions through the Config 600 configuration
tool:
♦ 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.
♦ Station densitometer.
♦ Station gas chromatograph.
♦ Forward, reverse and error totals.
♦ Comprehensive maintenance mode.
NOTE: The FloBoss S600 will not operate until a configuration has been sent from the host PC.
NOTE: Config 600 Lite is used to custom configure a new FloBoss S600 during installation.
NOTE: The Config 600 Pro is used to create and develop new FloBoss S600 applications.
♦ Edit process configuration data, including orifice size, analog input scaling, alarm limits, and
keypad values.
♦ 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.
♦ Add and remove objects from the database.
♦ Program special features using Logicalc.
♦ Reflash the CPU module firmware with software upgrades and transfer configurations via the
Transfer Editor.
For more details on using Config 600 Lite and Config 600 Pro software, refer to the appropriate Config
600 Software User Manual or on-line help.
Specifications
I/O CAPABILITY POWER REQUIREMENTS
Analog Inputs: 0 to 5.2 V dc or 0 to 22 mA, >16 Supply Voltage: 20-32 V dc, 24 W (nominal).
bits. Protection: 2.5 A Anti-surge fuse.
Analog Outputs: 0 to 21 mA, 12 bit minimum. Supply Isolation: Galvanically isolated from unit to
4-Wire RTD: PT100 (-100 to 200°C). earth ground, 50 V.
Digital Input: 30 V max optically isolated. Transducer Outputs: 24 V dc, 500 mA;
Digital Output: Open Collector, 36 V max, 100 mA. 15 V dc, 100 mA.
Dual Pulse Inputs: DC to 10 KHz, IP252/76, ISO ENVIRONMENTAL
6551:1996, and API Chapter 5.5 Level A, B or E.
Operating Temperature: 0 to 60°C.
Pulse Outputs: Open Collector, dc to 100 Hz.
Storage Temperature: -40 to 70°C.
Prover Pulse Bus: Open Collector, dc to 5 KHz.
Operating Humidity: To 90% non-condensing.
Sphere Switches: Supports 1, 2, or 4 switch mode.
Frequency Input: DC to 10 KHz, 3 V pk-pk. WEIGHT
CPU CAPABILITY 4.3 kg approx. with single I/O board.
50 MHz 486DX2. 16 MB DRAM. DIMENSIONS
1 MB SRAM (Battery Backed). 4 MB Flash. Case Depth: 304 mm. Allow an extra 300 mm
Form ‘C’ Watchdog relay. Real-Time Operating clearance for board extraction and connectors.
System Windriver VxWorks. Front Panel: 85 mm W x 270 mm H.
Real-time Clock battery supported calendar clock
chip, maintains system time during power loss. ENCLOSURE
CIRCUIT BOARDS Painted, welded steel outer case with plastic front
panel.
Eurocard-compatible. Slide in and out from rear of
case. APPROVALS AND COMPLIANCES
CALCULATIONS Available with European CE Mark.
OIML R117 compliant.
Gas: ISO 5167, ISO 6976, NX 19, SGERG, GPA EN12405 For EFM devices compliant.
2172 & 2145, PTZ, GOST 8.563.1 & 2 (97), AGA 3, Approved by NMI (Netherlands Measurement
AGA 5, AGA 7, AGA 8. Institute, CMI (Czech Metrology Institute), and OMH
Liquid: API 2540, API 11-2-1, API 11-2-2. (Hungarian National Office of Measure).
Prover: Compact, Uni-directional, Bi-directional, OMNL (Algeria).
Master Meter, Dual Chronometry, Pulse
Interpolation.
SECTION 2 – INSTALLATION
This section provides instructions on installing the FloBoss S600 unit, including installation preparation,
panel mounting procedures, and the installation and removal of the plug-in boards.
Note: It is strongly recommended that you familiarize yourself with the procedures described in
this section before you begin to install the FloBoss S600.
The FloBoss S600 uses a modular design that provides maximum flexibility and ease of installation. The
basic panel-mounted version consists of three major components:
♦ Fabricated metal case, complete with pre-installed PSU/backplate and four card slots for the plug-in
cards (comprising a dedicated CPU slot and three I/O slots).
♦ 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.
Where one or more units are installed in a confined space or with other heat producing
equipment, special attention should be given to the combined heating effect. This combined
heat could increase the environmental temperature beyond its acceptable threshold, thereby
impacting performance.
Note: Do not discard packaging material until all pieces of the shipment have been identified and
you are confident that all parts are working correctly.
3. Carefully slide the FloBoss S600 face up 4 mm (0.15 in) to allow it to clear the retaining groove
at the top of the case, and then allow the face to come forwards to clear the panel case
completely. Refer to Figure 2-3.
4. Disconnect the ribbon cable from the back of the front panel at the blue connector. Refer to
Figure 2-4. Observe the orientation of the connector with its mating keyway. The ribbon cable
must be correctly re-inserted at the end of the installation process.
Do not remove the ribbon cable from the FloBoss S600 housing entrance. This might cause
damage to the unit.
Disconnect
Here
5. Remove the top and bottom bosses from the unit housing, using a 5.5 mm (5 BA) hex wrench.
Part Dimensions
Display Keypad Moulding 85 mm (3.35") width x 269 mm (10.59") height x 28 mm (1.10") deep
Case 84.5 mm (3.327") width x 270 mm (10.63") height x 303.8 mm (11.94") deep
Panel Cutout 66 mm (2.6") width x 150 mm (5.9") height
Pitch Between Cases 110 mm (4.33") giving 25 mm (0.98") air gap
Max Panel Thickness 10 mm (0.39")
Access Allow 300 mm (11.81") clearance directly behind case for maintenance
1. Keeping the environmental considerations in mind, construct the framework of the cubicle to
support the operating panel.
Note: A standard 483 mm (19 in.) rack that is 311 mm (12.25 in.) high will accommodate up to
four FloBoss S600 flow computers with the rear of the case supported.
2. Refer to Figure 2-6 and Table 2-1 for position details for two 7 mm (0.276 in.) holes and a
cutout. The panel cut out should be rectangular in shape for each FloBoss S600 unit. A
tolerance of +/- 3 mm (0.12 in.) is allowed on each axis.
3. Panel thickness should be at least 3 mm (0.12 in) to prevent distortion. Thinner panels can be
used, but these require the rear of the case to be supported. Refer to Figure 2-7.
It is recommended that a rear support or anchor is always used to prevent twisting and other
distortion effects during installation and maintenance.
4. Place the front of the case against the rear of the prepared cutout.
5. Re-install the top and bottom bosses, and tighten with a 5.5 mm (5 BA) hex wrench.
6. When the rear support is fitted, you should use a self-tapping screw to secure the case to the
rear support. The maximum depth of the screw inside the case should be 3 mm (0.12 in.).
Observe the orientation of the connector with its mating keyway. The ribbon cable must be
correctly inserted. Do not use excessive force to refit the cable.
2. Place the top of the front panel over the retaining groove on the top boss and slide downwards.
3. To secure the front panel, place the hex cap screw into its recess in the bottom center of the
front panel.
4. Use a 2.5 mm Allen wrench to tighten the screw finger-tight. Turn an additional 180 degrees to
complete the installation.
Take care not to over-tighten the screw. Over-tightening may cause damage to the panel face.
The 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 covered with the blank plates designed for the
purpose.
Ensure suitable electrostatic discharge precautions are taken prior to removing any of the
plug-in boards.
The terminals on some boards may be wired to electrical potentials sufficiently high to cause
electrical shock and injury. Make sure the power sources of any connected devices are
turned off and discharged before performing any installation or repairs.
3. Unlatch the pull-tabs for the appropriate board and pull the board clear of the case. Some
rocking of the board may be required to release the connector. Refer to Figure 2-9 and Figure
2-10.
1. Install the plug-in boards with care by aligning them in the guides (located at top and bottom of
the case). Gently slide the board until it mates fully with the appropriate connector on the
backplane.
2. Each plug-in board has two “pull tabs” on the backplate. These should be pressed securely in
place upon insertion.
The insertion and location of the plug-in boards along the guides does not require excessive
force. Take care not to twist or otherwise distort the boards during installation.
3. Secure the board in the case with the retention screws (two per board).
SECTION 3 – CPU
This section includes information on plug-in connector blocks and bit link settings for the P152 CPU
board. This section includes the following information:
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 is recommended to be 16
AWG. All local wiring practices and regulations should be observed.
Do not use a Megger or similar instrument to check for isolation or continuity between
signals on any of the connectors of the FloBoss S600. These instruments produce voltages far
in excess of design parameters and damage may occur.
TB-1
POWER
COM 4
COM 3
COM 1-2
REMOTE I/O
TB-2
COM 5, 6, 7
RS 232/485
NETWORK
P152 CPU
NETWORK
SERVICE TB - 1 RJ45 SERVICE
24V DC
+ VE
1 1
INPUT
TX
24V DC SUPPLY
GND
2 2
+ 24v
3 3
ETHERNET
OUTPUT
ETHERNET N/C
DC
+ 15v 4 4 RX
N/C
GND 5 5
N/C
6 6
WATCH
DOG
COM N/C
COMPUTER ALARM 7 7
N/O N/C
8 8
COMM - 4
SERVICE RJ45
RS232
10.SEL(1)
RX
5 3
RS485
GND
CTS 6 PORT 8 4
PORT 8
RS485
5 RX + COMMS TO P144 I/O BOARDS
DSR 7
DCD 8 6 TX -
7 10.SEL(0)
COMM - 3 8 10.SEL(2)
SIG GND 1 0V
DTR 2
RTS 3
TX 4
RS232
RS232 TB 2
RX 5 SERVICE
CTS 6 1 RX -
RS422 2
7
PORT 5
DSR RX +
OR
DCD 8 RS485 3 TX -
4 TX +
5 RX -
RS422
PORT 6
COMM - 1/2
6 RX +
OR
SERVICE 15D MALE RS485 7 TX -
GND
1 8 TX +
TX-FP
2 9 RX -
RS422
3 10
PORT 7
RX +
GND OR
4 RS485 11 TX -
SPKR
5 12 TX +
N/C
6 13 COMPUTER GND
TX-CON
7
LCD & SETUP
The FloBoss S600 should be powered by a nominal 24 volts dc power source capable of supplying 2
Amps. The unit will operate between 20 and 32 volts dc.
The startup in-rush current may draw 6 Amps for approximately 100 milliseconds. This in-rush becomes
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 the unit.
Fully regulated 15 and 24 volts dc supplies are also available for applications, such as powering loops or
pre-amplifiers. These outputs are protected by resettable thermal fuses.
Pin Function
1 +24 V dc INPUT
2 0 V (Return) INPUT
3 +24 V dc OUTPUT (500 mA)
4 +15 V dc OUTPUT (100 mA)
5 0 V (Return) OUTPUT
The relay is energized during normal operation. A CPU failure causes the relay to de-energize. The
watchdog period is 2.5 seconds maximum.
NOTE: Contact is rated at 1 Amp, 30 volts dc and 30 volts ac, and is a Form “C” contact.
Pin Function
6 Normally Closed
7 Common
8 Normally Open
This is a factory-fitted option. To ensure that the battery is fully functional, a regular load test is performed
on the unit.
NOTE: The status of this battery is monitored by a voltage sensing circuit. An alarm is raised if the
battery voltage drops below the predefined limit.
NOTE: Comm Ports 1 and 8 contain internal connections to other boards in the FloBoss S600
which are not available for external host or local operator communications. Comm Port 1 can be
used for routing Remote Display connections.
For information on the optional second Ethernet port, refer to Section 3.6.
Converters are commercially available to configure either 9-way D type or 25-way D type connection. The
ports support baud rates 300 to 38400 bps.
Pin Function
1 GND
2 DTR
3 RTS
4 TX
5 RX
6 CTS
7 DSR
8 DCD
Maximum cable length is a function of the baud rate and quality of cable used. For example, a maximum
length of 15 m (50 ft) should be used at 19200 bps when using unscreened cable.
The ports should be connected to the peripheral devices using multi-conductor, shielded cable. It is
recommended that the cable screen be connected to protective earth, keeping signal ground separate,
particularly in noisy environments.
NOTE: For two-wire EIA-485 (RS-485) installations, jumper TX+ to RX+ and TX- to RX- on the
TB-2 connector on the P152 CPU board .
The port uses a FCC-68 RJ-45 connector. The port is labeled Network on the backplate of the P152 CPU.
It is the standard Ethernet port. No hardware configuration or wiring is required for this communications
port.
NOTE: For information on the optional, second Ethernet port, refer to Section 3.6.
The COM1-2 port uses a standard 15-way D-type female connector. The COM1-2 pin connections are
shown in Table 3-7.
Only shielded, multi-conductor cable should be used to connect to the COM1-2 port. It is recommended,
particularly in noisy environments that the cable shield is connected to earth ground, ensuring the signal
ground is separate.
NOTE: Do not reconfigure the bit link for Com1 and Com2 (bit link 11). The bit link is for factory use
only.
Pin Function
1 GND
2 TX to R. Display
3 GND
4 SPEAKER OUT
5 N/C
6 TX to PC
7 RTS to PC
8 GND
9 RX from R. Display
10 CTS to R. Display
11 GND
12 N/C
13 N/C
14 RX from PC
15 CTS to PC
Alternatively, you may fabricate your own link cable using the wiring details in Figure 3-4.
NOTE: Due to the high baud rate used for the communications between the host PC and the
FloBoss S600, it is recommended that the maximum cable length be restricted to 5 m (15 ft).
Table 3-8. Miscellaneous Device Connectors for the P152 CPU Module
Socket Description
J1 DIN Backplane Connector
J2 CPU cooling fan molex (12 VDC)
J3 PC/104 expansion bus (16- bit)
J4 Additional plug-in battery molex 3.6 V dc
J5 IDE Hard disk pin header
J6 Altera serial programming pin header (factory use only)
J7 Keyboard and mouse pin header
J8 Security bit link (Off = Level 1 Security Disabled)
J9 Optional communications LED backplate pin header
NOTE: For information on the standard Ethernet port, refer to Section 3.3.3.
The P190 Dual Ethernet communications port is comprised of a mezzanine card and a port backplate with
a FCC-68 RJ-45 connector. Refer to Figure 3-5
The mezzanine card plugs into the PC/104 slot on the P152 CPU board. Connections to the port are made
at a communications module backplate which connects to the mezzanine card via an extension of the card.
This backplate will use the first I/O slot beside the P152 CPU slot.
The second Ethernet port is usually shipped already installed in the S600 unit from the factory. Field
installation is possible, when a specialized backplane and P152 CPU card are also installed. If installed at
the factory, no hardware configuration or wiring is required.
NOTE: Before using this port, verify the IP settings of the port on the front panel. From the
Startup menu, select Network Setup > Network I/F 2. If no addresses have been assigned, you will
need to assign them.
NOTE: Exercise CAUTION. Network I/F 1 and Network I/F 2 must have unique subnet masks.
SECTION 4 – I/O
This section includes information on plug-in connector blocks, field wiring configurations (ANIN, PRT,
and DPR signals). This section includes the following information:
Do not use a Megger or similar instrument to check for isolation or continuity between
signals on any of the connectors of the FloBoss S600. These instruments produce voltages far
in excess of design parameters and damage may occur.
The P144 I/O board measures process signals used by the CPU while running the flow computer functions.
The I/O board supplies 12 Analog Inputs, 4 Analog Outputs, 16 Digital Inputs, 12 Digital Outputs, 4 Pulse
Inputs, 5 Pulse Outputs, 3 Frequency (Density) Inputs, and 3 PRT/RTD Inputs.
The backplate has three low density D-type connectors for field wiring. These connectors are labeled
SKT-A, SKT-B, and SKT-C.
SKT-A
ANIN 1-10
ANOUT 1-4
SKT-B
ANIN 11 - 12
DIGIN 1-6
DIGOUT 1 - 2
Freq Inputs
Pulse Outputs
SKT-C
DIGIN 7-16
DIGOUT 3-12
Turbine Inputs
P144 IIO 1
SUPPLY 15 22 ADC 4+
GROUND 5 12 ADC 8+
+15V 1-5V
SUPPLY 18 25 ADC 9+
PRT 1 V+
1 0-1 V
4 - 20 mA 7 ADC 12+
INPUT V- 21 20 GND
I- 24 1mA +12V
30 PULSE OUT 1+
I+ 5 31 PULSE OUT 2+
I- 25 1mA +12V
35 PULSE 1-4 COM
I+ 6 34 + PULSE
- OUTPUT 5
PRT 3 V+ 3 0-1 V 10K 12
INPUT V- 23 9 + DENSITY
LK3
I- 26 10K
1 27 - INPUT 1
DIG IN 1- 13 10 + DENSITY
LK3 - INPUT 2
DIG IN 2- 14 10K
2 28
DIG IN 3- 15 11 +
-
DENSITY
INPUT 3
LK3
DIG IN 4- 16 3 29
DIG OUT 1+
+24v COMMON + VE 17 36
DIG IN 5- 18 37 DIG OUT 2+
DIG IN 6- 19
SKT C SERVICE
SERVICE SKT C
37 DIG OUT 3+
DIG IN 7-
19 36 DIG OUT 4+
DIG IN 8-
18 35 COMMON GND 0v
+24v COMMON + VE
17 34 DIG OUT 5+
DIG IN 9-
16 33 DIG OUT 6+
DIG IN 10-
15 32 DIG OUT 7+
DIG IN 11-
14 31 DIG OUT 8+
DIG IN 12-
13 30 COMMON GND 0v
+24v COMMON + VE
12 29 DIG OUT 9+
1 + DUAL PULSE
HIT HIT
20 - CHANNEL 4
The primary measurement for ANIN 1-10 is voltage, which is compared to a stable reference source. The
channels are configurable to current using a bit link (jumper) on the board to place a high accuracy
calibrated shunt resistor in parallel with the input. Refer to Figure 4-3 and Figure 4-4.
NOTE: Exercise caution. The channels for each A/D converter should be set the same to
guarantee accuracy. Channels ANIN 1-5 on the first A/D converter should all be set for voltage or
all for current. Channels ANIN 6-10 on the second A/D converter should all be set for voltage or
all for current. Refer to Section 4.1.10 for a table of settings.
Figure 4-3. Analog Input Schematic (with IS Barrier and using Internal Resistor)
Figure 4-4. Analog Input Schematic (without IS Barrier and using External Resistor)
The ANIN channels use the connectors labeled SKT-A and SKT-B, which are located on the backplate of
the P144 board. Channels CH1 to CH10 are located on connector SKT-A and channels CH11 and CH12
are located on connector SKT-B. The ANIN pin connections are shown in Table 4-1 and Table 4-2.
Pin Function
8 ANIN-CH1
21 ANIN-CH2
9 ANIN-CH3
22 ANIN-CH4
10 ANIN-CH5
20 RETURN CH1-5
11 ANIN-CH6
24 ANIN-CH7
12 ANIN-CH8
25 ANIN-CH9
13 ANIN-CH10
23 RETURN CH6-10
Pin Function
8 ANIN-CH11 (current)
7 ANIN-CH12 (current)
20 GND
The D/A Converter output channels use the connector labeled SKT-A, which is located on the backplate of
the P144 board. The D/A Converter output pin connections on the back of the I/O card are shown in Table
4-3.
Figure 4-7. Analog Output Schematic (Externally Powered through FloBoss S600)
Pin Function
1 DAC-CH1 +15 V SOURCE
14 DAC-CH1 SINK
2 DAC-CH1 0 VDC
15 DAC-CH2 +15 V SOURCE
3 DAC-CH2 SINK
16 DAC-CH2 0 VDC
4 DAC-CH3 +15 V SOURCE
17 DAC-CH3 SINK
5 DAC-CH3 0 VDC
18 DAC-CH4 +15 V SOURCE
6 DAC-CH4 SINK
19 DAC-CH4 0 VDC
The DIGIN channels use the connectors labeled SKT-B and SKT-C, which are located on the backplate of
the P144 board. The DIGIN pin connections are in Table 4-4 and Table 4-5.
NOTE: The feed lines (Ex. pin 17 on SKT-B) must be connected to a 24 volts dc source. The
DIGIN lines (Ex. pin 13 on SKT-B) expect typical “open collector” (referenced to GND)
connections.
Pin Function
13 DIGIN-CH1
14 DIGIN-CH2
15 DIGIN-CH3
16 DIGIN-CH4
17 RETURN CH1-4
18 DIGIN-CH5
19 DIGIN-CH6
Pin Function
19 DIGIN-CH7
18 DIGIN-CH8
17 RETURN CH5-8
16 DIGIN-CH9
15 DIGIN-CH10
14 DIGIN-CH11
13 DIGIN-CH12
12 RETURN CH9-12
11 DIGIN-CH13
10 DIGIN-CH14
9 DIGIN-CH15
8 DIGIN-CH16
7 RETURN CH13-16
The DC polarity must be carefully checked. Use an external DC supply in series with the load. When
using inductive loads, such as relay coils, place a diode across the load. Refer to Figure 4-10 and Figure
4-11.
The DIGOUT channels use the connectors labeled SKT-B and SKT-C, which are located on the backplate
of the P144 board. The DIGOUT pin connections are shown in Table 4-6 and Table 4-7.
Pin Function
36 DIGOUT-CH1
37 DIGOUT-CH2
Pin Function
37 DIGOUT-CH3
36 DIGOUT-CH4
35 RETURN CH1-4
34 DIGOUT-CH5
33 DIGOUT-CH6
32 DIGOUT-CH7
31 DIGOUT-CH8
30 RETURN CH5-8
29 DIGOUT-CH9
28 DIGOUT-CH10
27 DIGOUT-CH11
26 DIGOUT-CH12
25 RETURN CH9-12
Each input has an input range of 1 to 10 KHz. Each channel has live integrity checking. A configurable
circuit fail alarm is activated if cabling faults develop or if the pre-amp power fails.
The electrical connection of these inputs is dependent on which DPR mezzanine card is fitted to the P144
I/O module. For example, a 12 volts dc P148 Mezzanine card is suitable for the pre-amp signals shown in
Figure 4-12. As another example, a 24 volts dc P148 Mezzanine card is suitable for the open collector
device shown in Figure 4-13.
The P148 Mezzanine card can interface to a variety of pre-amps. The following pre-amps are among those
supported: Spectra Tek F106, Spectra Tek IS106, Instromet MK15, Faure Herman FH71 2-wire, Faure
Herman FH71 3-wire, and ITT Barton 818U.
Pin Function
4 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-
Pin Function
30 PULSEOUT-CH1
31 PULSEOUT-CH2
32 PULSEOUT-CH3
33 PULSEOUT-CH4
35 RETURN CH1-4
34 PULSEOUT-CH5
12 RETURN CH5
Pin Function
24 Raw Output
5 Return
The frequency input channels use the connector labeled SKT-B, which is located on the backplate of the
P144 board. The frequency input pin connections are shown in Table 4-11.
Figure 4-17. Frequency Input Schematic (without IS Barrier and with DC Coupled)
Pin Function
9 FREQUENCY-CH1+
27 FREQUENCY-CH1-
10 FREQUENCY-CH2+
28 FREQUENCY-CH2-
11 FREQUENCY-CH3+
29 FREQUENCY-CH3-
The PRT/RTD inputs are suitable for Class A, 4-wire PRT devices that conform to the BS EN 60751:1996
standard. The temperature measurement range is -100 to +200°C (-148 to +392°F). Two styles of
PRT/RTD probes are supported:
♦ 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 selection coefficient (alpha) is still common for circumstances where a slightly
more pure Platinum is used to effect a higher absolute accuracy. The style of PRT/RTD must be
configured through Config 600 software.
Pin Function
4 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-
Point to point communications for the P144 I/O board require Link 2 to be ON and Link 11 to be OFF.
Multiplex (MUX) communications require Link 2 to be OFF and Link 11 to be OFF.
Address LK3 LK4 LK5 LK6 LK7 LK8 LK9 LK10 COMMENT
0 N/A N/A N/A N/A N/A N/A N/A 1-2 Not a Valid
address
1 OFF OFF OFF OFF OFF OFF ON 1-2 1st or only board
8 N/A N/A N/A N/A N/A N/A N/A 2-3 Not a Valid
address
The backplate has three low density D-type connectors for field wiring. These connectors are labeled
SKT-D, SKT-E, and SKT-F.
SKT-D
RAW IN 1-3
DENSITY 1-2
SPHERE SWITCH 1-4
PLLIN
RAW OUT
SKT-E
DIGIN 1-6 AND 17-32
DIGOUT 1-2
Pulse Outputs 1-4
SKT-F
DIGIN 7-16
DIGOUT 3-12
DUAL PULSE 1-4
PLLOUT
P154 IIO 2
INPUT 1 - 14 3K3
5 SWITCH 2 -
INPUT 2 - 15 26 SWITCH 4 -
+ 9 13 GND
DENSITY 1
- 21 19 GND
+ 10 24 GND
DENSITY 2
- 22 25 GND
0V
DIG IN 26 - 21 2 DIG IN 18 -
DIG IN 27 - 22 3 DIG IN 19 -
DIG IN 28 - 23 4 DIG IN 20 -
DIG IN 30 - 26 7 DIG IN 22 -
DIG IN 31 - 27 8 DIG IN 23 -
DIG IN 32 - 28 9 DIG IN 24 -
PULSE OUT 3+
33 15 DIG IN 3 -
DIG OUT 2+ 37
SKT F SERVICE
SERVICE SKT F
19 DIG IN 7 -
DIG OUT 3+
37 18 DIG IN 8 -
DIG OUT 4+
36 17 COMMON + VE +24V
OV COMMON GND
35 16 DIG IN 9 -
DIG OUT 5+
34 15 DIG IN 10 -
DIG OUT 6+
33 14 DIG IN 11 -
DIG OUT 7+
32 13 DIG IN 12 -
DIG OUT 8+
31 12 COMMON + VE +24V
OV COMMON GND
30 11 DIG IN 13 -
The DIGIN channels use the connectors labeled SKT-E and SKT-F, which are located on the backplate of
the P154 board. The DIGIN pin connections are shown in Table 4-15 and Table 4-16.
Note: The return lines (Ex. pin 17 on SKT-E) must be connected to a 24 volts dc source. The
DIGIN lines (Ex. pin 13 on SKT-E) expect typical “open collector” (referenced to GND)
connections.
Field wiring schematics are shown in Figure 4-8 and Figure 4-9 in Section 4.1.3.
Pin Function
13 DIGIN-CH1
14 DIGIN-CH2
15 DIGIN-CH3
16 DIGIN-CH4
17 RETURN CH1-4
18 DIGIN-CH5
19 DIGIN-CH6
1 DIGIN CH-17
2 DIGIN CH-18
3 DIGIN CH-19
4 DIGIN CH-20
5 RETURN CH-17-20
6 DIGIN CH-21
7 DIGIN CH-22
8 DIGIN CH-23
9 DIGIN CH-24
10 RETURN CH 21-24
20 DIGIN CH-25
21 DIGIN CH-26
22 DIGIN CH-27
23 DIGIN CH-28
24 RETURN CH 25-28
25 DIGIN CH-29
26 DIGIN CH-30
27 DIGIN CH-31
28 DIGIN CH-32
29 RETURN CH 29-32
Pin Function
19 DIGIN-CH7
18 DIGIN-CH8
17 RETURN CH5-8
16 DIGIN-CH9
15 DIGIN-CH10
14 DIGIN-CH11
13 DIGIN-CH12
12 RETURN CH9-12
11 DIGIN-CH13
10 DIGIN-CH14
9 DIGIN-CH15
8 DIGIN-CH16
7 RETURN CH13-16
The DC polarity must be carefully checked. Use an external DC supply in series with the load. When
using inductive loads, such as relay coils, place a diode across the load.
The DIGOUT channels CH1 to CH2 are located on connector SKT-E, and channels CH3 and CH12 are
located on connector SKT-F. The DIGOUT pin connections are shown Table 4-17 and Table 4-18. Field
wiring schematics are shown in Figure 4-10 and Figure 4-11 in Section 4.1.4.
Pin Function
36 DIGOUT-CH1
37 DIGOUT-CH2
Pin Function
37 DIGOUT-CH3
36 DIGOUT-CH4
35 RETURN CH1-4
34 DIGOUT-CH5
33 DIGOUT-CH6
32 DIGOUT-CH7
31 DIGOUT-CH8
30 RETURN CH5-8
29 DIGOUT-CH9
28 DIGOUT-CH10
27 DIGOUT-CH11
26 DIGOUT-CH12
25 RETURN CH9-12
Each input has an input range of 1 to 10 KHz. Each channel has live integrity checking. A circuit fail
alarm is activated if cabling faults develop or the pre-amp power fails.
The dual-pulse input pin connections are shown in Table 4-19. Field wiring schematics are shown in
Figure 4-12 and Figure 4-13 in Section 4.1.5.
Pin Function
4 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-
The PULSEOUT pin connections are shown Table 4-20. Field wiring schematics are shown in Figure 4-14
in Section 4.1.6.
Pin Function
31 PULSEOUT-CH1
32 PULSEOUT-CH2
33 PULSEOUT-CH3
34 PULSEOUT-CH4
35 RETURN CH1-4
The frequency input pin connections are shown in Table 4-21. Field wiring schematics are shown in
Figure 4-16 and Figure 4-17 in Section 4.1.8.
Pin Function
9 FREQUENCY-CH1+
21 FREQUENCY-CH1-
10 FREQUENCY-CH2+
22 FREQUENCY-CH2-
The connections are made through two 25 pin D connectors located on the backplate of the P188 module.
Socket A connects to a 25 pin Male connector; Socket B connects to a 25 pin Female connector. Refer to
Table 4-24 and Table 4-25.
Socket A Socket A
Channel Number Pin Number
Channel 1+ 1
Channel 1- 14
Channel 2+ 2
Channel 2- 15
Channel 3+ 3
Channel 3- 16
Channel 4+ 4
Channel 4- 17
Channel 5+ 5
Channel 5- 18
Channel 6+ 6
Channel 6- 19
Channel 7+ 7
Channel 7- 20
Channel 8+ 8
Channel 8- 21
Socket B Socket B
Channel Number Pin Number
Channel 9+ 13
Channel 9- 25
Channel 10+ 12
Channel 10- 24
Channel 11+ 11
Channel 11- 23
Channel 12+ 10
Channel 12- 22
Figure 4-22. HART Device and Hand Held Communicator Beyond the IS Barrier
5.1 Description
The front panel of the FloBoss S600 provides a local interface so that the user may view or make changes
to the values and status of parameters. The layout of the FloBoss S600 front panel is shown in Figure 5-1.
LCD Display
F1 to F4 Keys
LED
Menu Key
4 Direction Key
The pinouts when using a six pin connector are shown in Table 5-1. The pinouts when using the 15 way
D-type female connector are detailed in Table 3-7 in Section 3.3.4.
Pin Function
1 RTS
2 TX
3 GND
4 GND
5 RX
6 CTS
5.3 Keypad
The layout of the front panel keypad has been designed to make it easy to use and to reduce the possibility
of error. The keys on the keypad are color-coded by type:
♦ Function = yellow.
♦ 4 Direction & Menu = dark green.
♦ Numeric = light green.
♦ Operation = dark green.
5.3.1 F Keys
The top of the keypad has four function keys numbered F1 to F4. Each F key can be programmed as a
shortcut to a frequently used display page. For the procedure to program a F key, refer to Section 5.9.
Press the Menu key to return up one level of the display hierarchy. On a data page, this key returns you to
the parent menu. On a menu page, the ▲ key will return you to the Main menu.
The decimal point is also used to define shortcuts to access frequently used displays; refer to Section 5.8.
Exponent – The Expt key is used to enter numbers in scientific notation. Where the value to be entered
exceeds the space available on the display (20 characters), it is necessary to express the data in
exponential terms.
Clear – The Clear key is used to cancel or exit from the current operation and return to the previous data
display. Clear is also used to activate the default display (if configured).
Display – The Disp key is used to enter the path of a required display. The path is shown on the Status/ID
line at the bottom of every data page.
Print – The Print key is used to display the print menu, where commands can be requested for various
pre-configured reports or logs to a printer or computer terminal.
Change – The Chng key is used to edit a displayed database item. Only items marked with an asterisk (*)
are changeable.
Enter – Used in combination with the numeric and Chng keys, the key is used to confirm the data
has been entered correctly and complete an operational sequence.
During normal operation, with no alarm activated, the Alarm LED is green.
Alarms can be triggered when measurements exceed the pre-set limits for a parameter or when there is a
malfunction. The alarm may be relayed to a terminal or klaxon in the Control Room. On the panel of the
S600, a flashing red LED indicates an alarm, and the source of the alarm can be shown on the display.
When an alarm is activated, the light flashes red until the cause for the alarm has been viewed and the
Accept key has been pressed. Once acknowledged, the light shows a constant red until all the alarm
conditions have been cleared.
Press 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. Whilst the alarm remains
unaccepted, the date is shown in inverse video. The second and third lines are used to describe where the
alarm has been activated and its nature. The total number of alarms, accepted and unaccepted, is shown on
the bottom line.
When there is more than one alarm to be viewed, the display can be cycled around all the alarms, using the
<up> or <down> keys.
Press the Accept key to notify the S600 that you have viewed all the alarms and are prepared to
acknowledge them all together. The inverse date on all the alarms then returns to normal video.
Once an alarm condition is cleared, its alarm prompt is automatically cleared from the display. When all
the alarms in the system have cleared, the Alarm light resets to a constant green.
5.5 Display
The LCD display offers eight lines of information displayed as alpha-numeric characters. An example of a
typical display is shown below.
1. UVOL FR
2. CVOL FR
3. MASS FR
4. ENERGY
All eight lines of the display are used to show the available menu options, which are arranged in a
hierarchy of menus and sub-menus. Each menu and associated sub-menu is allocated a number between 1
to 8 and can be selected using the numeric keys.
An asterisk (*) before a menu option indicates that further sub-menus are available. A decimal point ( . )
before the menu option shows there is a data display page available and no further sub-menu.
Generally, each data display page shows one or more data item(s) from the FloBoss S600 database along
with the associated text, units, and description.
Which data items can be modified depends upon the database configuration. A changeable (Read
Writable) data item is indicated by an asterisk (*) at the end of the display line. Prompts and messages
appear when you enter or edit data items. Display lines without asterisks are Read Only.
On the bottom line of every data display page is the Status/ID line. A typical Status/ID line is shown in
Figure 5-4.
On the left-hand side of the Status/ID line is the Page Reference Number. For example, P1.1 followed by
the number of associated data pages that can be navigated using the ◄ and ► keys.
The Page Reference Number indicates the location of a data item on the FloBoss S600 displays. One way
to understand the FloBoss S600 displays is to visualize the data items as if they were written on the
exterior of a very large cylinder. The Page Reference Number calls out the column on the cylinder,
followed by the row, in a “column.row” format.
In addition, the Status/ID line indicates whether the flow computer is in Prove mode or Maintenance mode
by displaying the characters P or M, respectively, on the right-hand side.
The Status/ID line on the bottom of the display changes as you move between data display pages.
Use the ◄ or ► keys to view the previous or next display. The number of the current display is indicated
after the decimal point on the Status/ID line.
NOTE: The ◄ key is also used as the delete/backspace key when entering or changing data.
Use the ▲ and ▼ keys to move from the data display pages of one menu item to the data display pages of
the previous or next menu item.
An alternative method of selecting the required data page is to enter the unique page address using the
Disp key. If you know the page reference number of the parameter (found in the Status/ID line) you wish
to view, proceed as follows:
1. Press Disp followed by the Page Reference Number in the format of “column.row,” such as 1.3.
2. Press Enter.
If you only enter a single number, such as the column value, then the first cell of the row displays.
To return to a higher level menu, press the Menu key. Repeatedly pressing the Menu key moves you up to
the Main menu. If you are on a menu or data display page, you can return directly to the Main menu at any
time (except during an edit sequence) by pressing the Menu key followed by the ▲ key.
If you have pressed the Chng key and are therefore in an edit sequence, the Menu key will not respond
until either Clear (to abort the change) or Enter (to complete the change) has been pressed.
Refer to Appendix A for more information on navigating the front panel display screens.
1. Press the Chng key. If more than one asterisk is shown on a data display, the FloBoss S600
highlights the first object on the page. Use the ▲ and ▼ keys to move the highlight to the required
point.
2. Press the Chng key again to change the data values. The system automatically determines whether
your assigned security level allows you to change the selected data. If not permitted, you will be
requested to enter your security code. In order to prevent 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
the displayed data. The Clear key can be pressed at any time to abort the current operation or task.
If the value is changeable (R/W), the data is marked with an asterisk; if there is no asterisk, the data cannot
be modified from the keypad.
Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required data page.
5. At the prompt ENTER NEW VALUE: key in the new value in integer, numeric, or scientific
notation as appropriate (the current value and any entry limits associated with this parameter are
also shown).
6. Press Enter to confirm.
The edit sequence is automatically exited on accepting or rejecting the value change if only one data item
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 to delete
single figures or characters. If you wish to abort the change, press Clear.
Deleting or cancelling the change to the parameter should be done before pressing Enter. The Enter
command confirms that you wish the change to be written.
Locate the parameter to be changed using one of the methods described under Section 5.6
If the mode is changeable, the mode is marked with an asterisk; if there is no asterisk, the mode cannot be
modified.
Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required data page.
The edit sequence is automatically exited on accepting or rejecting the mode change if only one data item
is changeable on the data page.
The Clear key enables you to cancel the mode change to the parameter, if necessary.
Each user is allocated a security level between 0 (highest) and 9 (lowest). The security levels determine
which data you will be able to change. Level 0 is reserved and cannot be set as a login level for users.
The security level can be assigned or modified for each user from within CONFIG 600 software.
To clear the default display, go to a menu page and repeat steps 2 and 3. To invoke the default display, use
the Clear key. Note that the Clear key will not work while in Edit mode.
The displayed value will be shown in scientific notation if it can not be displayed as a normal number. The
data value can be forced to always display in scientific notation from within Config 600 software. For
information, refer to the Config 600 User Manual or on-line help.
For example, to enter the figure 0.00000009 as an exponential value: Key in 9.0 or 9, press Expt, enter -8
(to represent the power), and press Enter to confirm.
Constants Log – Lists all the constant parameters and values that are available for change from the
display.
Security Dump – Lists the whole display matrix, along with the current security levels assigned to data
items.
All Alarms – Lists all possible alarms that can be generated by the alarm system on this configuration.
Current Report – Lists the current report as configured, normally this would consist of the meter run
totals.
Config Report – Lists the configuration-specific parameters, including any configured installed
calculation sets.
Archived Reports – Lists all archived reports, sorted by time and date.
Current Alarms – Lists all the acknowledged and un-acknowledged alarms currently set in the flow
computer in separate chronological lists.
Modbus Maps – Lists the Modbus maps stored in the FloBoss S600 that are assigned to a telemetry link.
NOTE: Alternate web browsers may also work. However, Windows® Internet Explorer® version
6 or greater is recommended for full features.
The web server access will allow the user to view reports, displays, and diagnostics. The number of items
available for viewing is dependent on the user’s security access level. Some values and statuses are
read/writable and may be modified from the web server access. Whether items may be modified from the
web server access is also subject to the security level access of the user.
The standard or optional second Ethernet communications port may be used for the connection.
1. On a PC currently connected to the internet, open the Windows Internet Explorer browser (version
6 and greater).
2. In the Address bar of the browser, type in the IP Address of the FloBoss S600 unit.
To learn the IP address of the Ethernet port on the S600 unit, use the front panel display. From the
startup menu, select Network Setup > Network I/F 1 > TCP/IP Address 1 or 2.
3. A dialog box will appear that asks for your user name and password (security code).
Use the same password that you would use for access to the PCSetup Editor. The passwords are
established in the configuration. If you are unsure of your user name or password, check with the
person who created the configuration for your application.
The security level assigned to your security code will determine how many options are available on
the web access interface.
4. Click OK.
The browser will now display information from the FloBoss S600 unit.
When an element is selected from the menu bar, a hierarchy tree menu appears in the navigation bar on the
left side of the browser. From this hierarchy menu, you may select which screen of data points to view.
Menu Bar
Hierarchy
Menu
Many of the screens present the data points in a format identical to the front panel display. Refer to Figure
6-2. To view related data point screens, use the navigational arrows at the bottom of the screen.
Navigational Arrows
Some of the screens allow the viewer to interact with the FloBoss S600 unit. If the text appears in bold,
the data is changable. If the text appears in red, the object is in an alarm state. Modifications to the screen
will be sent to the FloBoss S600 unit as they are made.
To close a screen, select another element from the menu bar or another screen from the hierarchy menu.
To close the web server access link, use the Log Off button in the menu bar and close the browser.
NOTE: Exercise CAUTION. Due to the caching mechanism on many internet browser
applications, please remember to close the browser on your PC. This will ensure the browser does
not remember the FloBoss S600 details.
SECTION 7 – STARTUP
This section describes the various procedures for starting and restarting the FloBoss S600 unit.
During a warm start, the FloBoss S600 displays the message RESTARTING.
Following a successful warm start, the Main menu displays. The Main menu is the starting point of the
display screens. For information on navigating the display screens, refer to Section 5.
If a valid configuration can not be found, the FloBoss S600 will not warm start. It will instead go to the
Startup menu. Please refer to Section 7.4 for details.
A cold start is used after sending a new configuration to the FloBoss S600 or to recover from extreme
situations, such as a corrupted database. A cold start builds a new metering database, using the
configuration data stored in the Flash memory of the FloBoss S600. A cold start must also be performed if
the firmware has been updated or changed.
1. Select the COLD START command from the Startup menu. The Startup menu is shown in
Figure 7-1.
2. Press 1 or 2 to keep or reset the totals.
3. Press 1 to confirm and the following message displays:
CONFIGURING - PLEASE WAIT
A new database is then built using the configuration files held in the Flash memory.
NOTE: After modifying any data in the startup menu, a power cycle may be required.
1. WARM START
2. COLD START
3. NETWORK SETUP
4. REFLASH FIRMWARE
5.
6.
7.
8. FACTORY SETUP
Prior to any network communications, the necessary network settings should be set. These parameters can
only be viewed or changed via the Startup menu.
These settings are kept in a separate area of the SRAM database and will be retained following the sending
of a configuration to the FloBoss S600 unit.
When any Modbus slave configuration builder has an address of zero specified, the Modbus port will be
configured with the address entered here. This is typically used when the same configuration file is loaded
into multiple FloBoss S600 flow computers on the same Modbus network; thus, giving each FloBoss S600
a unique node address.
Before establishing an Ethernet LAN connection (for host communications, local operator
communications, or web server access), you will need to verify and/or define the TCP/IP Address.
SECTION 8 – TROUBLESHOOTING
This section provides instructions for maintaining and troubleshooting the FloBoss S600. If you are still
experiencing difficulties after using the troubleshooting procedures in this section, please contact your
local sales representative or Flow Computer Division technical support.
When you are done troubleshooting, perform a warm start or cold start. Refer to Section 7.
If you are instructed by your local sales representative or technical support to return the FloBoss S600 unit,
replace the troubled parts with spares and return the troubled parts to the address given by the local sales
representative or technical support.
♦ Check the wiring connections at Terminal Block TB1 on the P152 CPU backplate and the wiring at
the power source.
♦ Check the power supply voltage.
♦ Check the fuse on the P152 CPU board. Refer to Section 8.3.4.
♦ Check the bit link LK13 on the P152 CPU board. If it is in the closed (cold start) position, then
move it into the open (warm start) position to allow a warm start. This will allow the unit to
bypass the Startup menu in future.
♦ Check for a valid configuration. If no configuration is present, refer to Section 8.3.2.
♦ Check whether a Clear SRAM command has been issued.
♦ Check the I/O board connections. Power down, remove and reseat the I/O board, and then re-apply
power.
♦ Check the front panel display and LED. If they are not lit, you may have a power issue.
♦ Check with the person who configured the unit whether you have the correct I/O boards fitted.
♦ Check from Main menu of the running configuration for any Bad Tx or Bad Rx messages. Select
TECH/ENGINEER > COMMUNICATIONS > SERIAL PORTS > PORT 8.
8.3 Procedures
Under no circumstances should you allow the FloBoss S600 to be turned off while it is erasing
or reprogramming the Flash memory. Doing so will render the FloBoss S600 unusable.
Should this occur, the FloBoss S600 must have a basic version of the VxWorks binary file
loaded from the BIOS chip. The correct version of the VxWorks binary and configuration
files would also then need to be reloaded.
NOTE: Do NOT proceed if the message FLASH FAILED displays. Remove the power connector
for 5 seconds and re-apply power. The FloBoss S600 will return to the startup menu.
6. The FloBoss S600 proceeds to erase and reprogram the Flash memory, and displays the following
message:
RESETTING - PLEASE WAIT
The FloBoss S600 then restarts; if the FloBoss S600 has not restarted after 30 seconds, remove the
power connector for 5 seconds to return to the startup menu.
1. From the Config 600 software, select the Transfer Data option.
2. Choose the Comm port connected to the FloBoss S600. Default parameters for serial ports are
38400 bps, 8 data bits, 1 stop bit, and no parity.
NOTE: Configurations can also be transferred via Ethernet, as well as by the serial
communications port.
3. Select the configuration you require, then select the sections you desire to transfer to the FloBoss
S600.
4. Click on Send Now to download to the FloBoss S600.
Once completed, the FloBoss S600 will restart and the Startup menu displays.
The Clear SRAM option is used to clear out the FloBoss S600 by overwriting the SRAM area. All
battery-backed configuration data will be lost, including system configuration data, process configuration
data, metering totalizers, and network settings.
Following a Clear SRAM command, the FloBoss S600 will restart and return to the Startup menu. The
FloBoss S600 will not be able to warm start again until a full configuration is sent from a PC running
Config 600 software.
Fuse
The FloBoss S600 software system is organized as a structured database of parameters, such as TOTALS, I/O, and CALCULATIONS. The
database groups the parameters logically by data points in a matrix of display screens. For example, the parameters used for averaging totals are
grouped together.
NOTE: The content of the display screens is application-specific. Although details may vary between different applications, the principle
described is the same. Refer to your Application Manual for details of parameters installed in your FloBoss S600.
The defaults for the screens described in this section assumed a configuration with two stations (Gas EU and Liquid EU) and four streams (Gas
Turbine, Gas DP, Liquid Coriolis, and Prover Ball). The Gas DP stream is assigned to station 1, and the Liquid Coriolis is assigned to station 2.
As mentioned in the note above, please apply the example of navigation presented here to your application which may vary. That is to say, if
your application has fewer stations and more streams, you will see more stream choices and fewer station choices than this example shows. Also,
if you have different types of streams, you will see parameters and submenu choices not listed here.
Main Menu
1* Flow Rates
2* Totals
3* Operator
4* Plant I/O
5* System Settings
6* Tech/Engineer
8* Calculations
1. INLET VALVES
2. OUTLET VALVES
Densitometers Submenus (for Station 1 and Streams 1-4 menus)
NOTES: AVE T&P refers to the average temperature and pressure parameters. STAT&CTRL refers to status and control parameters.
4. ADC 16 – ADC04
5. ADC 17 – ADC05
6. ADC 18 – ADC 06
7. ADC 19 – ADC 07
8 NEXT
1 PREVIOUS
2. ADC 20 – ADC08
3. ADC 21 – ADC09
4. ADC 22 – ADC10
5. ADC 23 – ADC11
6. ADC 24 – ADC12
Calculations Submenus
Station 1 (Gas EU) Station 2 (Liquid EU) Stream 1 (Gas Stream 2 (Gas DP) Stream 3 (Liquid Stream 4 (Prover Ball)
Turbine) Coriolis)
[Empty Screen] [Empty Screen] 1* AGA7 1* DOWN/UP CORR 1* IP2 [Empty Screen]
2* AGA8 2* PIPE CORRECTION 2* KF LINEARISATION
3* ISO6976 3* AGA8
4* KF/MF LIN 4* ISO5167
5* ISO6976
Stream 1, 2, &3 > AGA7, AGA8, ISO6976, ISO5167, KF/MF LIN, KF Linearisation, Down/up Corr, Pipe Correction, and IP2 Submenus
1. INPUTS
2. OUTPUTS
GLOSSARY
A
ADC – 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.
Analog – A signal that has no defined steps, its value being determined by its size.
B
Baud – Refers to the rate of serial data transfer, e.g. baud rate of 10 = 10 bits per second.
Bit Link - A metal bridge that closes an electrical circuit. Typically, a bit link consists of a plastic
plug that fits over a pair of protruding pins. By placing a bit link plug over a different set of
pins, you can change a board's parameters. Also known as jumpers.
Buffer – A device inserted between devices to match impedance, equipment speeds or to supply
additional drive capability.
Bus – One or more conductors used as a path over which information is transmitted.
C
Cold Start – The FloBoss S600 unit starts and the configuration file is copied from flash.
D
DAC – 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 storage
and peripheral devices.
Digital – A signal that has only two states e.g. On/Off 1/0 5V/0V.
DP – Differential Pressure.
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
assumed to be lost.
E
Ethernet – Network hardware connection.
F
Flash Memory – Non-volatile storage memory. Although slower to access than SRAM and
DRAM, once its contents have been programmed, it requires no further attention to support that
data. The configuration files and operating system are kept here. Write protect jumpers are used
to prevent accidental programming of this memory.
H
Hex – Hexadecimal. Numbers in base 16, i.e. numbers 0 to 9 and letters A to F are used.
I, J, K
Integer – A whole number.
Intelligent I/O – P144 Intelligent Input Output module, also known as IIO.
IPL 600 – Interactive program loader tool for transferring application programs from the PC to the
FloBoss S600.
IS – Intrinsically Safe.
L
LED – Light Emitting Diode (an indicator).
M
Mantissa – Numerically significant part of a floating point number.
Modbus – Modbus is the communication protocol utilized on the station supervisory computer data
link.
N
Noise – Random Electrical Interference.
Non-Volatile Memory – Memory type that retains data when the power supply is disconnected.
O
Object - Generally, any item that can be individually selected and manipulated. This can include
shapes and pictures that appear on a display screen as well as less tangible software entities. In
object-oriented programming, for example, an object is a self-contained entity that consists of
both data and procedures to manipulate the data.
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.
P, Q
PCB – Printed Circuit Board.
PID – Three term control action. Using Proportional, Integral and Derivative components to
modify a control output, with the goal of achieving a measured process variable at a set point.
R
ROM – Read Only Memory (fixed storage).
RX – Received information.
S
Security Code – Security Codes are used to limit access by operators to parameters retained in the
micro memory.
T
Task - An operating system concept that refers to the combination of a program being executed
and bookkeeping information used by the operating system. Whenever a program is executed,
the operating system creates a new task for it.
TX – Transmitted information.
U
Underrange – Under preset current limit for A/D Converter.
V
Variables – Changeable values.
W, X, Y, Z
Warm Start – The FloBoss S600 starts and the configuration remains untouched.
Watchdog – A hardware circuit that monitors correct program operation and causes program
restart in the event of malfunction.
INDEX
DIGIN..................................................................... 4-6
4 Digital Outputs
DIGOUT........................................................4-8, 4-20
4 Direction Key............................................................5-3 DIN............................................................................ 4-13
Disp ......................................................................5-3, 5-5
A Display ........................................................................ 5-3
LCD ........................................................................ 5-4
Accept ..........................................................................5-3
Navigating .............................................................. 5-5
Alarm ...........................................................................5-3
Display Dump.............................................................. 5-9
All Alarms....................................................................5-9
Display Shortcut .......................................................... 5-8
AMERICAN ..............................................................4-13
Dual Ethernet............................................................. 3-10
Analog Inputs
ANIN.......................................................................4-3
Analog Outputs ............................................................4-4 E
Archived Reports .........................................................5-9 Enter ............................................................................ 5-3
Arrow key ....................................................................5-3 Entering Data............................................................... 5-6
Environmental Considerations .................................... 2-2
B Ethernet LAN Port....................................................... 3-6
Ethernet Port.............................................................. 3-10
Backup
Exponent...................................................................... 5-3
Battery .....................................................................3-3
Exponential Format ..................................................... 5-8
Battery Backup.............................................................3-3
Expt ......................................................................5-3, 5-8
Bit Link ........................................................................3-8
F
C
F Keys ......................................................................... 5-2
Cable ............................................................................3-5
Factory Setup............................................................... 7-3
Change .........................................................................5-3
Figure 1-1. The FloBoss S600 Flow Manager............ 1-2
Changing a Value.........................................................5-6
Figure 1-2. CPU Board............................................... 1-3
Changing Mode............................................................5-7
Figure 1-3. Intelligent I/O Board................................ 1-4
Changing the Fuse........................................................8-5
Figure 2-1. FloBoss S600 System .............................. 2-2
Chng.............................................................................5-6
Figure 2-10. Board Ready for Removal or Final Insertion2-
Clear.............................................................................5-3
9
Clear SRAM.................................................................8-4
Figure 2-2. Removing the Front Panel ....................... 2-3
Cold Start ............................................................. 7-1, 7-3
Figure 2-3. Lift Front Panel........................................ 2-4
COM1 ..........................................................................3-6
Figure 2-4. Remove Connector .................................. 2-4
COM2 ..........................................................................3-6
Figure 2-7. Panel Mount............................................. 2-6
Comm 2........................................................................5-2
Figure 2-8. Unscrewing the Retention Screws ........... 2-8
Communications ..........................................................3-4
Figure 2-9. Using the Pull Tabs.................................. 2-8
Config 600 Lite ............................................................1-5
Figure 3-1. P152 CPU Backplate ............................... 3-1
Config 600 Pro.............................................................1-5
Figure 3-2. P152 CPU Terminations .......................... 3-2
Config Report...............................................................5-9
Figure 3-3. Pin Connections ....................................... 3-5
Constants Log ..............................................................5-9
Figure 3-4. Link Cable ............................................... 3-8
CPU Board ...................................................................3-1
Figure 3-5. Dual Ethernet Communications Card .... 3-10
CPU On-board Connectors ..........................................3-8
Figure 4-1. Backplate ................................................. 4-1
Current Alarms.............................................................5-9
Figure 4-10. Digital Output Schematic (Relay).......... 4-8
Current Report .............................................................5-9
Figure 4-11. Digital Output Schematic (24 V Switched
Indicator) ................................................................... 4-8
D Figure 4-12. Pulse Input Schematic (using EU 12 V P148
Data Mezzanine Card)........................................................ 4-9
Entering ...................................................................5-6 Figure 4-13. Pulse Input Schematic (using US 24 V P148
Data display .................................................................5-5 Mezzanine Card)...................................................... 4-10
Data Pages....................................................................5-5 Figure 4-14. Pulse Output Schematic ....................... 4-10
Default display .............................................................5-8 Figure 4-15. Raw Pulse Output Schematic............... 4-11
Digital Inputs Figure 4-16. Frequency Input Schematic (with IS Barrier
DIGIN ...................................................................4-19 and AC Coupled) ..................................................... 4-12
I R
Initialization .................................................................7-1 Reflash Config File ..................................................... 8-4
Installation ...................................................................2-3 Reflash Firmware ................................................. 7-3, 8-3
Boards .....................................................................2-7 Reinstalling the Front Panel ........................................ 2-7
Panel-Mounted Unit ................................................2-5 Remote Display or PC................................................. 3-6
Preparing .................................................................2-1 Removal
Removing the Front Panel.......................................2-3 Boards..................................................................... 2-7
Tools .......................................................................2-2 RESETTING ............................................................. 7-1
Unpacking ...............................................................2-3 RS-232......................................................................... 3-5
IPL 600 ........................................................................1-5 RS-422 Port................................................................. 3-6
RS-485 Port................................................................. 3-6
J RTD Inputs................................................................ 4-13
Jumpers ........................................................................3-8
S
K Security Code .............................................................. 5-8
Security Dump............................................................. 5-9
Keypad.........................................................................5-2 Send Config File.......................................................... 8-4
Serial Port.....................................................................3-5 Table 4-2. ANIN Pin Connections for SKT-B ........... 4-4
Setup and Wiring .........................................................4-1 Table 4-20. PULSEOUT Pin Connections for SKT-E4-22
Software Table 4-21. Frequency Input Pin Connections for SKT-D4-
Config 600 Lite .......................................................1-5 22
Config 600 Pro ........................................................1-5 Table 4-22. P154 Prover Bit Links........................... 4-23
IPL 600....................................................................1-5 Table 4-23. Node Addressing
SRAM ..........................................................................7-1 Communications Mode Selection......................... 4-23
Clear ........................................................................8-4 Table 4-24. P188 HART Pin Connections (Socket A)4-24
Start..............................................................................7-1 Table 4-25. P188 HART Pin Connections (Socket B)4-24
Startup menu ........................................................ 7-3, 8-2 Table 4-3. D/A Converter Output Pin Connections for
Status/ID Line ..............................................................5-5 SKT-A ....................................................................... 4-5
Table 4-4. DIGIN Pin Connections for SKT-B .......... 4-7
T Table 4-5. DIGIN Pin Connections for SKT-C .......... 4-7
Table 4-6. DIGOUT Pin Connections for SKT-B ...... 4-8
Table 2-1. Mounting Dimensions ...............................2-5 Table 4-7. DIGOUT Pin Connections for SKT-C ...... 4-9
Table 3-1. TB-1 Pin Connections................................3-3 Table 4-8. Dual-Pulse Input Pin Connections for SKT-C4-
Table 3-2. TB-1 Pin Connections................................3-3 10
Table 3-3. Battery Specifications................................3-4 Table 4-9. PULSEOUT Pin Connections for SKT-B4-11
Table 3-4. Communication Ports ................................3-4 Table 5-1. Front Panel Port Connections.................... 5-2
Table 3-5. COM3 and COM4 Pin Connections ..........3-5 Tools............................................................................ 2-2
Table 3-6. COM5, COM6, and COM7 Pin Connections3-6 Troubleshooting
Table 3-7. COM1-2 Pin Connections..........................3-7 Flash Failed............................................................. 8-4
Table 3-8. Miscellaneous Device Connectors for the P152 Turbine Pulse Inputs...........................................4-9, 4-21
CPU Module...............................................................3-8
Table 3-9. CPU Bit Links ...........................................3-9
U
Table 4-1. ANIN Pin Connections for SKT-A............4-4
Table 4-10. Raw Pulse Output Pin Connections for SKT-C Unpack ........................................................................ 2-3
..................................................................................4-11
Table 4-11. Frequency Input Pin Connections for SKT-B4- V
12
Table 4-12. PRT Input Pin Connections for SKT-B .4-14 Value
Table 4-13. .................................................................4-15 Changing................................................................. 5-6
Table 4-14. Multiplex Mode Addressing ..................4-16 View ............................................................................ 5-3
Table 4-15. DIGIN Pin Connections for SKT-E.......4-19
Table 4-16. DIGIN Pin Connections for SKT-F .......4-20 W
Table 4-17. DIGOUT Pin Connections for SKT-E...4-20
Warm Start ...........................................................7-1, 7-3
Table 4-18. DIGOUT Pin Connections for SKT-F ...4-21
Watchdog Relay .......................................................... 3-3
Table 4-19. Dual-Pulse Input Pin Connections for SKT-F
Wiring...................................................................3-1, 4-1
..................................................................................4-21
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