NFE 2923 Q MA 001 - A - Manufacturer's Standard O&M Manual

No.
PO PO15298
SAN JUAN LNG FACILITY
No. DOCUMENT NFE-2923-Q-MA-001
REV. DATE 2023-06-06

METERING SKID
REV. A PAGE 1 OF 685
MANUFACTURER'S STANDARD O&M MANUAL
DOCUMENT N°:
NFE-2923-Q-MA-001
METERING SKID
A 2023-06-06 Issued for Review / Emitido para Revisión DRS ERM MVG
REV. DATE REVISION ISSUED BY CHECKED BY APPROVED BY

No. PO PO15298
REV. DATE 2023-06-06

METERING SKID
Contenido
1. ULTRASONIC FLOWMETER .................................................................................................................. 3
2. FLOW ALIGNER .................................................................................................................................. 280
3. VALVES – 3/4" ..................................................................................................................................... 287
4. VALVES – 8” 600# ............................................................................................................................... 327
5. VALVE WITH ACTUATOR – 8” 600# .................................................................................................. 344
6. FLOW COMPUTER ............................................................................................................................. 517
No. PO PO15298
REV. DATE 2023-06-06

METERING SKID
1. ULTRASONIC FLOWMETER
Operating Manual
Ultrasonic Flowmeter USM GT400
Issued: 07.05.2021
Version: 10
Firmware: 1.5
Contact
Manufacturer Our customer service is available for technical queries:
Address RMG Messtechnik GmbH

Otto-Hahn-Straße 5
D-35510 Butzbach
Telephone Switchboard +49 6033 897 – 0
Telephone Service +49 6033 897 – 0
Telephone Spare Parts +49 6033 897 – 173
Fax +49 6033 897 – 130
E-Mail service@rmg.com
Original Document The Ultrasonic Flowmeter USM GT400 OPERATING

INSTRUCTION 07.05.2021 is the original document.
This document may serve as a reference for translations into

other languages. Please use in case of any uncertainties the
German version as main reference.
Note Unfortunately, paper is not updated automatically, whereas
technical development continuously advances. Therefore, we
reserve the right to make technical changes regarding the rep-
resentations and specifications of these operating instructions.
The latest version of this manual (and other devices) can be
downloaded at your convenience from our Internet homepage:
www.rmg.com
Date created 1/31/2014

…
4th revision date 02/12/2018
Document version Document version Ultrasonic Flowmeter USM GT400

and language manual de May 7th 2021
Language EN
Manual USM GT400 · EN10 · May 2021

Contents
Content
1 ABOUT THIS MANUAL ......................................................................... 1
1.1 Objective of the manual ....................................................................................... 1
I
1.2 Specialized knowledge required ....................................................................... 2
1.2.1 Specialized knowledge required .......................................................................... 2
1.2.2 Abbreviations....................................................................................................... 3
1.2.3 Layout of instructions .......................................................................................... 4
1.2.4 Working with the device ...................................................................................... 5
1.2.5 Risk assessment and minimization ................................................................... 11
1.2.6 Validity of the manual ........................................................................................ 13
1.2.7 Transport ........................................................................................................... 14
1.2.8 Scope of delivery ............................................................................................... 16
1.2.9 Disposal of packaging material ......................................................................... 16
1.2.10 Storage .............................................................................................................. 16
1.3 Explosion-proof design .....................................................................................17
1.3.1 General information ........................................................................................... 17
1.4 Inspection and maintenance work ..................................................................18
1.4.1 General information ........................................................................................... 18
2 QUICK GUIDE ....................................................................................... 20

2.1 Mechanical connection ......................................................................................21
2.1.1 Connection flanges ............................................................................................ 21
2.1.2 Inlet / outlet piping ............................................................................................. 21
2.1.3 Joining pressure connections ............................................................................ 21
2.2 Electrical connection .........................................................................................22
2.3 Start up ..................................................................................................................22
2.4 Earthing .................................................................................................................23
2.5 Parameter setting ................................................................................................24
3 DEVICE OVERVIEW ............................................................................ 25

3.1 Main components................................................................................................25
3.2 Ultrasonic electronics ........................................................................................27
3.3 Arrangement of the ultrasonic transducers .................................................31
4 FUNCTIONAL PRINCIPLE – ULTRASONIC-FLOW

MEASUREMENT .................................................................................. 32

Contents
4.1 General description ............................................................................................ 33

4.2 Correction of the base line ............................................................................... 37
4.2.1 Base line correction via polynomial ................................................................... 38
4.2.2 Correction via a piecewise linearization ............................................................ 39
4.3 Diagnostic function Speed of Sound ............................................................. 40
II 4.3.1 Standard method of SoS calculation ................................................................. 40
4.3.2 SoS calculation via gas components ................................................................ 40
4.3.3 Extended SoS calculation ................................................................................. 41
4.4 Import of gas composition data ...................................................................... 42
4.4.1 Option 4: Data input on fixed defaults ............................................................... 43
4.4.2 Data input on fixed defaults for air .................................................................... 43
4.4.3 Data input via RMGBus .................................................................................... 45
4.4.4 Data via Modbus (USM GT400 is SLAVE) ....................................................... 46
4.4.5 Import of data via Modbus (USM GT400 is Master).......................................... 47
4.5 Batch mode .......................................................................................................... 52
4.6 Signal damping ................................................................................................... 52
5 SAFETY.................................................................................................. 53
5.1 Intended use ........................................................................................................ 54
5.2 Layout of instructions ....................................................................................... 55
5.3 Qualification of the personnel ......................................................................... 56
5.4 Safety instructions ............................................................................................. 57
5.4.1 Hazards during transporting .............................................................................. 58
5.4.2 Hazards during installation ................................................................................ 58
5.4.3 Hazards during start up ..................................................................................... 60
5.4.4 Hazards during cleaning ................................................................................... 61
5.4.5 Hazards during maintenance and repairs ......................................................... 61
5.4.6 Hazards during operation .................................................................................. 62
5.4.7 Hazards for operation in potentially explosive environments ............................ 63
5.5 Responsibilities of the operator ...................................................................... 64
6 TRANSPORT AND STORAGE .......................................................... 65

6.1 Transport .............................................................................................................. 66
6.1.1 Scope of supply ................................................................................................ 66
6.1.2 Transporting the device .................................................................................... 67
6.1.3 Unpacking the device ........................................................................................ 67
6.1.4 Disposal of packaging material ......................................................................... 70
6.1.5 Prior to installation ............................................................................................ 70
6.1.6 Removing the transporting locks ....................................................................... 71

Contents
6.2 Packing the device for transportation............................................................73

6.3 Storage ..................................................................................................................79
6.3.1 Packing the device for storage .......................................................................... 79
6.3.2 Checking the device after storage ..................................................................... 80
7 CONSTRUCTION AND PLANNING .................................................. 81 III

7.1 Connection flanges.............................................................................................81
7.2 Seals .......................................................................................................................82
7.2.1 Flat seal ............................................................................................................. 83
7.2.2 Grooved gaskets ............................................................................................... 84
7.2.3 Spiral seals ........................................................................................................ 85
7.3 Screws ...................................................................................................................87
7.4 Installation possibilities ....................................................................................88
7.4.1 Dependency on the gas flow direction .............................................................. 88
7.4.2 Two devices series connected (Face to Face) .................................................. 91
7.5 Flow computer .....................................................................................................93
8 INSTALLATION .................................................................................... 95
8.1 Assembly work preparations ...........................................................................96
8.2 Installation of the device ...................................................................................99
8.2.1 Mounting the inlet and outlet piping ................................................................... 99
8.2.2 Installation of the connection box .................................................................... 101
8.3 Connecting the device electrically ............................................................... 103
8.3.1 Connecting the power supply .......................................................................... 108
8.3.2 Digital interfaces of USM-GT400 ..................................................................... 108
8.3.3 Connecting the computer for RMGViewUSM ..................................................... 110
8.3.4 Connecting the flow computer ......................................................................... 110
8.3.5 Connection of external DSfG-Device-F via Modbus ........................................ 113
8.3.6 Interface converter .......................................................................................... 124
8.3.7 Connecting the device to earth ........................................................................ 126
8.4 Installing the pressure connection .............................................................. 128
8.5 Outdoor installation ......................................................................................... 130
9 START UP ........................................................................................... 132

9.1 Comparing meter parameters ....................................................................... 132
9.2 Checking functions of the USM .................................................................... 132
9.3 Reading out speed of sound ......................................................................... 133

Contents
10 OPERATION........................................................................................ 134
10.1 Measuring values and parameters ............................................................ 135
10.1.1 Input protection for parameters ....................................................................... 135
10.1.2 Parameter and measuring values with variable units ..................................... 135
10.1.3 Calibration and Service Switch ....................................................................... 136
IV 10.1.4 Interfaces to converters and controllers .......................................................... 136
10.1.5 Interface for service and parameterization ...................................................... 137
10.1.6 Adaptation of the DZU protocol to ERZ 2400 ................................................. 138
10.2 Calling up and changing the parameters via the ultrasonic electronics
139
10.2.1 Calling up the value of a parameter ................................................................ 140
10.2.2 Entering data ................................................................................................... 141
10.2.3 Changing the parameters of protection E and S ............................................. 144
10.3 Parameterize the USM interface ................................................................. 149
10.3.1 Interface 0 ....................................................................................................... 149
10.3.2 Interface 1 ....................................................................................................... 150
10.3.3 Interface 2 ....................................................................................................... 150
10.4 Modbus communication in detail .............................................................. 161
10.4.1 Codes supported ............................................................................................. 161
10.4.2 Data types ....................................................................................................... 161
10.5 Configuration of the current output .......................................................... 163
10.6 List of the measurement values and parameters ................................. 163
11 MAINTENANCE .................................................................................. 164

11.1 Maintenance schedule ................................................................................. 165
11.2 Checking the device for leaks .................................................................... 165
11.3 Checking the device for any signs of damage ....................................... 166
11.4 Changing the battery .................................................................................... 166
11.5 Changing the transducer ............................................................................. 166
11.6 Changing the ultrasonic electronics......................................................... 167
11.7 Cleaning the device ...................................................................................... 167
11.8 Check the official seal .................................................................................. 168
11.9 Decommissioning and disposal ................................................................ 168
12 ALARM AND WARNING MESSAGES ........................................... 170

12.1 Alarm messages ............................................................................................ 171
12.2 Warning messages........................................................................................ 172

Contents
12.3 Notes ................................................................................................................ 175

12.4 Troubleshooting ............................................................................................ 175
13 TECHNICAL SPECIFICATIONS ...................................................... 177

13.1 Performance data.......................................................................................... 178
V
13.2 Approved gas types ..................................................................................... 180
13.2.1 Suitability and safety for natural gas containing H2 ........................................ 180
13.3 Approved measuring range according to MID ....................................... 181
13.4 Type plate ....................................................................................................... 182
13.4.1 Type plate ATEX / IECEx ................................................................................ 183
13.4.2 Type plate NEC (CSA) .................................................................................... 184
13.5 Weights and dimensions ............................................................................ 184
13.5.1 NEC (CSA) ...................................................................................................... 185
13.5.2 ATEX / IECEx .................................................................................................. 186
13.6 Inner diameter of connecting spool pieces ............................................ 189
13.7 Official seal diagram .................................................................................... 192
13.7.1 Type plate........................................................................................................ 192
13.7.2 Ultrasonic electronics ...................................................................................... 193
13.7.3 Ultrasonic gas meter ....................................................................................... 195
13.8 Transducer types .......................................................................................... 197
14 SPARE PARTS AND ACCESSORIES ........................................... 199
15 LISTS OF PARAMETERS AND MEASURED VALUES .............. 201
16 USM GT400 APPROVAL .................................................................. 246

16.1 Metrological approvals ................................................................................ 246
16.2 Pressure devices approval ......................................................................... 246
16.3 Electromagnetic compatibility ................................................................... 246
16.4 Explosion protection approval .................................................................. 246
16.5 Standards, directives and guidelines ...................................................... 247
17 USM GT400 GLOSSARY .................................................................. 249
18 USM GT400 ATTACHMENT............................................................. 250

Contents
VI

1 About this manual
1 About this manual

Content
1
1.1 Objective of the manual 1

1.2 Specialized knowledge required 2
1.2.1 Specialized knowledge required 2
1.2.2 Abbreviations 3
1.2.3 Layout of instructions 4
1.2.4 Working with the device 5
1.2.5 Risk assessment and minimization 11
1.2.6 Validity of the manual 13
1.2.7 Transport 14
1.2.8 Scope of delivery 16
1.2.9 Disposal of packaging material 16
1.2.10 Storage 16
1.3 Explosion-proof design 17
1.3.1 General information 17
1.4 Inspection and maintenance work 18
1.4.1 General information 18
1.1 Objective of the manual

In this chapter you will be given information on this manual.
The manual provides you with the information that is designed for trouble-free and
safe operation.
The ultrasonic gas meter is state of the art and conceived and manufactured ac-
cording to the recognized safety standards and guidelines.
However, risks may arise during use that can be easily avoided by observing this
manual.
For this reason, you may only use the device as intended and in technically sound
condition.
If the ultrasonic gas meter is not used for its intended purpose, warranty claims will
be void.

1 About this manual
1.2 Specialized knowledge required

This manual provides information that is necessary for fault-free and safe opera-
tion.
2
The Ultrasonic Flowmeter USM GT400 was designed and produced according to
the state of the art and generally recognized safety standards and directives. How-
ever, its use can entail dangers that are avoidable by complying with this manual.
The device must only be used as intended and in technically sound condition.
Vorsicht
Unintended use voids all warranty claims and the Ultrasonic Flowmeter
USM GT400 can also lose its approvals.
1.2.1 Specialized knowledge required

Persons working with or on the device must have the following knowledge:
• training / education for working in potentially explosive environments.
• the ability to correctly assess dangers and risks when using the device. Possi-
ble dangers are, e.g., components under pressure or the result of incorrect in-
stallation.
• recognize dangers that could be caused by the used flow medium.
• training / education by RMG for working with gas measuring instruments.
• education / instruction in all country-specific standards and directives to be ob-
served for work that is to be carried out on the device.
Further information can be found under:

Chapter 5.3, „Qualification of the personnel“ on page 56

1 About this manual
1.2.2 Abbreviations
The following abbreviations are used:
AGC Automatic Gain Control 3

ca. circa, approximately
as app. as applicable
max. maximum
MC Measurement Canada
MID Measurement Instruments Directive
min. minimum
SNR Signal to Noise Ratio
SoS Speed of Sound
TD Transducer (ultrasonic transmitter and receiver)
TNG Transducer of a certain production type.
USE Ultrasonic electronics
USM Ultrasonic gas meter
e.g. For example

1 About this manual
1.2.3 Layout of instructions

The following notices are used:
4
Danger
This warning notice informs you of imminently threatening dangers that
can arise due to misuse/operator error. If these situations are not avoided,
death or severe injuries can occur.
Warning
This warning notice informs you of potentially dangerous situations that
can arise due to misuse/operator error. If these situations are not avoided,
minor injuries can occur.
Caution
This notice informs you of potentially dangerous situations that can arise
due to misuse/operator error. If these situations are not avoided, damage
to the device or nearby property can occur.
Note
This notice provides you with helpful tips to make your work easier. This
notice also provides you with further information about the device or the
work process in order to prevent operator error.

1 About this manual
1.2.4 Working with the device

1.2.4.1 Safety instructions Danger, Warning, Caution and Note
5
Danger
All of the following safety notices must be observed!
Disregard of the safety notices can result in danger to the life and limb or
environmental and property damage.
Bear in mind that the safety warnings in this manual and on the device cannot
cover all potentially dangerous situations, because the interaction of various condi-
tions can be impossible to foresee. Merely following the instructions may not suf-
fice for correct operation. Always remain attentive and consider potential conse-
quences.
• Read this operating manual and especially the following safety notices care-
fully before working with the device for the first time.
• Warnings are provided in the operating manual for unavoidable residual
risks for users, third parties, equipment, or other property. The safety in-
structions used in this manual do not refer to unavoidable residual risks.
• Only operate the device in fault-free condition and in observance of the op-
erating manual.
• Compliance with local statutory accident prevention, installation and assem-
bly regulations is also mandatory.
Caution
All notices in the manual must be observed.
Use of the gas chromatograph PGC 9300 is only permitted in accordance
with the specifications in the operating manual.
RMG assumes no liability for damages arising due to disregard of the op-
erating manual.

1 About this manual
Danger
Service and maintenance tasks or repairs that are not described in the op-
erating manual must not be carried out without prior consultation with the
6
manufacturer.
Changes to the device are not permitted.
The technical specifications must be observed and followed for safe oper-
ation (see chapter 13: Technical specifications).
Performance limits must not be exceeded.
Please only use screws, bolts, nuts and seals or parts with comparable
characteristic values for installing the meter in the pipeline. (see chapter 7
Construction and Planning)
For safe operation, the device must only be used in the scope of the in-
tended use. (see chapter 5.1 Intended use).
1.2.4.2 Dangers during commissioning
Initial commissioning The initial commissioning must only be carried out

by specially trained personnel (training by RMG) or
RMG service personnel.
Note
An acceptance test certificate and corresponding test report must be cre-

ated for the commissioning.
These, the operating manual and the CE Declaration of Conformity must
be stored so that they are always readily available. In the process, the en-
tire documentation, including the conformity declarations and certificates
must be checked for completeness.
As far as possible, all sharp edges on the device have been removed. Nev-
ertheless, personal protective equipment must be used for all work, which
must be provided by the operator.

1 About this manual
Danger
This symbol is used in the manual as a warning of the dan-

ger of explosion; observe the instructions following the 7
symbol.
With the danger of explosion, the following must be observed, in particular:

• Install the device as specified in the operating manual. If the device is not
installed as specified in the operating manual, there may be a risk that other
connected devices do not have adequate explosion protection.
The explosion protection is lost!
• Inadequately qualified persons working on the equipment are unable to cor-
rectly estimate dangers. Explosions can be triggered. Only work on the
equipment if you have the appropriate qualifications.
• Components can be damaged if you do not use suitable tools and materi-
als. Use tools that are recommended for the respective work in the operat-
ing manual.
Mechanical installation Mechanical installation must only be performed by ap-

propriately qualified technicians.
Electrical installation Installation on electrical components must only be car-
ried out by qualified electricians.
Mechanical and/or elec- These qualified personnel require training specifically for
trical installation work in explosion-prone areas. Qualified personnel are
persons who have training / education in accordance
with DIN VDE 0105, IEC 364 or comparable stand-
ards.
Danger
Connection of pressurized pipelines must only be carried out by trained
qualified personnel.

1 About this manual
Danger
The installation and removal of the USM GT400 may only take place in a
depressurized state and in an explosion-free atmosphere. During the in-
8
stallation process, the descriptions in the operating instructions must be
observed.
In general, it is recommended to carry out an exchange only in consulta-
tion with RMG Service.
After working on pressure-bearing components, the tightness must be
checked.
All of the above points also apply to repair and maintenance work and gen-
erally when the meter has to be opened.
Flange fastening elements, screw plugs, screw connections and check
valves as well as pressure extraction screw connections, valves and pro-
tective tubes must not be loosened during operation.

1 About this manual
1.2.4.3 Dangers during maintenance and repair
Operating personnel The operating personnel use and operate the device in
the scope of the intended use. 9
Maintenance personnel Work on the device must only be carried out by qualified
personnel who can carry out the respective tasks on the
basis of their technical training, experience and familiar-
ity with the applicable standards and requirements.
These qualified personnel are familiar with the applica-
ble statutory regulations for accident prevention and can
independently recognize and avoid potential dangers.
Maintenance and clean- Maintenance and cleaning must only be performed by
ing appropriately qualified technicians.
Danger
Inadequately qualified persons working on the equipment are unable to

correctly estimate dangers. Explosions can be triggered. If work on live
equipment must be conducted in explosion-prone areas, sparks that are
created can trigger an explosion.
Only work on the equipment if you have the appropriate training and quali-
fications.
Danger
The device can be damaged if it is not cleaned as specified in the operat-
ing manual. Only clean the device as specified in the operating manual.
If you do not use the appropriate tool, components may be damaged. The
explosion protection becomes invalid.
• Only clean the device with a slightly damp cloth!

1 About this manual
Danger
The USM GT400 must only be used as intended! (Chapter 5.1).
10
Danger
Prevent use of the USM GT400 as a potential climbing aid or use of attach-
ments of the USM GT400 as potential handles.
1.2.4.4 Qualifikation of the user

Notice
In general, the following is recommended for all persons working with or on

the USM GT400:
• Training / education for work in explosion-prone areas.
• The capacity to be able to correctly estimate dangers and risks when work-
ing with the gas USM GT400 and all connected devices. Possible dangers
include components that are under pressure and consequences of incor-
rect installation.
• Recognition of dangers that can arise from the flow medium that is used.
• Training / education by RMG for work with gas measuring devices.
• Education / instruction in all national standards and directives to be com-
plied with for the work to be carried out on the USM GT^^400 analytical
computer.

1 About this manual
1.2.5 Risk assessment and minimization

According to assessment by qualified employees of RMG, the USM GT 400 is
subject to risks during its use. Risks can also arise due to high pressures and oc-
casionally due to pressures that are too low. Work outside of the permissible tem- 11
perature range can also lead to dangers. Impermissible current and voltage values
can trigger explosions in explosion-prone areas. The risk assessment requires an
emptying and ventilation of the pipeline for connection of a USM GT 400. Then
and only then it is assured that there is not an explosion-prone gas mixture in the
pipeline. Naturally, work must only be carried out by trained personnel (see chap-
ter 5.3 Qualification of the personnel) who are also trained to recognize suitable
tools and use them exclusively. These risks were summarized alongside develop-
ment and measures were taken to minimize these risks.
Measures for risk minimization:

- All pressurized parts are designed in accordance with AD 2000 rules and regu-
lations, Pressure Equipment Directive, Annex 1
- The complete pressure design has been inspected by TÜV Hessen
- All pressurized parts have been manufactured with a material certificate; there
is an uninterrupted change of batch tracing of pressurized components
- The mechanical properties of all relevant pressurized components have been
subjected to tension tests, notch impact bending tests and hardness tests
- Non-destructive testing was also carried out: X-ray and ultrasonic inspection of
the meter housing for defective points in material, surface crack testing with
magnetic powder and a color penetration process
- Strength tests for components were conducted at 1.5 times the nominal pres-
sure for the pressure testing; the leak testing for the assembly was conducted
at 1.1. times the nominal pressure. Certificates were issued for successfully
passed tests.
- The maximum operating pressure and the permissible temperature range are
specified on the type plate of the device. Operation of the device is only permit-
ted within these specified ranges.

1 About this manual
Danger
The following applies for work in explosion-prone areas (all zones):
12 - Only tools that are approved for Ex Zone 1 are permitted for mainte-
nance and repair tasks. Components can be damaged if you do not
use suitable tools.
The explosion protection is lost.
- Otherwise, work must only be carried out when there is not an ex-
plosive atmosphere.
- The risk of ignition due to impact or friction must be avoided.
- The wiring from and installation of the gas chromatograph PGC 9300
in explosion-prone areas must only be carried out by trained person-
nel in accordance with EN60079-14 and in observance of national
regulations.
- Qualified persons must satisfy the definitions in accordance with
DIN EN 0105 or IEC 364 or directly comparable standards.
- Only trained and instructed personnel are permitted. Work on the
measuring system must only be carried out by qualified persons and
inspected by responsible qualified supervisors.
- Qualified persons have been authorized by the person responsible
for safety of personnel to carrying out such work on the basis of
their training, experience or instruction and familiarity with applica-
ble standards, provisions, accident prevention regulations and sys-
tem conditions. It is essential that these persons are able to recog-
nize and avoid potential dangers in good time.

1 About this manual
1.2.6 Validity of the manual

This manual describes the Ultrasonic Flowmeter USM GT400. The Ultrasonic
Flowmeter USM GT400 is only part of a complete system. The manuals of the
other components of the system must be observed, too. If you find contradictory 13
instructions, contact RMG and/or the manufacturers of the other components.
Caution
Ensure that the power data of the current connection matches the specifi-
cations on the type plate. Observe any applicable national regulations in
the country of use. Use cable that is appropriate for the cable fittings (see
chapter 8.3 Connecting the device electrically).
Danger
Only work on the equipment if you have the appropriate training and quali-
fications.
1.2.6.1 Danger during operation

Observe the specifications of the system manufacturer and/or system operator.
1.2.6.2 Dangers of operation in EX areas

Danger
Only use the ultrasonic flowmeter USM GT 400 in its original condition.
• Only operate the USM GT 400 in fault-free and complete condition. If you make
technical changes to the device, safe operation can no longer be guaranteed.
• When connecting additional measuring components or additional equipment in
explosion-prone areas, ensure that the appropriate explosion protection is pro-
vided for these components.
• They are intrinsically safe devices for which galvanic isolation must be provided
with connection of these devices.

1 About this manual
The USM GT 400 is permitted for operation in Ex Protection Zone 1, but only
within the permissible temperature range (Chapter 13: Technical specifications).
14
1.2.6.3 Responsibility of the operator
As the operator, you must ensure that only adequately qualified personnel work on
the device. Ensure that all employees who work with the device have read and un-
derstood this manual. You are also obligated to train personnel regularly and in-
form them of the dangers. Ensure that all work on the device is carried out exclu-
sively by qualified persons and inspected by responsible qualified supervisors. The
responsibilities for installation, operation, fault rectification, maintenance and
cleaning must be clearly regulated. Instruct your personnel with regard to the risks
involved with working with the device.
Suitable personal protective equipment must be used for all work on the USM
GT400, which you as the operator must provide. This also applies even though all
sharp edges on the device have been removed as far as possible.
1.2.7 Transport
The device is packaged specific to the transport requirements for each customer.
Ensure safe packaging that absorbs light impact and vibrations is used for any fur-
ther transport. Nevertheless, inform the transport company that all types of impact
and vibrations should be avoided during transport.
The following applies in particular to transport:

• Shocks and vibrations are to be avoided
• Protect the USM GT400 from moisture
• If you suspect improper transport or damage during transport, please contact
RMG's service department immediately

1 About this manual
Warning
Risk of injury during transport
Any foot screws must be mounted if they are provided as a transport safe- 15
guard to prevent rolling and tipping. Additional measures must be taken to
ensure that impermissible rolling and tipping are prevented.
Only use the provided lifting eyes / ring screws to lift the meter. Please ob-
serve the relevant permissible loads for the lifting equipment. Prior to lift-
ing, ensure that the load is securely fastened. Do not stand under sus-
pended loads.
The device can slip, topple over or fall down when being lifted and set
down. The device can fall over if the bearing capacity of the lifting equip-
ment is disregarded. There is a risk of severe injury for nearby persons.
If the device is delivered on a Euro pallet, the device can be transported
on the pallet using a pallet truck or forklift.
The gas meters and accessories must be protected from jarring and vibra-
tions during transport.
The gas meters or any inlet/outlet pieces have a flange as an end piece.
The flanges are sealed with a protective sticker or fitted with a plastic
dummy plug. The protective stickers and/or dummy plugs must be re-
moved without leaving any residue prior to installation in the pipeline.
Residue from this film changes the flow and causes measuring errors!
This protection must be re-applied to the flanges for transport or storage
of the device.

1 About this manual
1.2.8 Scope of delivery

The scope of delivery can differ depending on the optional orders. The following is
"normally” included in the scope of delivery:
16
Part Quantity
Ultrasonic Flowmeter USM GT400 1
Manual 1
Test log 1
Calibration certificate 1
Material test certificate 1
Strength test certificate 3.1 optional
1.2.9 Disposal of packaging material

Dispose of the material in an environmentally friendly manner in accordance with
national standards and directives.
1.2.10 Storage
Avoid extended periods of storage. After storage, inspect the device for damage
and test for correct function. Contact the RMG service department to arrange for
inspection of the device after a storage period of longer than one year. For this
purpose, return the device to RMG.
If storage is nevertheless necessary, the following must be observed:
• Storage must take place in a dry and protected room.

• It must be ensured that all open pipes are sealed.

1 About this manual
1.3 Explosion-proof design

1.3.1 General information
17
Danger
The USM GT400 is permitted for installation in explosion-prone areas in Zone 1 that
are endangered by gas and vapor assigned to explosion group IIB+H2 and tempera-
ture class T6.
ATEX – Zulassungsnummer: BVS 14 ATEX E 034 X
Code: II 2G Ex de IIB+H2 T6 Gb
The device conforms to the requirements of Directive 94/9/EC.
The applicable regulations must always be observed during installation and opera-
tion. The device is approved for operation in hazardous areas. The permitted elec-
trical data can be found in chapter 8.3 Connecting the device electrically.
Danger
Risk of destruction by body electricity, e.g. due to friction of clothing - ap-
propriate protective clothing must be worn.
Notice
During installation, it must be ensured that the enclosure protection class
is observed. Direct sunlight must be avoided.
The USM GT400 complies with protection class IP66 due to EN 60529.

1 About this manual
Temperature range
MID:
-20°C bis +55°C (Umgebungstemperatur, für eichamtliche Messung)
18
Nach ATEX:
-40°C bis +80°C
Notice
In case of doubt, the limited range of the MID applies: -25°C to +55°C
(optional -40° bis +55°C)
1.4 Inspection and maintenance work

1.4.1 General information
Explosion-proof electrical control units must be regularly maintenanced. The time
intervals of this maintenance depend on the operating and environmental condi-
tions.
Notice
We recommend at least one check per year (e.g. in connection with the an-
nual calibration).
This chapter provides information on how you can extend the service life of the de-
vice through maintenance. You can only protect the device from premature wear if
you adhere to the maintenance interval described here.
Danger
Work on live electrical equipment is generally prohibited in hazardous ar-
eas (except for intrinsically safe circuits).
In special cases, work can also be carried out on live electrical equipment in haz-
ardous areas if it is ensured that no potentially explosive atmosphere is present.
This may only be done with explosion-proof, approved measuring instruments.

1 About this manual
Danger
If access to electrical modules is necessary, the following precautions
must be taken: 19
• The entire device must be disconnected from the power supply.
• When working with electronic assemblies, a connection must be
established between an earthed object and the body.
Notice
Pay attention to accumulation of water in the housing, because the explo-
sion-proof housing is only conditionally protected from water by the gap
protecting against ignition sparks (IP54).
Rusted or corroded gaps must not be cleaned with grinding materials or
wire brushes; chemical means must be used, such as reducing oils. Then
acid-free anti-corrosive agents, such as ESSO RUST BAN 397, Mobil Oil
Tecrex 39 or equivalent products must be applied to the gaps for protec-
tion.
Danger
The seal for the Ex-e housing must be inspected for damage and replaced
as necessary.
Check cable connections and sealing plugs for tight seating.
Damage to the housing can negate the Ex protection!
If the device is repaired regarding a part which depends on explosion protection, it

may only be put back into operation after it has been checked by a certified expert
(section 1.2.4.4 Qualifikation ).
If repairs are carried out by RMG service, no acceptance by an expert is required.

2 Quick guide
2 Quick guide
This chapter does not replace the rest of the operating instructions. It shows only a
20 brief section of the steps necessary in order to make the device ready for
operation.
The chapter is only directed at experienced users.

• Observe the chapter safety.
Section 5, “Safety” on page 53
Detailed information for this content can be found under:

Section 7, “Construction and Planning” on page 81
Section 8, “Installation” on page 95
Section 9, “Start Up” on page 132
Section 12.4, “Troubleshooting” 175
Danger
This chapter is only intended for experienced users!

It does not replace all safety instructions that are primarily listed in the
first part of the manual but can also be found in the remaining chapters.
Moreover, use of this chapter “Quick guide” requires that the experienced
user is familiar with all of these safety instructions and implements them
when working with the device.
RMG rejects liability for any damage to the device or other connected de-
vices if a user disregards even one of the safety notices in the overall
manual because of this chapter “Quick guide”. This also applies to safety
instructions to which reference was only made in this manual but were not
explicitly listed.

2 Quick guide
2.1 Mechanical connection

2.1.1 Connection flanges
1 Make sure that the device and the connection flange have the same pressure 21
rating / flange standards.
2 Make sure that the device is sealed with the appropriate seals.
2.1.2 Inlet / outlet piping

Operating mode Inlet piping Outlet piping Temperature sensor
position
Unidirectional operation 10 D (no flow condi- 3D 1,5 D to 5 D
tioner)
Unidirectional operation 3 / 5 D (with RMG or 3D 1,5 D to 5 D
standardized flow condi-
tioner)1
Bidirectional operation 10 D (no flow condi- 10 D (no flow condi- 3 D to 5 D
tioner) tioner)
Bidirectional operation 3 / 5 D (with RMG or 3 / 5 D (with RMG or 2 D zo 5 D1
standardized flow condi- standardized flow condi-
tioner)1 tioner)1
1 Depending on the nominal width.
See also “Inner diameter of connecting spool pieces” on page 189
2.1.3 Joining pressure connections
◼ Establish connection with the clamping screw connection.

3 Unscrew the union nut of the clamping screw connection.
4 Remove the blind plug.
5 Push the union nut and clamping rings onto the pipe.
6 Push the pipe into the clamping screw connection until the stop.
7 Tighten the union nut in order to fix and seal the pipe.
◼ Establish connection with the female thread.

8 Unscrew the blind plug.
9 Seal the connection in the thread.

2 Quick guide
2.2 Electrical connection
22
1 Terminal Connections
Fig. 2.1: Connection assignment on the terminal strip
10 Connect the computer to the terminals RS 485-0.

11 Allocate the terminal strips according to the applications.
Option: connect ERZ 2000 (-NG) to RS 485-1.
You find recommended cable types in the chapter 8.3 Connecting the device electri-
cally.
2.3 Start up
12 Supply the device with power supply (24 V DC) via the system.
If the power LED illuminates green permanently, the device is ready for
operation.
If the alarm and warning LED do not flash, the device operates trouble-free.
Section 3.2, "Light emitting diodes" on page 30
The USM-GT-400 is supplied without connection box to the North American

region, the connection is made to cables that are led through a flame arrester.
The marking of the cable (numbers) is (always) identical to the terminal as-
signment.

2 Quick guide
2.4 Earthing
23
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 2.2: Earthing – Ultrasonic gas meters DN100 (4”) and DN150 (6”)
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 2.3: Earthing – Ultrasonic gas meters ≥ DN200 (8”)
13 Connect the earthing cable according to the ultrasonic gas meter version
DN100 (4") to DN150 (6") or from DN200 (8").

2 Quick guide
2.5 Parameter setting

The device shall be supplied pre-assembled according to customer agreement.
Changes to the pre-assembly are more extensive and are therefore not described
24
in this brief instruction. If this should be necessary, you will then find the descrip-
tion:
Section 10.1.3, “Calibration and Service Switch” on page 136

3 Device overview
3 Device overview
In this chapter you will receive information on the main components
of the ultrasonic gas meter and the arrangement of the 25
ultrasonic transducers in the housing of the ultrasonic gas meter.
Content
3.1 Main components 25

3.2 Ultrasonic electronics 27
3.3 Arrangement of the ultrasonic transducers 31
3.1 Main components
1 Covers of the transducer and transducer lines

2 Covers of the transducer
3 Ultrasonic electronics
4 Lifting eyes
5 Joining flanges
6 Transducer
7 Retaining bolts
Fig. 3.1: Main components of the ultrasonic gas meter

3 Device overview
The ultrasonic gas meter consists of the following main components:
Covers of the transducers (1 and 2)

26 The covers protect the connections and the lines of the transducer (TD) against
contamination and mechanical damage.
Ultrasonic electronics (3)
The ultrasonic electronics is in a pressure tight, encapsulated housing mounted on
the ultrasonic gas meter. The ultrasonic electronics evaluates the data recorded by
the transducers. In addition to the display, the parameters can be shown and eval-
uated on a computer using the RMGViewUSM software.
Lifting eyes (4)
The lifting eyes can be used to safely transport the device using a suitable lifting
gear.
Connection flange (5)
The device is bolted onto the gas line using the connection flanges.
Transducer (6)
The transducers are installed in the housing of the ultrasonic gas meter and are
not visible once installed.
Retaining bolts (7)
The retaining bolts are mounted when delivering the device. The retaining bolts
secure the product from tipping over or rolling away. The bolts must be mounted to
ensure for a safe installation or de-installation.

3 Device overview
3.2 Ultrasonic electronics
27
1 Service- and calibration switch

2 Control panel
3 Display
4 Magnet for operation
5 Cover with viewing window
6 Pressure tight housing
Fig. 3.2: Ultrasonic electronics and display
Device data (readings and parameters) can be set and evaluated via the display
and the operating elements.
Moreover, the device data (readings and parameters) can also be shown, evalu-
ated and set using the RMGViewUSM software.
Service and calibration switch (1)

The service switch (right switch) is only for RMG service. The service switch is,
e.g., used to install new firmware.
The calibration switch (left switch) protects the parameters against unauthorized
changes. The device can be configured by opening the calibration switch.
Control panel (2)
The control field comprises buttons that are triggered by pressing a button or mag-
netically. Parameters, readings, warning, alarm and status messages are called up
using the button.
Display (3)
The display shows the readings, warning, alarm and status messages as well as
the parameters.
Magnet for operation (4)
The magnet is used to operate the control panel of the ultrasonic electronics when
the housing is closed. If the magnet is placed above the symbol on the viewing
window, this function is activated.

3 Device overview
Cover with viewing window and pressure tight housing (5 and 6)

The cover and the pressure tight housing encapsulate the ultrasonic electronics
against the potentially explosive atmosphere.
28 During operation, information can be read through the viewing window from the
display and status indicators of the LEDs.
Electrical connection (Terminal strip)
More information on the electrical connection can be found here:
Chapter 8.3, „Connecting the device electrically“ on page 103
Display screen
Fig. 3.3: Ultrasonic electronics display
First line
Shows the name of the parameter (coordinates) called-up, e.g., p-maximum value
(maximum pressure value).
Second line
Shows the value of the parameter (coordinates) called-up, e.g., 52.00 bar a.
Third line
Shows the coordinate designation, e.g., A-06, thus column A, line 06.
The calibration switch is open. The value of the parameter can be

changed.
The calibration switch is closed. The value of the parameter cannot

be changed.
Forth line
Shows the warning, alarm and status messages, e.g., -01 power failure.

3 Device overview
Buttons
When the cover is closed, the buttons can be operated through the glass using the
magnet supplied. The cover must not be opened.
29
Change to the columns. Jump, e.g., from A to B and back again.
When holding for a longer time, you can change the columns by quickly
scrolling back.
When holding for a longer time, you can change the columns by quickly
scrolling back.
When holding for a longer time, you can change the lines quickly scrolling
forward.
Change or scroll back in the lines step by step, e.g., from A-01 to A-02.
When holding for a longer time, you can change the lines with quick return.
Enter values.
Reset button
1 The reset button (1) is for RMG service only. If the reset
button is pressed, the ultrasonic electronics is restarted.
Switches
1 Calibration switch: Activate to change parameters.

2 Service switch: For RMG service only. For installing a new firm-
ware.

3 Device overview
Light emitting diodes
30
1 Flow 6 Calibration
2 Power (calibration switch state)
3 Alarm 7 Service
4 Warning (service switch state)
5 Reset 8 Button states
Fig. 3.4: LEDs of the electronic ultrasonic electronics
LED Illuminates flashing

continuously
Voltage supply is ---
Power
switched on
Flow Gas flow present. ---
Alarm message is Alarm is active.

Alarm
stored.
Warning message is Warning is active.
Warning
stored.
Reset is running. ---
Reset
Calibration switch is ---

Calibration
open.
Service switch is open. ---
Service
---
Control panel Panel is being pressed.

3 Device overview
3.3 Arrangement of the ultrasonic transducers
31
1 Level 1
2 Level 2
3 Level 3
4 Path 1 and 2
5 Path 3 and 4
6 Path 5 and 6
Fig. 3.5: Transducer paths and levels of the ultrasconic gas meter
The figure shows the arrangement of the transducers that are located in the
ultrasonic gas meter. The arrangement of the transducers in the three levels is
shown in three section representations.
Four transducers are installed per level. The transducers form two paths per level
for the measurement.

4 Functional principle – Ultrasonic-flow measurement
4 Functional principle – Ultrasonic-

32
flow measurement
Content
4.1 General description 33

4.2 Correction of the base line 37
4.2.1 Base line correction via polynomial 38
4.2.2 Correction via a piecewise linearization 39
4.3 Diagnostic function Speed of Sound 40
4.3.1 Standard method of SoS calculation 40
4.3.2 SoS calculation via gas components 40
4.3.3 Extended SoS calculation 41
4.4 Import of gas composition data 42
4.4.1 Option 4: Data input on fixed defaults 43
4.4.2 Data input on fixed defaults for air 43
4.4.3 Data input via RMGBus 45
4.4.4 Data via Modbus (USM GT400 is SLAVE) 46
4.4.5 Import of data via Modbus (USM GT400 is Master) 47
4.54.5 Batch modeBatch mode 52

4.1 General description

In this chapter, you are provided with information as to how the ultrasonic gas
meter records the data. The necessary formulas are listed for this purpose.
33
Figure 4.1 shows the general working principle. Transducer TD1 and TD2 are
positioned opposite to each other for the measurement and form a measurement
path with distance L. An ultrasonic pulse travels along the measuring path from
sensor TD1 to transducer TD2 more quickly than the other way around. This is
caused physically by vector addition of the flow velocity to the speed of sound, the
arrow above the ṽ shows the direction of flow.
Fig. 4.1: Two sensors form one path for the measurement
The transit time from TD1 to TD2 (:= tTD12 ) and from TD2 to TD1 (:= tTD21 )
re calculated according to the following formula:
Formulas
𝐿 𝐿
𝑡𝑇𝐷12 = 𝑡𝑇𝐷21 =
𝑐0 + 𝑣̅ · 𝑐𝑜𝑠𝛽 𝑐0 + 𝑣̅ · 𝑐𝑜𝑠𝛽
These transit times of the ultrasonic pulses are determined by the electronic
ultrasonic system. These are used to determine the average velocity ṽ along the
measuring path:
Formula, average path velocity

𝐿 1 1
𝑣̅ = ∙( − )
2 ∙ 𝑐𝑜𝑠𝛽 𝑡𝑇𝐷12 𝑡𝑇𝐷21
𝐿2 𝑡𝑇𝐷21 − 𝑡𝑇𝐷12 𝐿2 𝛥𝑡
𝑣̅ = ∙ = ∙
2 ∙ 𝑑 𝑡𝑇𝐷12 ∙ 𝑡𝑇𝐷21 2 ∙ 𝑑 𝑡𝑇𝐷12 ∙ 𝑡𝑇𝐷21

Legend
v̄ Average flow velocity
34 c0 Speed of sound
β. Path angle to the pipe
L: Path length
d: Diameter D
(For a center path. Outer paths have a corresponding value.)
For this calculation, it is important that only the transit times and the device param-
eters such as the transducer distance and the angle of the measuring path to the
flow direction are required. All parameters that include a gas dependency are
omitted.
In order to consider the average flow profile, in particular an asymmetrical or swirl-

affected flow, a total of 6 paths is measured in 3 levels with the USM-GT-400 ultra-
sonic gas meter. The 3 levels can be derived mathematically via an integration
procedure, the so-called Gauss integration.
„Arrangement of the ultrasonic transducers" on page 33
The respective average path velocities (designated with vi = v̄i for the respective
measuring path i) along these measuring paths results analogically to the formula
above.
Under certain conditions such as, e.g., smaller deviations from the tolerances
during the production, it may be necessary to correct the path velocities with a
common factor:
vki = k vi
Legend
vki = Corrected path velocity (m/s)
k = Correction factor for the path velocities

(This factor is named vw factor d1 for the forward
direction and vw factor d2 for back-flow; see pa-
rameter list)

Thus, one obtains for the average flow velocity:

v
vw = ∑ wi ∙vki
35
i=1
Flow velocity
Legend
vw = Average flow velocity (m/s)
wi = Weighting factor with regard to the flow profile
The summation and the weighting specified result from the mathematic Gaussian
integration procedure.
Quality of installation
The USM-GT-400 provides parameters that allow a rating of the installation. If the
values are within given ranges, then good measurement conditions can be as-
sumed. If the values are outside the accuracy of the reading may be affected by
disturbed flow conditions. Please contact in this case the RMG service.
"Manufacturer" on page I
Turbulence
Due to the actual flow, in particular the turbulence, there will be

characteristic variations (variance σi ) of the individual path velocities
(i = 1..6; number of ultrasonic measuring paths), which
allow an assessment of the installation. The ultrasonic path averaged
turbulence (Tui ) is calculated as follows:
𝑁
1
𝜎𝑖 = √ ∑(𝑣𝑗,𝑖 − 𝑣̅𝑖 )2 ˄ 𝑖 = 1. .6; 𝑁 = 20
𝑁−1
𝑗=1
Variance
𝜎𝑖
𝑇𝑢𝑖 =
𝑣̅𝑖
Turbulence

Legend
v̅i = Time averaged flow velocity along the ultrasonic path
36 v̅j,i = Flow velocity along the ultrasonic path
N = N = number of measured values according to parameter

E-9 “moving average cnt”. For a significant determination
of turbulence, the number should be at least 10.
Typical values at very good flow conditions for middle paths are at 2-3%, for the
outer paths, the turbulence increases to 4%. If these values are above 10%, then
disturbed conditions can be assumed affecting the measurement accuracy. At
lowest velocities the turbulence calculation is switched off.
Profile and symmetry factor
For a fully developed flow the middle path (3 + 4) have the highest velocity, the
two outer paths (1 + 2; 5 + 6) are more or less equal. The profile factor ( PF ) is
typically between 1.05 to 1.20; at values below 1.00 or above 1.50, the flow condi-
tions should be checked.
2(𝑣̅3 + 𝑣̅4 )
𝑃𝐹 =
(𝑣1 + 𝑣̅2 ) + (𝑣̅5 + 𝑣̅6 )
Profile factor
The symmetry factor ( SY ) usually is between 0.9-1.10; at values below 0.75 or

above 1.25 the flow conditions should be checked.
(𝑣̅5 + 𝑣̅6 )
𝑆𝑌 =
(𝑣1 + 𝑣̅2 )
Symmetry factor
Meter performance
This value ( MP ) indicates whether the velocity of all ultrasonic paths could be
measured and involved in the flow calculation. It is calculated on base of the last
20 measurements (same as turbulence).
∑1..100 ∑𝑖=1..6 1(˄𝑣𝑗,𝑖 = 𝑜𝑘)˅0(˄𝑣𝑗,𝑖 ≠ 𝑜𝑘)

𝑀𝑃 =
600

The highest value is 100%; under normal conditions it is above 95%. Since 2
measurement paths can fail before the USM-GT-400 loses its calibrated accuracy,
the value may drop down to 66%; if the path failure is caused by a defect trans-
ducer
an immediate repair of the failed transducers should be initiated. 37
All of these values are given at the display of the USM-GT-400; they are identical
to the values in the RMGViewUSM.
4.2 Correction of the base line

Correction of the baseline for the velocity
There are several influences (e.g. Reynolds number) resulting in a not exactly pro-
portional relation between the measured and according to the formula 4.5 calcu-
lated mean velocity to the exact mean velocity. Here the following correction helps
to compensate these variations:
Formula, corrected average flow velocity

𝐹
𝑣𝑤𝑘 = 𝑣𝑤 ∙ 𝐾𝑣 ∙ (1 + )
100
Legend
vwk = Corrected average flow velocity (m/s)
Kv = Meter factor
F = Error from the characteristic curve correction
These values can be used to calculate the process volume flow rate respectively
the corrected process volume flow:
Formula, process volume flow

𝐷𝑖2 𝑠
𝑄𝑚 = 𝑣𝑤 ∙ 𝜋 ∙ ∙ 3600 ∙
4 ℎ
Formula, corrected process volume flow
𝐷𝑖2 𝑠
𝑄𝑚𝑘 = 𝑘𝑘 ∙ 𝑣𝑤𝑘 ∙ 𝜋 ∙ ∙ 3600 ∙
4 ℎ

Legend
Qmk = Corrected process volume flow
38 vwk = Corrected weighted flow velocity
Di = Inside pipe diameter
Kk = Characteristic curve correction
A 4th degree polynomial permits the so-called basic correction of the device:
4.2.1 Base line correction via polynomial

Formula - Basic correction of the device
𝐾𝑜𝑛𝑠𝑡 − 𝐺𝑚2 𝐾𝑜𝑛𝑠𝑡 − 𝐺𝑚1
𝐹1 = + + 𝐾𝑜𝑛𝑠𝑡 − 𝐺0 + (𝐾𝑜𝑛𝑠𝑡 − 𝐺1 ) ∙ 𝑣𝑤 + (𝐾𝑜𝑛𝑠𝑡 − 𝐺2 ) ∙ 𝑣𝑤2
𝑣𝑤2 𝑣𝑤2
Legend
F1 = Deviation of the error curve (%)
vw = Average flow velocity (m/s)
const-Gx = Constants of the basic correction

(x=m2, m1, 0, 1, 2)
The constants const-Gx (x = m2, m1, 0, 1, 2) are calculated from the measured
value pairs of the deviation with the respective flow velocity. The calculated correc-
tion F1 is used for the corrected average flow velocity for F in the formula above.
Formula, corrected meter factor

𝐹 𝐹1
𝑣𝑤𝑘 = 𝑣𝑤 ∙ 𝐾𝑣 ∙ (1 + ) → 𝑣𝑤 = 𝑣𝑤 ∙ 𝐾𝑣 ∙ (1 + )
100 100
The process volume flow and the corrected process volume flow result, as listed
above, from the multiplication of the corresponding velocities with the pipe cross-
section. The correction formulas above are therefore accordingly easy to transfer
to the volume flows.
Polynomial
The characteristic curve correction is also carried out via a 4th degree polynomial
that represents the error curve of the device.

Formula error equation

𝑐𝑜𝑛𝑠𝑡 − 𝑚2 𝑐𝑜𝑛𝑠𝑡 − 𝑚1
𝐹2 = 2 + + 𝑐𝑜𝑛𝑠𝑡 − 0 + (𝑐𝑜𝑛𝑠𝑡 − 1) ∙ 𝑄𝑏 + (𝑐𝑜𝑛𝑠𝑡 − 2) ∙ 𝑄𝑏2
𝑄𝑏 𝑄𝑏
39
Legend
F2 = Deviation from the error curve (%)
Qb = Flow (m/s)
const-n = Constants
The constants Konst-n (n = m2 bis n = 2) are calculated from the measured value
pairs error F2i and flow Qbi. The characteristic curve correction Kk is used for fur-
ther calculation of the corrected process volume flow.
Formula characteristic curve correction

1 + 𝐹2
𝐾𝑘 = (1 + )
100
4.2.2 Correction via a piecewise linearization

The correction of the base line with a polynomial described in section 4.2.1 takes
into account the typical, characteristic curve of the USM-GT-400 in an ideal way.
This correction is recommended for custody transfer metering in all countries
where the MID is valid. Nevertheless, a comparable accuracy can be achieved
with a piecewise linearization, if a sufficient number of interpolation points are
used. Between the interpolation points, a simple linear interpolation is used. The
correction of the base line with the piecewise linearization may also be used in all
countries where the MID is valid if the error curve of the raw data meets the re-
quirements of the ISO 17089.
In order to achieve a sufficient accuracy most of the measuring points should be

placed in the relevant flow rate range. To take into account the higher gradient of
the curve at lower flow rates the intervals should not be equidistant; recommended
are more
points in this lower flow rate range.

4.3 Diagnostic function Speed of Sound

The USM-GT-400 can calculate the SoS in 3 different ways.
40
4.3.1 Standard method of SoS calculation
The first calculation is realized with help of the transit time tTD12 and tTD12 of the ul-
trasonic pulses (see above) along the measuring path with the length L . It is
straight forward to result in the speed of sound SoS or c0 to:
Calculation of SoS
𝑆𝑜𝑆 = 𝑐0
𝐿 𝑡𝑇𝐷12 +𝑡𝑇𝐷21
= ∙
2 𝑡𝑇𝐷12 ∙𝑡𝑇𝐷21
This first option is pretty fast and is almost permanently "online" available.
4.3.2 SoS calculation via gas components

The second version of SoS calculation uses pressure, temperature and composi-
tion of the gas to determine the SoS according to the specifications of the AGA 10
standard (AGA Report No. 10, Speed of Sound in Natural Gas and Other Related
Hydrocarbon Gases; January 2003; AGA - American Gas Association). The calcu-
lation is based on statistical considerations of thermodynamics; since it is very
complex, it will not be presented here. Knowing the gas composition precisely val-
ues such as density, sound velocity and other gas properties can be calculated
with very high accuracy.
Depending on the type of gas analyzer it may take 5-10 minutes to determine the
volume fractions of the individual gas components accurately. Accordingly, the
precise allocation of flow to the gas composition can be done in this time frame
only.
Diagnostic function SoS

The USM-GT-400 determines with highest accuracy the flow rate of the gas flow-
ing through it. For the payoff the gas quality, respectively the calorific value of the
gas resulting from the gas composition is of course of big interest, too. The USM-
GT-400 allows a second billing of the volume flow rate with the "right" gas compo-
sition, ie the "right" calorific value.
This temporal resolution can be achieved receiving permanently the gas composi-
tion data from a gas analyzer. A comparison of the two differently calculated SoS‘s
in the USM-GT-400 allows the immediate detection of any deviation; in particular,
another gas composition results in a different SoS. A confirmation of another gas
composition then provides the next comparison with the data of the gas analysis
instrument.

The temporal correlation of the actual gas composition (using the SoS calculated
via the gas composition) to the SoS using method 1 results in the higher temporal
resolution for the gas composition, respectively the calorific value.
41
4.3.3 Extended SoS calculation

The third possibility SoS calculation is presented under the name "Extended SoS
measurement". This new method is introduced as an additional determination.
Fig. 4.2: Extended SoS calculation
Transducer TD2 receives at first the ultrasonic pulse (light blue) coming from TD1
at the time (tTD12). This pulse is partially reflected and moves back to TD1 (dark
blue). There this pulse is reflected, too and reaches TD2 (red) again after the time
(tTD12 21 12). The differences of tTD12 21 12 and tTD12 results in a new possibility to cal-
culate SoS:
Calculation of extended SoS
𝑆𝑜𝑆 = 𝑐0
𝐿 𝑡𝑇𝐷12 +𝑡𝑇𝐷21
= ∙
2 𝑡𝑇𝐷12 ∙𝑡𝑇𝐷21
𝐿 (𝑡𝑇𝐷12 21 12 −𝑡𝑇𝐷12 )
= ∙
2 𝑡𝑇𝐷12 ∙(𝑡𝑇𝐷12 21 12 −2∙𝑡𝑇𝐷12 )
Due to a 10-times smaller variance of the SoS calculation this method offers signif-
icantly more accurate result compared to the standard method (version 1). There
are 2 reasons for this result; first, the transmitter / receiver error is eliminated (es-
pecially TW; the transit time of the pulse in electronic and transducer is different in
the individual transducers) and secondly, any flow turbulence in medium has low-
est influence to the transit time (the time interval between tTD12 and tTD21 is as short

as possible). Having typical measuring conditions, this method can easily be ap-
plied, but there are conditions at which this method may fail.
The SoS calculation according to method 1 and 3 run simultaneously and con-
42 trolled using the same criteria. If correct, the result of the extended measurement
is preferred due to its higher accuracy. Otherwise, the standard method 1 is used;
after any change the measurement conditions, both methods are revalued again. If
correct the extended SoS calculation will be chosen again.
TW-setting
Measurement tolerances and/or errors of the standard method are permanently
controlled using the comparison with the expanded method. Having both values a
correction for TW can be determined. When the calibration switch is open, the TW-
value of the standard measurement can be corrected to the value of the extended
measurement. This is an important adjustment help in case of a transducer re-
placed, but also serves as an accurate path lengths determination between the
transducers during the dry calibration.
4.4 Import of gas composition data

To use the diagnostic function SoS, respectively to calculate it from the gas com-
position the USM-GT-400 requires the volume fractions of the individual gas com-
ponents in the gas (up to 21 components), the pressure and the temperature.
From these data SoS is calculated using the guidelines of the AGA 10 standard.
For the data transfer of the gas components four options are available:
Fig. 4.3: Import of gas composition data

4.4.1 Option 4: Data input on fixed defaults

If there are no live data available for the gas analysis, then the gas data can be
stored as fixed values in the USM-GT-400. For the AGA-10 calculation these de-
fault values are used as fixed gas shares (AX-20 - AX-44; in chapter 10 the matrix 43
notation of parameters, measured values and variables will be explained). To
change these values, they have to be confirmed by selecting “Accept new Comp.”
in parameters AX-11 and to be confirmed in “takeover gas components”. Only
then they will be taken over as new values for the AGA-10 calculation.
1. Parameter AX-01 “AGA-10 Source”

Default data
2. Setting of the default values of the individual gas components
Parameter AX-20 to AX-44
Methane default value ....
....
Propene default value
3. Takeover with parameter AX-11 “AGA-10 Source”
“Taking over new components”
4.4.2 Data input on fixed defaults for air

In mode “default air” fixed values of air composition for the gas analysis can be
used. With the additional parameter "rel. humidity" in AX-06 the water content and
component is calculated in mol-% and the remaining components of the air are
normalized to 100%. The unnormalized default values for air are:
Nitrogen: 78,105 mol-%
Oxygen: 20,946 mol-%
Argon: 0,916 mol-%
Carbon dioxide: 0,033 mol-%
Water: 0,0 .. mol-% (calculated)
The water content is calculated via the relative humidity.
1. Parameter AX-01 “SoS source”:
“Default air”
2. Setting of the default values relative humidity
Parameter AX-06 “relative humidity”

All other possibilities to transmit the volume fractions of the individual gas compo-
nents on the USM-GT-400, will use interface 2 of the USM-GT-400.
Terminal connections
44
The following figure shows the terminal connections.
1 Terminal connections
2 COM
3 Gas-Chromatograph
Fig. 4.4: Terminal connections
The SoS calculation depends in addition to the gas components also on the gas
pressure and temperature. How to measure the pressure is described in chapter
8.4; temperature measurement is given in chapter 7.4. Setting of the parameters
AX-02 "SoS Source Temp." and AX-03 "SoS Source Pressure" allows to select
whether these measured values of temperature and pressure are used for AGA-10
calculation or default values AX-04 and AX-05.

45
Fig. 4.5: Pressure and Temperature input
The electric connection of pressure (p) and temperature (T) has to be done a
terminals 26 to 31; AUX1 = p; AUX2 = T.
4.4.3 Data input via RMGBus

The data of a gas chromatograph (eg. RMG GC9000 or GC9300) can be delivered
as RMGBus telegram via the RMGBus protocol. Therefore, the coordinate AX-01
“SoS AGA-10 source data“ is set to "Serial port 2" and the serial interface in the
mode "RMG- Bus". Additionally the parameters of the interfaces USM-GT-400 and
the RMGBus master device have to be aligned to each other.
Because the content of the telegram may have data from different streams, the
„right“ stream has to be set with the parameter AX-09 "Stream selection". Parame-
ter AX-08 "RMGBus mode" fixes how many components are part of the telegram.
When using a GC9000 this parameter has to be set to "RMGBus" to offer a correct
evaluation for older versions of the software GC9000.
1. Parameter J-25 "Opt. Ser2 mode":
"RMGBus"
2. Schnittstellenparameter von Seriell 2 anpassen:
J-26 „baud“
J-27 „bits“
J-28 „parity“
Match RMGBus master:
„Serial port 2“
3. Parameter AX-01 "AGA-10 source“:
"Serial port 2"

4. Parameter AX-07 "maximum timeout":

Time in minutes, within which a new telegram has to come via RMGBus
5. Parameter AX-08 "RMGBus mode":
46
GC9000: "RMGBus"
GC9300: "RMGBus 24 Komp."
6. Parameter AX-09 "Stream selection":
Allows the setting of the desired streams.
4.4.4 Data via Modbus (USM GT400 is SLAVE)

The gas data can be written to Modbus USM-GT-400 (USM-GT- 400 is Slave).
Data source can be any field devices that operate as a Modbus master on the bus.
The individual gas components will be written into the Modbus register of parame-
ters AY-20 to AY-44. To accept these values for the AGA-10 calculation parame-
ters AX-11 has to be set to "Set new comp.". The parameters will be set as:
"Modbus"
2. The parameters of serial port 2 have to be adapted to the setting of the
Modbus master:
J-26 "baud"
J-27 "bits"
J-28 "parity"
3. The Modbus has to be set to "RTU" or "ASCII" according to the setting of
the master. Due to the configuration of the hardware it has to be set to
RS232 or RS485, too:
J-29 "Modbus-2 protocol"
J-30 Modbus-2 HW-mode
4. Parameter AX-01 "AGA-10 source":
"Serial port 2"
"Modbus-Master"

47
Fig. 4.6: Import of data via Modbus
4.4.5 Import of data via Modbus (USM GT400 is Master)

USM-GT-400 gets the gas data via Modbus. It is Modbus master and asks contin-
uously if new data are available. In this case, all the components are re-read and
fed to the AGA-10 calculation. Parameter AX-10 "Modbus Master Target" sets
which device the USM-GT-400 is addressing. If the GC9300 is chosen no Modbus
register needs to be set at AZ-01 to AZ-54 for status and part of the gas compo-
nent.
Time [minutes] in which a new telegram must have come via RMGBus.
2. Adjustment of the parameter of serial port 2
J-26 "baud"
J-27 "bits"
J-28 "parity"
3. Modbus configuration:
J-29 "Modbus-protocol 2"
Master has to be set to "RTU" or "ASCII"
J-30 Modbus-2 HW-mode
Hardware configuration can be selected as RS232 or RS485
J-31 "Modbus-address 2"
Slave-address of the device with the gas data
4. Parameter AX-01 "AGA-10 source":
"Serial Port 2"


Time [minutes] in which a new telegram must have come
48
Time [minutes] in which a new telegram must have come
Timeout: During the transfer of data, an adjustable time-out is
available, generating a status signal if no new data arrived within
the adjusted time.
6. Parameter AX-10
"Modbus-Master Target": "GC9300"?
If yes, continue after 8, otherwise at 7.
7. Parameter AZ-01 - AZ-54
Enter Modbus registers of the gas components and status of the
slave device
Treatment of the gas data

The gas data are validated after transmission and optionally normalized. The
AGA-10 gas equation accepts up to 21 gas components; it might even accept up
to 24 components adding some (surplus) gas components to other components.
Neo-pentane: added to n-pentane (see ISO 12213-2)
Propene: added to propane
Ethen: added to CO2 (see ISO 12213-2).
Hexane+: sum of n-hexane, n-heptane, n-octane, n-nonane and n-decane. If there

is only hexane+ in the samples and none of the above-mentioned components,
then hexane+ is added to hexane. In case one of these components is > 0, then
hexane is + ignored.
.
Normalization to 100 mol-%: If the sum of gas components isn‘t 100 mol-%, then
the components are normalized to a total of ˃ 100 mol-% (can only be applied if
the sum is > 0 mol-% and < 110 mol-%). Otherwise, Bit 0 in AW-01 "SOS calcula-
tion status" will be set and the calculation takes place with 100 mol-% methane in-
stead.

49
Fig. 4.7: Sequence of gas components treatments
Fig. 4.8: Classification of gas components
The following examples demonstrate the classification of the gas components into
the 21 AGA-10 components.

Example 1:
Component Input AGA-10 AGA-10
mol-% unnormalized normalized
50 mol-% mol-%
Methane 35.0 35.0 70.0
Ethane 5.0 5.0 10.0
Propane 1.0 2.0 4.0
Propene 1.0 - -
iso-Pentane 1.0 - -
n-Pentane 1.0 2.0 4.0
CO 2 0.2 1.0 2.0
Ethen 0.8 - -
Hexane+ (5.0) - -
Hexane 3.0 3.0 6.0
Nonane 2.0 2.0 4.0
Sum 50.0 50.0 50.0
Example 2:
Component Input AGA-10 AGA-10
mol-% unnormalized normalized
mol-% mol-%
Methane 80.0 80.0 80.0
Ethane 5.0 5.0 5.0
Propane 2.0 2.0 2.0
n-Butane 1.0 1.0 1.0
neo-Pentane 1.0 - -
n-Pentan 0.0 1.0 1.0
CO 2 0.0 2.0 2.0
Ethen 2.0 - -
Hexane+ 5.0 - -
Hexane - 5.0 5.0
Nitrogen 4.0 4.0 4.0
Sum 100.0 100.0 100.0

Status code der AGA-10 calculation

Coordinate AW-01 gives the status code of the AGA-10 calculation. This is a bit-
coded value represented as a hexadecimal code. A value of "0000h" indicates a
AGA-10 calculation with errors. The meaning of the individual bits are: 51
Bit Meaning
0 Components invalid
Sum of the un-normalized gas components
is <= 0 or > 110 mol-%
1 Timeout of new gas data exceeded
Within the defined time period in AX-07, no new data arrived. Possible
reason:
• Time too short
• Communication interrupted
• transfer register has not been filled (for Modbus slave)
• Wrong RMGBus telegram or wrong stream selection
If there are new gas components latest within three times of the given
timeout time, the error status will be reset.
2 Temperature Error
The temperature measurement is disturbed. Calculation will be done
with the default value.
3 Pressure errors
The pressure measurement is disturbed. Calculation will
be done with the default value.
4 Simulation active
Parameter E-01 „USE09 mode“ is set to simulation no data (results) of
the DSP will be accepted
5 no value
6 no value
7 no value
8 Error AGA-10 calculation
There is an error within the AGA-10 calculation. The calculation is on
hold. Reason may be wrong pressure or temperature values, ...
9-15 no value
The message "188: AGA-10" appears, if the status code is not 0. The Modbus
master function is flexible in order to support PGC's other manufacturers, too; for
example a Siemens PGC. Activating the RS 485 interface as Modbus master is
described in  chapter 10.3.3, “Interface 2” on page 150.

4.5 Batch mode

In general, the USM-GT-400 is set for an optimal operation without disturbance.
The setting / changing of the batch mode allows adaptation to disturbed condi-
52
tions. The setting allows operation at "high-turbulent" flow conditions as well as at
"strong background noise" conditions. High turbulent means highly distorted veloc-
ity profiles and rapidly changing asymmetries. A "smallest" batch mode should be
chosen. At strong background noise, the signal detection can be disturbed, too. A
"longer" batch mode increases the signal stability significantly. The number of
batches permits a change of the signal duration.
• P1 Number of F-batches per measuring path 1

• ...
• P8 Number of F-batches per measuring path 8
The default values are 2. 0 and 1 are identical; there is no batch activated. All
larger values are squared; F-Batch 2 means there are 4 signals superimposed. If
the F-Batch is active the ring down time should be chosen as short as possible,
preferably to 0 ms. The slow batch mode can be activated in coordinate AI-09; it is
to be squared for all paths, too.
4.6 Signal damping

The output signal of the USM can be smoothed using the parameters E-9 (number
of GDs) and AK-34 to AP-24 (F-Batch). The choice of the settings for these
parameters is an optimization between interference immunity (high damping) and
short response time to changes in flow rate (low damping). As standard, the USMs
are delivered with GD=10 and F-Batch=2. This means:
a) The output signal is the moving average over the last 10 measurements. The
number of measured values included in the moving average is entered directly
in E-9.
b) The mean value of 4 raw signals is included in the measurements. The number
of these measurements (F-batch) is path-specific and equal to the square of
the input value in AK-34 to AP-34.
The shortest possible response time is therefore obtained with E-9 = 1 and AK-34
to AP-34 = 1. However, these settings should only be used with stable flow profiles
and low noise levels. If necessary, these parameters must be optimized during
commissioning.

5 Safety
5 Safety
In this chapter you will receive information on using the device in a safe manner.
53
Content
5.1 Intended use 54

5.2 Layout of instructions 55
5.3 Qualification of the personnel 56
5.4 Safety instructions 57
5.4.1 Hazards during transporting 58
5.4.2 Hazards during installation 58
5.4.3 Hazards during start up 60
5.4.4 Hazards during cleaning 61
5.4.5 Hazards during maintenance and repairs 61
5.4.6 Hazards during operation 62
5.4.7 Hazards for operation in potentially explosive environments 63
5.5 Responsibilities of the operator 64

5 Safety
5.1 Intended use

The Ultrasonic Flowmeter USM GT400 device is used to measure the flow velocity
of the gases in a pipeline and calculate the operating flow during running opera-
54
tion.
The Ultrasonic Flowmeter USM GT400 is hereafter designated as ultrasonic gas

meter or device in the following.
When used for its intended purpose, the ultrasonic gas meter is suitable for use in
potentially explosive areas classified as zone 1.
The device complies with ignition protection class

II 2 G Ex de IIB+H2 T6 Gb, ambient temperature between
40°C and +55°C
or
Class 1, Division 1 Group B, C and D, ambient temperature for
code T5/T6 is -40°C to +40/+55°C.
The ultrasonic gas meter complies with the standards, directives and guidelines.
Chapter 16.5, “Standards, directives and guidelines” on page 247
These technical limits must be maintained for a safe use of the ultrasonic gas me-
ter:
Chapter 13, “Technical specifications” on page 177

5 Safety
5.2 Layout of instructions

The following instructions are used:
55
Danger
This warning instruction informs you of potentially hazardous situations that can
occur as a result of incorrect operation or human error. If these situations are
not avoided, they can lead to fatal or severest injuries.
Warning
This warning instruction informs you of possible hazardous situations that can
not avoided, they can lead to fatal or severe injuries.
Caution
This warning instruction informs you of possible hazardous situations that can
not avoided, they can lead to slight or minor injuries.
Notice
This warning instruction informs you of potentially hazardous situations
that can occur as a result of incorrect operation or human error. If
these situations are not avoided, they can result in material damage to
the device or the vicinity.
Dieser Hinweis gibt Ihnen Tipps, wie Sie Ihre Arbeit erleichtern können.
Zusätzlich erhalten Sie mit diesem Hinweis weitere Informationen zum
Gerät oder zum Arbeitsprozess.

5 Safety
5.3 Qualification of the personnel

Operating personnel The operating personnel are to use and operate the
device within the scope of the intended purpose.
56
Maintenance personnel Work on the device must only be carried out by special-
ist personnel that can carry out the respective work as-
signed to them as a result of their training, knowledge
and experience as well as the applicable regulations.
These specialist personnel are familiar with the legal
guidelines for accident prevention and can evaluate and
avoid possible risks by themselves.
• Mechanical installation must only be carried out by

the respectively qualified specialist personnel.
• Installation on electrical components must only be

carried out by qualified electricians.
The specialist personnel require a training especially for

working in potentially explosive environment.
Specialist personnel are persons that can verify a train-
ing / further education according to DIN VDE 0105, IEC
364 or a similar national standards.
• Initial start up must only be carried out by especially

trained personal (training by RMG) or by service per-
sonal from RMG.
• Maintenance and cleaning must only be carried out

by the respectively qualified specialist personnel.
Danger
Observe the following safety instructions
Non-observance of these safety instructions can lead to a risk of life and limb
and health of the person as well as damage to the environment or property
damage.

5 Safety
5.4 Safety instructions

Note that the safety instructions in this operating instruction and on the device
cannot cover all possible hazardous situations as the combination of different
57
circumstances is impossible to predict. To simply follow the instructions specified
may not normally be sufficient enough to ensure for correct operation. Always be
observant and also consider the following:
• Before working with the device for the first time, read through this operating in-
struction and, in particular, follow the safety instructions carefully.
• Always keep the operating instructions within reach for use at the place of in-
stallation.
• The operating instruction warns against the residual risks for users, third par-
ties, devices or other material assets. The safety instructions used refer to
residual risks that cannot be avoided due to the design.
• For safe operation, the safety instructions must be observed and followed.
• Operate the device only in a sound state and when observing the operating
instruction.
• Also observe the local legal accident prevention, installation and assembly
• guidelines.
• The manufacturer is not responsible for any damage that result as a conse-
quence of not observing the operating, instruction.
• Service and maintenance work or repairs that are not described in the operat-
ing instruction must not be carried out without previous consultation with the
manufacturer.
• Changes to the device are forbidden.
• For safe operation, the technical specifications must be observed and followed.
Performance limits must not be exceeded.
• For a safe operation, the device must only be used in the scope of its intended
use.
The device is exposed to different life phases, such as, e.g., installation,
start upstart up, operation, maintenance and cleaning.
The following sections must be sorted thematically according to the life phases.

5 Safety
5.4.1 Hazards during transporting

The device may be damaged when lifting and putting down, tipping over or falling
down. By disregarding the load bearing capacity of the lifting gear, the device may
58 fall. There is a risk of severe injuries for persons in the vicinity.
• Lift the device only on the intended lifting eyes.
• Before lifting, make sure that the load is safely secured.
• Never stand under suspended loads.
Observe the weight specifications for the ultrasonic gas meter at hand.
5.4.2 Hazards during installation

When you carry out work on electric systems in potentially explosive environ-
ments, incorrect work may lead to explosions.
• Make sure that no potentially explosive atmosphere is at hand before starting

work.
If personnel that have insufficient qualifications carry out work, they can incorrectly
assess hazards. Explosions can occur.
• Carry out the work only if you have the respective qualification and are a
trained specialist person.
• Carry out the installation according to the following standards:
• CAN/CSA-C22.2 No. 0-1191
• CSA C22.2 No. 30
• CSA C22.2 No. 142
• UL 916
• UL 1203
or similar national standards.
In potentially explosive atmospheres, dangerous voltages can still remain as igni-

tion sources for up to one minute after being switched off.
• Disconnect the device from the power supply before starting the maintenance
work.
• Securing against reconnection.
• Cordon-off the work area of the device, e.g., using a barrier and signs.
• After switching off the device, wait at least one minute before starting work. En-
sure that the device is voltage-free. Then connect to earth and short-circuit.

5 Safety
• Make sure that the insulation of the cables are intact.

• Make sure that no stripped cable is located outside the housing of the ultra-
sonic electronics and the connection box.
59
If the device is not installed according to the operating instruction, then there is
not enough explosion protection.
• Install the device according to the operating instruction.
If you do not use the appropriate tool and material, component may be dam-
aged. The explosion protection is void.
• Use tools that have been recommended for the respective work in the operat-
ing instruction.
• Make sure that the performance data of the power connection comply with the
specifications of the type plate.
• Use only an Atex or IECEx certified EMC cable screw connection in the protec-
tion category increased safety with a metric thread (M20x1.5).
• Creepage distances and clearances must be maintained.
• Openings for line feeds not used must be sealed by impact resistant, anti-self-
loosening and twisting safe blind plugs.
• The line insulation must reach to the terminals. When stripping, the conductor
itself must not be damaged.
• When closing the housing, take care that the seals remain effective in order to
ensure for the protection category IP 66 / NEMA 4X.
• Housing cover or housing with damaged thread must be replaced immediately.
• Observe the applicable national guidelines in the individual countries.
• Use cables that match the cable glands.
Gas may represent a risk to life and limb in different ways. Depending on the gas
type, different hazards may have an effect on you with respective consequences.
You may experience intoxication and injuries. There is also a risk of explosion.
• Before working, inform yourself about the media in the system.
• Install the device only when the system is switched off, depressurized and se-
cured.
• Make sure that there is no potentially explosive gas mixture at the installation
location.
The device is exposed to high pressures. If components under pressure are re-
moved / assembled, the high pressure may escape suddenly causing the compo-
nent to fly around. Mortal danger!

5 Safety
• Install the device only when the system is depressurized.

• With systems subjected to pressure:
Have the assembly work (Hot-Tapping) only carried out by specially trained
60 personnel.
If gas escapes at high temperature, there is a risk of life-threatening burns. You
may suffer burn injuries in the event of contact with hot surfaces.
• Allow the components to cool down before working in the system.
• Wear personal protective equipment.
If connections not required during operation remain open, gas will escape. Risk of
explosion and intoxication!
• Before start up, seal all open connections with certified blind plugs according to
94/9/EC.
• Replace the blind plugs that have been installed for transportation with certified
blind plugs according to 94/9/EC or NEC500.
5.4.3 Hazards during start up

assess the hazards. Explosions can occur.
• Carry out the work only if you have the respective qualification and are a spe-
cialist person.
If the device is not sealed correctly during installation, then gas may escape. Ex-
plosions can occur. Danger of poisoning!
• Check the connections for leaks.
• Take the system immediately out of operation if you detect a leak.

5 Safety
5.4.4 Hazards during cleaning

If the device is not cleaned according to the operating instruction, then the device
may be damaged.
61
• Clean the device only according to the operating instruction.
If you do not use the appropriate tool, components may be damaged. The explo-
sion protection is void.
• Use tools that have been recommended for the respective work in the operat-
ing instruction.
Cleaning agents / corrosion protection used may be harmful to health.
• Always wear protective gloves and eye protection.
• Ensure for good ventilation and do not inhale vapours!
• Observe the safety data sheet!
5.4.5 Hazards during maintenance and repairs

assess hazards when working. Explosions can occur.
• Carry out the work only if you have the respective qualification and are a
trained specialist person.
Flange joining elements, pressure tapping screw connections and valves must not
be removed if the system is subject to pressure. Components may dangerously
spray. Escaping gas may cause intoxication and burns. Risk of explosion!
• For the flange connection, use only the matching combination of screw bolts,
nuts and seals. Select the appropriate tightening torque of the flange connec-
tion for this combination.
• In doing so, observe the specifications of the system manufacturer or system
operator.
• Use only genuine spare parts from RMG.
It is forbidden to install spare parts from third-party manufacturers. It voids all
guarantees and claims for guarantee. The explosion protection is no longer en-
sured.
When working on live devices in potentially explosive atmospheres, resulting
sparks may lead to an explosion.

5 Safety
• Only work on de-energized devices when in potentially explosive atmospheres

(except for intrinsically safe circuits).
• Make sure that there is no potentially explosive atmosphere before starting
62 work.
• After working provide on pressurized components, leaks may occur. Escaping
gas may lead to intoxication, Risk of explosion!
• Check all components for leaks!
Special requirements for a safe operation in potentially explosive areas classi-
fied as zone 1:
Under normal operating conditions, the transducer cannot be accessed from
the outside, thus no sparks can result from impacts or friction of the transducer
against hard materials.
• The transducers are made from titanium. If objects knock or rub against the
transducers, this can generate a spark thus leading to an explosion!
• prevent hard objects from knocking or rubbing against the transducers.
Also observe these warning instructions:

“Hazards during installation” on page 58
5.4.6 Hazards during operation

If the device is loaded with a pressure that is too high, components may leak and
burst.
• Never exceed the maximum operating pressure (see specifications on the type
plate).
Flange joining elements, pressure tapping screw connections and valves must not
be removed if the system is subject to pressure. Components may dangerously
spray. Escaping gas may cause intoxication and burns. Risk of explosion!
• Observe the specifications of the system manufacturer or system operator.

5 Safety
The device can be heated or cooled by the temperature of the gas. You may be
subject to burns when making skin contact with the device.
• Wear protective gloves that protect against heat and cold for this work.
63
Breakages or cracks may be caused to the device if the gas temperature or ambi-
ent temperature is outside the specified temperature ranges. Gas escaping may
cause intoxication and burns. Risk of explosion!
• Never exceed the maximum gas temperature and / or ambient temperature of
80°C.
5.4.7 Hazards for operation in potentially explosive environ-

ments
If the device is operated with damaged or missing components, then gas may es-
cape. In event of damaged threads, the ignition penetration safe gap is no longer
guaranteed. Escaping gas may cause intoxication and burns. Risk of explosion!
• Operate the device only in a sound and complete state.
If you carry out technical changes to the device, safe operation can no longer be
guaranteed.
• Use the device only in its original state.

5 Safety
5.5 Responsibilities of the operator

• You being the operator must ensure that only sufficiently qualified personnel
64 work on the device.
“Qualification of the personnel” on page 56
• Make sure that all employees that are using the device have read and under-
stood this operating instruction. Moreover, you are also obliged to train the per-
sonnel at regular intervals and inform them of the hazards.
• Make sure that all work on the device is only carried out by qualified persons
and checked by responsible specialist personnel.
• The responsibilities for installation, operation troubleshooting, maintenance and
cleaning must be clearly specified.
• Provide the personnel with the necessary protective equipment.
“Qualification of the personnel” on page 56

Using suitable measures, ensure that that constructive risks are ruled out when
using the device. Inform your personnel about the risks when using the device.

6 Transport and storage

In this chapter you will receive information on the scope of supply, transport and 65
storage of the device.
Content
6.1 Transport 66
6.1.1 Scope of supply 66
6.1.2 Transporting the device 67
6.1.3 Unpacking the device 67
6.1.4 Disposal of packaging material 70
6.1.5 Prior to installation 70
6.1.6 Removing the transporting locks 71
6.2 Packing the device for transportation 73
6.3 Storage 79
6.3.1 Packing the device for storage 79
6.3.2 Checking the device after storage 80

6.1 Transport
The device will be packed to customer-specifics according to the transport require-
ments. In this chapter you will receive information on the standard packaging of
66
the device.
6.1.1 Scope of supply
The scope of supply may deviate depending on the options of the orders.
The following are included in the scope of supply:
Component Quantity
Ultrasonic gas meter 1
USM GT400 (including US-Electronic)
Extension box 1
(In countries where ATEX / IECEx
standards apply, connected at the
ultrasonic electronic)
Special tools to open the US electronic 2
Inlet and outlet spool piece 1 (optional)
Certificate of flow calibration 1
Certificate of material used 1
Certificate of stability 1
Certificate of density 1
Software RMGViewUSM 1
Operating instruction of the device 1

Screws and set of blank plugs 1

6.1.2 Transporting the device
67
1 Euro pallet
2 Retaining bolts x 2
3 Ultrasonic gas meter
4 Retaining strap x 2
5 Timber wedge x 2
Fig. 6.1: Device secured on a Euro pallet
The device is as standard supplied on a Euro pallet (1). The device can be pro-
tected by a customer-specific outer packaging. To secure the device against tip-
ping-over and rolling away, the device (3) is supplied with retaining straps (4) and
bolted to timber wedges (5). The retaining bolts (2) of the device provide
additional support.
The device can be transported on the pallet using a lifting cart or a fork lift.
6.1.3 Unpacking the device

Remove the outer packaging
The outer packaging of the device is suited to customer specifics in order to pro-
tect the device against damage or influences from the environment during
transport.
Options for the outer packaging can be, for example:

• sea-proof wooden crate
• cardboard packagings

1 Remove the outer packing.

2 Recommendation: store the outer packaging for the future or for returning to
RMG for service work.
68
1 Retaining bolts
Fig. 6.2: Retaining bolts of the device
3 Make sure that the retaining bolts (1) are screwed in, if necessary.
▪ Removing the device from the pallet
1 Lifting eyes
2 Lifting gear chains
Fig. 6.3: Attaching the lifting gear

Warning
The device may be damaged when lifting and putting down, tipping over or
69
falling down. By disregarding the load bearing capacity of the lifting gear, the
device may fall. There is a risk of severe injuries for persons in the vicinity.
• Observe the weight specifications for the ultrasonic gas meter at hand.
1 Attach a suitable lifting gear (2) to the lifting eyes (1) of the device.
2 Tension the chain of the lifting gear slightly to secure the device.
1 Timber wedge
2 Tension straps
Fig. 6.4: Remove the timber wedges and retaining straps
3 Undo and remove the tension straps (2).

Warnung
70
4 Carefully lift the device with a lifting gear until the Euro pallet can be pulled
from underneath the device.
5 Pull the Euro pallet from under the device.
6 Recommendation: store the Euro pallet for the future or for returning to
RMG for service work.
6.1.4 Disposal of packaging material

If the packaging material and the Euro pallet are no longer required, dispose of the
material in an environmentally responsible manner according to the country-spe-
cific standards and guidelines.
6.1.5 Prior to installation

The transport locks must only be removed once the device has been installed in
the system and the device has been transported to the installation location.
Hinweis
Damage to the device from contamination and humidity
If transport locks are removed too early, contamination and humidity
may enter the device. The device could be damaged.
• Disassemble the transport locks immediately before installing the device.

The following belong to the transport locks:
▪ Blind plug
▪ Protective sticker 71
▪ Retaining bolts
▪ Recommendation: remove the retaining bolts only if it is absolutely
necessary. This is the only way to ensure that the device does not tip over or
roll away after being installed.
▪ Corrosion protection mat
6.1.6 Removing the transporting locks

The removal of the transport locks is described here on the example of a connec-
tion or flange. The transport locks also have to be removed from all connections
where the transport locks are located.
▪ Removing the protective sticker / blind plugs from the flanges
The flanges are supplied sealed with a protective sticker or blind plug made
of plastic.
1 Protective sticker
2 Flange
Fig. 6.5: Removing the protective sticker

Removing the protective sticker 1 Release the protective sticker from

the sealing surface of the flange.
2 Remove any residual adhesives or
other impurities from the sealing
72 surfaces of the flange using a gentle
cleaning agent.
Remove the blind plugs 1 Pull the blind plugs out of the
openings.
▪ Remove the corrosion protection mat

The inside of the device is protected using a corrosion protection mat. The corro-
sion protection mat must be removed before installation.
1 Corrosion protection mat

Fig. 6.6: Position of the corrosion protection mat
1 Remove the corrosion protection mat (1) from the device.

6.2 Packing the device for transportation

The device must be packed to customer-specifics according to the transport re-
quirements. In this chapter you will receive information as to how the device is as
73
standard packed.
For packaging, use the original packaging material and sealing set that was
supplied with the device.
If you no longer have the original packaging material and sealing set, you can or-
der the packaging material and sealing set required from RMG.
RMG service would be pleased to consult you as to how the device should be
packed.
You need the following for standard packaging:
• Euro pallet with timber wedges (with the original packaging, the timber
wedges are already pre-mounted on the Euro pallet).
• Two tensioning straps
• Transport locks
• Sealing set (blind plugs)
• Acid-free corrosion protection agent, e.g., ESSO RUST BAN 397,
Mobil Oil Tecrex 39
▪ Ensure for a safe position of the device
Caution
Risk of injury from missing retaining bolts
If the device is put down without the retaining bolts, it can tip over or roll away.
Severe injuries may occur.
• Before starting work, make sure that the retaining bolts are screwed in.

74
1 Retaining bolts with counter-nuts

Fig. 6.7: Check the retaining bolts
The retaining bolts are screwed into the device ex-factory. These ensure for a safe
position.
1 Make sure that the retaining bolts are screwed in and that the counter-nuts
are secured.
Recommendation: remove the retaining bolts only if it is absolutely necessary.

This is the only way to ensure that the device does not tip over or roll away
after being installed
▪ Lifting the device onto the Euro pallet
1 Lifting eyes
2 Lifting gear chains
Fig. 6.8: Attaching the lifting gear

Warning
75
1 Attach a suitable lifting gear (2) to the lifting eyes (1) of the device.
2 Tension the chain of the lifting gear slightly.
3 Undo the bolted connections from the system so that the device can be lifted
out.
1 Retaining bolts
2 Tension straps
3 Timber wedge
Fig. 6.9: Secure the device on the Euro pallet
4 Place the Euro pallet under the device.

Without the retaining bolts (1) the flange must be guided between the timber
wedges (3).

Warning
76 The device may be damaged when lifting and putting down, tipping over or
5 Carefully place the device on the Euro pallet with the lifting gear.
6 Secure the device using the tensioning straps (2).
The tensioning straps must have a tight fit and must secure the device.
▪ Place the corrosion protection mat inside the device
Notice
Damage to the device from corrosion
If the device is not protected against corrosion, the function of the
device may be affected.
• Place the corrosion protection mat inside the device.
1 Position of the corrosion protection mat

Fig. 6.10: Corrosion protection mat in the device

1 Clean the device and protect all blank parts against corrosion with an acid-
free corrosion protection agent, e.g., ESSO RUST BAN 397, Mobil Oil Tecrex
39.
Chapter 11.7, “Cleaning the device” on page 167 77
2 Place the corrosion protection mat (1) inside the device.

▪ Provide the connection box (ATEX / IECEx) with blind plugs
1 Wrench
2 Screwed cable gland
3 Blind plug
Fig. 6.11: Mount the blind plugs
1 Insert the blind plugs (3) into the connection.

2 Tighten the screw connection (2) with a suitable wrench (1).
The following sealing bolts supplied must be used in countries where CSA
guidelines apply. If only transport is taking place, you can use 1/2" or 1"
screws with appropriate length as an alternative.
▪ Applying the protective sticker / blind plugs to the flanges

The flanges must be sealed with a protective sticker or blind plug made of
plastic.

Sealing the flange with protective stickers
78
1 Protective sticker
2 Flange
Fig. 6.12: Applying the protective sticker
1 Clean the sealing area with grease remover.

The sealing surface must be free of grease and contamination.
2 Stick the protective sticker (A) onto the sealing surface of the flange (B).
Sealing the flange with blind plugs

1 Insert the blind plugs into the opening of the flange so that the blind plugs
have a tight fit.
▪ Applying the outer packaging to the device
Notice
Damage caused to the device from incorrect storage / transport
If the device is not protected correctly by the packaging material, dirt or humidity
may enter the device and damage it.
• Pack the device according to the instruction.
• Consider the special transport requirements on the packaging material, e.g., for
transport overseas.
• Please contact RMG service in case of doubt.

Use the original packaging that was supplied along with the device. Please contact
RMG service if you have any questions.
Options for the outer packaging can be, for example:

79
• sea-proof wooden crate
• cardboard packaging
1 Protect the device in the outer packaging against environmental influences.
6.3 Storage
In this chapter you will receive information on the correct storage of the device.
You are also provided with information that must be observed when storing for
long periods.
Danger
Mortal danger from damage in the warehouse
If the device is stored for longer than one year, the device may be damaged
from incorrect outer packaging or securing of the device. In potentially explosive
environment, a defective device may lead to an explosion. Danger of poisoning!
• Avoid long storage times.
• Have the device checked by RMG service if the storage time is longer than
one year. For this purpose, send the device to RMG.
6.3.1 Packing the device for storage
Notice
Damage caused to the device from incorrect storage / transport
If the device is not protected correctly by the packaging material, dirt or humidity
may enter the device and damage it.
• Pack the device according to the instruction.
• Consider the special transport requirements on the packaging material,
e.g., for transport overseas.
• Please contact RMG service in case of doubt.

1 Packing the device.

“Packing the device for transportation” on page 73
80 2 Observe the approved ambient temperature for storage.

Chapter 13.1, “Performance data” on page 178
6.3.2 Checking the device after storage

Gefahr
Mortal danger from damage in the warehouse
If the device is stored for longer than one year, the device may be damaged
from incorrect outer packaging or securing of the device. In potentially explosive
environment, a defective device may lead to an explosion. Danger of poisoning!
• Avoid longer storage times.
• Have the device checked by RMG service if the storage time is longer than
one year. For this purpose, send the device to RMG.
▪ Checking the device for any signs of damage

There is a high risk to life and limb if a damaged device is used.
The following damage can compromise safety and the function of the device:
• notches on the flange sealing surfaces
• corrosion in the device or on the sealing surfaces
• cracked glass of the viewing window
• clouded glass of the viewing window
• cracks, flaking on the housing or the covers
• flaking paint
1 Check that the device is intact by a visual inspection.
If you discover that there is, e.g., any damage or other damage to the device,
the device may only be re-used after consulting RMG.
2 If damaged: please contact RMG services.

7 Construction and Planning

In this chapter you will receive information on how you can integrate the device
into the system and what you have to observe during this process. 81
Content
7.1 Connection flanges 81

7.2 Seals 82
7.2.1 Flat seal 83
7.2.2 Grooved gaskets 84
7.2.3 Spiral seals 85
7.3 Screws 87
7.4 Installation possibilities 88
7.4.1 Dependency on the gas flow direction 88
7.4.2 Two devices series connected (Face to Face) 91
7.5 Flow computer 93
7.1 Connection flanges

The devices from RMG are equipped with connection flanges.
The joining dimensions of the flanges for the pipelines to be connected must corre-
spond to the connection dimensions of the device flanges.
• ANSI pressure stages: The flange joining dimensions comply with the standard
ASME B 16.5.
• DIN pressure stages: The flange joining dimensions comply with the standard
DIN EN 1092.

Notice
The USM GT400 with a nominal width of DN 80 (3“) uses different connec-
tion flanges. Instead of the screw lead-throughs - as in the flanges of all
82
other nominal sizes - there are blind holes with internal threads. Corre-
sponding screws are included in the scope of delivery, but can also be re-
ordered if necessary.
7.2 Seals
Danger
Escaping gas from incorrect seals
If incorrect flange seals are used for several ultrasonic gas meters, potentially
explosive gas mixtures can escape due to leaks. Risk of intoxication and explo-
sion! Moreover, the pressure of the flange increases with the improper tighten-
ing of the screw bolt.
• Make sure that the flat seal does not protrude over the sealing surface into
the pipeline.
Notice
Malfunctions from incorrect seals
If flange seals are used for ultrasonic gas meters that protrude into the pipeline,
the measuring accuracy may be influenced.
the pipeline.
The durability of the flange connections has been verified for seals with the follow-
ing maximum material values according to the AD2000 regulations.
Flat seals: k0 x KD = 20 x bD | k1 = 1.3 x bD (N/mm)

Grooved gaskets: k0 x KD = 15 x bD | k1 = 1.1 x bD (N/mm)
Spiral seals: k0 x KD = 50 x bD | k1 = 1.4 x bD (N/mm)
Octagonal ring joint seal: KD = 480 N/mm2

7.2.1 Flat seal

Flat seal according to DIN 2690 / EN 12560-1 Form IBC
83
Dimensions of the seal:

d1 = Inside diameter
d2 = Outside diameter
X = Seal thickness 1.5 to 5 mm
Fig. 7.1: Flat seal
PN10 PN16 ANSI150 PN25 PN40
DN d1 d2
in mm (inch) in mm (inch) in mm (inch)
80 (3) 90 (3.54) 142 (5.59) 142 (5.59) 136.5 (5.37) 142 (5.59) 142 (5.59)
89 (3.5)/ANSI150
100 (4) 115 (4.53) 162 (6.38) 162 (6.38) 175 (6.89) 168 (6.61) 168 (6.61)
150 (6) 169 (6.65) 218 (8.58) 218 (8.58) 222 (8.74) 225 (8.86) 225 (8.86)
200 (8) 220 (8.66) 273 (10.75) 273 (10.75) 279 (10.98) 285 (11.22) 292 (11.52)
250 (10) 274 (10.79) 328 (12.91) 330 (12.99) 340 (13.39) 342 (13.46) 353 (13.90)
300 (12) 325 (12.80) 378 (14.88) 385 (15.16) 410 (16.14) 402 (15.83) 418 (16.46)
400 (16) 420 (16.54) 490 (19.29) 497 (19.57) 514 (20.24) 515 (20.28) 547 (21.54)
500 (20) 520 (20.47) 595 (23.43) 618 (24.33) 607 (23.90) 625 (24.61) 628 (24.72)
600 (24) 620 (24.41) 695 (27.36) 735 (28.94) 718 (28.27) 730 (28.74) 745 (29.33)

7.2.2 Grooved gaskets

Grooved gaskets according to EN 12560-6 with centering ring
84

d1 = Inside diameter
Fig. 7.2: Grooved gaskets
ANSI 300 / ANSI 600 PN64
DN d1 d2 d1 d2
in mm (inch) in mm in mm in mm in mm
80 (3) 98.4 123.8 95 121
100 (4) 123.8 154.0 118 144
150 (6) 177.8 221.7 170 204
200 (8) 228.6 266.7 220 258
250 (10) 282.6 320.7 270 315
300 (12) 339.7 377.8 320 365
400 (16) 422.3 466.7 426 474
500 (20) 530.2 581.0 530 578
600 (24) 631.8 682.6 630 680

7.2.3 Spiral seals

Spiral seals according to EN 12560-2 with centering ring
85

d1 = Inside diameter of the centering ring
d2 = Inside diameter of the seal
Fig. 7.3: Spiral seals
ANSI 300 PN 64 ANSI 600
DN d1 d2 d3 d1 d2 d3 d1 d2 d3
in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm
(inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch)
80 81 101.6 120.7 86 95 119 81 101.6 120.7

(3) (3.19) (3.98) (4.75) (3.39) (3.74) (4.69) (3.19) (3.98) (4.75)
100 106.4 127.0 149.4 108 120 144 106.4 120.7 149.4
(4) (4.19) (5.00) (5.88) (4.25) (4.72) (5.67) (4.19) (4.75) (5.88)
150 157.2 182.6 209.6 162 174 200 157.2 174.8 209.6
(6) (6.19) (7.19) (8.25) (6.38) (6.85) (7.87) (6.19) (6.88) (8.25)
200 215.9 233.4 263.7 213 225 257 215.9 225.6 263.7
(8) (8.5) (9.19) (10.38) (8.39) (8.86) (10.12) (8.5) (8.88) (10.38)
250 268.3 287.3 317.5 267 279 315 268.3 274.6 317.5
(10) (10.6) (11.31) (12.50) (10.5) (10.98) (12.40) (10.6) (10.81) (12.50)
300 317.5 339.9 374.7 318 330 366 317.5 327.2 374.7
(12) (12.5) (13.38) (14.75) (12.5) (12.99) (14.41) (12.5) (12.88) (14.75)

400 400 422.4 463.6 414 426 466 400 412.8 463.6
(16) (15.7) (16.63) (18.25) (16.3) (16.77) (18.35) (15.7) (16.25) (18.25)
500 500 525.5 577.9 518 530 574 500 520.7 577.9
86 (20) (19.7) (20.69) (22.75) (20.4) (20.87) (22.60) (19.7) (20.50) (22.75)
600 603.3 628.7 685.8 618 630 674 603.3 628.7 685.8
(24) (23.8) (24.75) (27.00) (24.3) (24.80) (26.54) (23.8) (24.75) (27.00)

7.3 Screws
Temperature range for bolts and nuts
87
-40°C to +80°C
Pressure Version 1 Version 2 Version 3

stages
PN10, PN16, Boldt according to – –

PN25, PN40, DIN EN ISO 4014 of
PN64 material 25CrMo4, nuts
according to
DIN EN ISO 4032 of
material 25CrMo4
ANSI150, Bolts according to Bolts according to Bolts with reduced shank

ANSI300, ANSI B1.1 of material ANSI B1.1 of material according to DIN 2510 of
ANSI600 ASTM A 320 Grade L7, 42CrMo4, nuts according material 25CrMo4, nuts
nuts according to to ANSI B1.1 of material according to DIN 2510 of
ANSI B1.1 of material 42CrMo4 material 25CrMo4
ASTM A 320 Grade L7
The stability of the flange connection was verified using the screws listed above in
conjunction with the seals listed in Chapter 7.2. Other screw / flange versions have
not been inspected.
Notice
Variant 3 bolts with reduced shank may only be used for devices within the area
of PED (Pressure Equipment Directive) application.
Notice
DN 80
Screws are provided by RMG for the USM-GT400 for diameter DN80.
Depending on the flange type the following hexagonal bolts are used for DN80:

PN10/16 PN25/40 PN64 ANSI150 ANSI300 ANSI600
DIN EN 24014 DIN EN 24014 DIN EN 24014 5/8“ - 11 UNC 3/4“ - 10 UNC 3/4“ - 10 UNC
(DIN931 (DIN931 (DIN931 2A x 2 1/8“ 2A x 2 1/4“ 2A x 2 5/8“
88 ISO4014) ISO4014) ISO4014) L=54mm (2 1/8“) L=57,2mm (2 L=66,7mm (2
M16 x 48 M16 x 52 M16 x 56 UNC A320 1/4“) 5/8“)
L=48 mm or ma- L=52 mm or ma- L=56 mm or ma- Grad7 UNC A320 UNC A320
terial: terial: terial: or material: Grad7 Grad7
25CrMo4 25CrMo4 25CrMo4 42CrMo4 or material: or material:
galvanized galvanized galvanized galvanized 42CrMo4 42CrMo4
galvanized galvanized
These screws can be used down to -40°C.
7.4 Installation possibilities

You have different possibilities when installing the device into your system. Please
verify a proper inner diameter of any pipe that is connected to the meter.
See chapter 13.6 “Inner diameter of connecting spool pieces” on page 189
7.4.1 Dependency on the gas flow direction

In order for the installation to correspond to the requirements of the Measurement
Instrument Directive 2004/22/EC (MID) or Measurement Canada (MC), the device
must be installed with an inlet and outlet piping.
With this installation, the device can be used for calibrated measurements
and for secondary measurements.

89
1 Temperature sensor
Fig. 7.4: Unidirectional operation
1 Flow conditioner
Fig. 7.5: Unidirectional operation compact installation

Bidirectional operation
90
Fig. 7.6: Bidirectional operation
1 Flow conditioner
Fig. 7.7: Bidirectional operation compact installation < DN 300 (12")

91
1 Flow conditioner
Fig. 7.8: Bidirectional operation compact installation ≥ DN 300 (12")
7.4.2 Two devices series connected (Face to Face)

You can install one or several devices in series.
Notice
Malfunctions from pairing the devices incorrectly
If the devices do not match one-another for these installation possibilities,
incorrect measurements may occur.
• Please consult RMG if a Face-to-Face installation is possible with the de-
sired devices and number of devices.

92
1 Tapered bore
2 Inner diameter
Fig. 7.9: Face-to-Face Installation
With this installation option, two or several devices are connected with one-
another via the flanges. Third-party manufacturer devices can also be connected
to RMG devices.
For this purpose, a tapered bore can be applied to the flanges on the inlet and out-
let piping.
The flanges that are used to connect the devices with one-another do not require a
tapering. For third-party manufacturer devices, you have to check if a tapering is
required.
Notice
For the device with the smaller inner diameter it is mandatory to use a tapering.
If two RMG devices are connected with one-another, the inner diameter must be
continuously the same.
Different sized devices cannot be connected to one-another.

7.5 Flow computer

If required, you can connect one or two flow computers to the device.
Follow the installation guidelines of the flow computer:
93
Observe the installation instructions for the flow computer
The 2 interfaces RS485-1 and RS485-2 have the same features and you may
change in the following1 to 2 (and 2 to 1) freely.
However, the RS 485-1 (in contrary to the RS 485-2) does not permit a parameter-
izable byte sequence for the data types Long and Float. We therefore recommend
that you use the RS 485-1 for the DZU protocol and the RS 485-2 for instance F
communication. You may find more information in chapter 8.3.
Flow computer from RMG

The device is compatible with the following flow computer series from RMG:
• ERZ 2000NG
• ERZ 2400
If you want to use the flow computer from RMG specified above, you do not have
to carry out any configurations. The flow computers from RMG can directly pro-
cess the protocol of the ultrasonic gas meter from RMG directly. For this purpose,
the flow computer has to be connected to the digital interface RS485-1 in order to
allow all diagnosis functions to be used. If you want to install an additional flow
computer for reasons of security, this must be connected via the interface
RS485-2.
Flow computer from third party manufacturer

Flow computers from third-party manufacturers can be connected to the device.
These can only be connected to the digital interface RS485-2. This interface com-
municates via a Modbus protocol. In order to be able to use all diagnosis func-
tions, the Modbus must be configured. You can also use the high-frequency out-
puts pulse 1 and 2. When parameterizing, take care that the maximum possible
gas flow rate correlates to a maximum frequency of 2 kHz. All diagnosis functions
cannot be used via this interface. If you are using a third-party manufacturer de-
vice, you have to configure the flow computer.

Connecting a flow computer for example an

ERZ 2000 / ERZ 2400
94
1 Explosive atmospheres Device group II zone I or Class 1, Division 1

2 Maximum distance 500m
3 Safe area
4 Temperature
5 Pressure
6 Pulse
7 Alarm
8 RS 486-2 (Modbus ASCII oder RTU)
9 Service-Interface RS 485-0 for RMG View
Fig. 7.10: Connection diagram for connection of a flow computer
for example ERZ 2000 / ERZ 2400
The cable length must not exceed a length of 500 meters / 1640 feet.
More information on the installation of a flow computer can be found here:
Operating instructions of the flow computer

8 Installation
8 Installation
In this chapter you are provided with information on how you can correctly install
the device and what you have to observe during the process. 95
The tasks of the chapter described must only be carried out by trained and
certified personal.
Content
8.1 Assembly work preparations 96

8.2 Installation of the device 99
8.2.1 Mounting the inlet and outlet piping 99
8.2.2 Installation of the connection box 101
8.3 Connecting the device electrically 103
8.3.1 Connecting the power supply 108
8.3.2 Digital interfaces of USM-GT400 108
8.3.3 Connecting the computer for RMGViewUSM 110
8.3.4 Connecting the flow computer 110
8.3.5 Connection of external DSfG-Device-F via Modbus 113
8.3.6 Interface converter 124
8.3.7 Connecting the device to earth 126
8.4 Installing the pressure connection 128
8.5 Outdoor installation 130

8 Installation
8.1 Assembly work preparations

Danger
96
Mortal danger from electric current
In potentially explosive environments, dangerous voltages can still remain as ig-
nition sources for up to one minute after being switched off.
• Disconnect the device from the power supply before starting the mainte-
nance work.
• Secure the device against being switched back on.
• Cordon-off the work area of the device, e.g., using a barrier and signs.
• After switching off the device, wait at least one minute before starting work.
Ensure that the device is voltage-free. Then connect to earth and
short-circuit.
Mortal danger from components under pressure
Flange joining elements, pressure tapping screw connections and valves must
not be removed if pressure is applied to the device. Components may be flung
around. Gas escaping may cause intoxication and burns. Risk of explosion!
• Carry out work on the device only when it is in a voltage-free state, is vented
and without pressure.
Mortal danger from incorrect work
Hazards can only be recognized and avoided by specially trained personnel.
If work is carried out by persons who have not been trained for these special ac-
tivities in potentially explosive areas, they may cause an explosion.
• Have installations only carried out by especially trained personnel, (expert
according to DIN VDE 0105, IEC 364 or similar national, standards).
Mortal danger from damaged sealing surfaces
If sealing surfaces are damaged, e.g., from notches or scratches, leaks may
occur. Risk of intoxication and explosion!
• Install only an undamaged device

8 Installation
Warning
97
falling down. By disregarding the load bearing capacity of the lifting gear, the de-
vice may fall. There is a risk of severe injuries for persons in the vicinity.
Caution
Risk of injury from missing retaining bolts
If the device is put down without the retaining bolts, it can tip over or roll away.
Serious injuries may occur.
• Before starting work, make sure that the retaining bolts are screwed in.
Notice
Damage to the device when used as a climbing aid
If the device is used as a climbing aid, components may be damaged.
• Do not use the device as a climbing aid.
• Use a suitable non-slip step that allows you to reach the components easily
and safely.
▪ Carry out preparatory work

1 Unpack the device.
Chapter 6.1.3, “Unpacking the device” on page 67
2 Remove the transporting locks.
Chapter 6.1.6, “Removing the transporting locks” on page 71

8 Installation
For ATEX / IECEx
98
1 Wrench
2 Screwed cable gland
3 Blind plug
Fig. 8.1: Remove the blind plugs
3 Unscrew connection (2) with a suitable wrench (1).

4 Pull the blind plugs (3) out of the connection.
5 Screw glandes not required must be replaced by explosionproof screw
connections.
Recommendation: store the blind plugs for the future or for returning to RMG
for service work.
For NEC 500

In countries where CSA guidelines apply, the connections not required must be
provided with gasket screws ex-factory. Please leave these in the screw connec-
tion and only connect the cable that leaves the conduit seal. When joining the con-
duits to the flame block, ensure for a slight gradient away from the flame block in
order to avoid the accumulation of water on the conduit seal. Moreover, also en-
sure that you do not twist the conduit seal when securing the conduit as the cable
in the electrics housing may tear-off as a result. If necessary, use a respective
bolted connection (union).

8 Installation
For all devices

6 Secure the device with retaining bolts for the installation.
Chapter 6.2, “Ensure for a safe position of the device” on page 73
99
7 Check the device for any signs of damage.
Chapter 6.3.2, “Checking the device after storage” on page 80
8 Clean the sealing surface of the flange from contamination with a gentle
cleaning agent.
8.2 Installation of the device

8.2.1 Mounting the inlet and outlet piping
Danger
Escaping gas from incorrect seals
If flange seals are used for ultrasonic gas meters that protrude into the pipeline,
potentially explosive gas mixtures may escape due to leaks. Risk of intoxication
and explosion!
the pipeline.
Observe the instructions for the dimensions!

Chapter 13.5, “Weights and dimensions” on page 184

8 Installation
100
1 Inlet piping
2 Ultrasonic gas meter
3 Outlet piping
Fig. 8.2: Installation of the Inlet and outlet piping
The bolted connection of Inlet (1) and outlet piping (3) must be tightened according
to the tightening torque of the plant manufacturer. The tightening torque must com-
ply with the bolts and seals used.
1 Clean the sealing surface of the flange from contamination with a gentle
cleaning agent.
2 Tighten the bolts crosswise in order to avoid tensioning.
Notice
In general, only the horizontal installation of the USM GT400 is strongly
recommended. Turning the meter by more than 2 flange holes should not be
used to avoid the collection of condensates in the sensor pockets. Only in dry
and clean gas, other installation positions might be possible also, but it is not
recommendable.

8 Installation
8.2.2 Installation of the connection box

The device can be ordered in different versions. Depending on the version or-
dered, another procedure must be carried out for the installation.
101
These are the order versions:
• connection box according to ATEX / IECEx
“Installation of the connection box (ATEX / IECEx)” on page 101
• connection according to NEC 50

no box must be installed here, only connect the cable according to their des-
ignation.
Cable connection “Connecting the device electrically” on page 103
Installation of the connection box (ATEX/IECEx)
1 Connection box Ex-de

Fig. 8.3: Connecting the connection box
This version of the connection box is supplied in countries where the

ATEX / IECEx standards apply.
The external connecting housing is pre-assembled and connected electrically to

the ultrasonic electronics ex-factory.

8 Installation
Open the connection box (Ex-de)
102
1 Cover
2 Screws
3 Screwdriver
Fig. 8.4: Opening the connection box cover
1 Unscrew the screws (2) using a suitable screwdriver (3).

2 Remove cover (1).
▪ Closing the connection box (Ex-de)

1 Place cover (1) onto the connection box.
2 Screw in the screws (2) using a suitable screwdriver (3).
Joining the device to the customers flameproof connection box
With this order version, no connection box is mounted on the device.
The device offers the connection by cable that are routed through the flame block.
The wiring in the ultrasonic electronics is carried out ex-factory. The cables are
marked accordingly for connecting and can be connected in a customer’s connec-
tion box.
Observe the following when installing:
• The cables must be connected according to the lettering.

• Select a maximum cable length of three meters. If you need to use longer ca-
bles, please contact RMG services.

8 Installation
8.3 Connecting the device electrically

In this chapter you will receive information on connecting the electrical connec-
tions.
103
The terminal strip for the electrical connection is located in the external connection
box. The terminal assignment and the markings of the cable are always identical.
Maximum assignment
The maximum assignment is always completely available for the connections of
the Ex-de connection box.
• Current / voltage supply (24 VDC)
• Warning message (Warn)
• Alarm message (Alarm)
• Pulse output for "Forwards mode" (Pulse 1) and "Backwards mode" (Pulse 2)
• 2 x direction detectors for bi-directional operation (I/O1/2)
• Interface for RMGViewUSM (RS 485 0)
• Interface for an RMG flow computer (RS 485 1)
• Interface for any flow computer (RS 485 2)
• Analog output (4-20 mA)
• Connection for a pressure sensor as a 2-wire 4-20mA
(AUX1; Terminal 26: [P +] Terminal 27: [P -])
• Connection for a temperature sensor (PT100; AUX2; Terminal28: [PT100 ++],
Terminal 29: [PT100 +] Terminal 30: [PT100 -] Terminal 31: [PT100 -])
Cable specification
The following cable specifications are according to a complete assignment of the
USM-GT-400 ATEX / IECEx version. The cable types listed are recommendations
that can be replaced by technically comparable cable types.

8 Installation
Power supply ÖLFLEX® CLASSIC Cable Ø

3 x 1.5 mm² oder 12.3 mm
24 VDC 3 x 2.5 mm² 13.5 mm
104 Interface: LIYCY (TP)
RS 485-0,
RS 485-1, RS 485-2 3 x 2 x 0.75 mm² 9.4 mm
(can be laid in one cable)
AUX1 LIYCY
2 x 0.75 mm² 6.0mm
AUX2 LIYCY
2 x 2 x 0.75 mm² 8.5 mm
Analog out LIYCY 6.0 mm
4-20 mA 2 x 0.75 mm²
Warning + alarm LIYCY
2 x 2 x 0.75 mm² 8.5 mm
Pulse 1 + pulse 2 + LIYCY (TP)
I/O 1 + I/O 2 4 x 2 x 0.75 mm² 10.7 mm
Twisted pair cable (TP) are only required in case of multiple circuits in one cable.
Otherwise, LIYCY 2 x 0.75 mm² is sufficient for all signal outputs.
Connection box according to ATEX / IECEx
1 Ex-de connection box for Europe

Fig. 8.6: Close the connection box
In those countries where the standards ATEX and IECEx are valid,
the device is supplied with the connection box Ex-de (1).

8 Installation
The external connection box is connected electrically to the ultrasonic electronics

ex-factory and pre-assembled on the ultrasonic electronics. The external connec-
tion box does not have to be mounted.
105
Connection according to NEC 500
The number of lines that are permitted to be routed through the cable gland (½”
and ¾”) on the electrics housing and flame block is limited. Accordingly, this re-
sults in 4 different constellations that reflect the possibilities for connection.
The numbers given below at each figure only counts the limited number of cables;
all cables are labeled due to the number of the basic upper terminal block
Version 1: Minimum assignment-½” sealing fitting
Fig. 8.7: ½” cable gland with 11 wires, size AWG 18
1 1½” sealing fitting, connected with 11 wires, size AWG 18 (permitted, max.
11; Killark Type ENY-1TM).
For this version, the ERZ 2000 or ERZ 2000 NG cannot be connected via the DZU
protocol (RS 485-1).

8 Installation
Version 2: Minimum assignment for bi-directional operation - ¾” sealing

fitting
106
Fig. 8.8: ¾” cable gland with 20 wires, size AWG 18
2 ¾” sealing fitting, connected with 20 wires, size AWG 18 (permitted, max. 20;
Killark Type ENY-2TM).
For bi-directional operation.

For this version, the ERZ 2000 or ERZ 2000 NG cannot be connected
via the DZU protocol (RS 485-1).
Version 3: Minimum assignment for operation with pressure and tempera-

ture measurement - ¾” sealing fitting
Fig. 8.9: Measuring with pressure and temperature

8 Installation
For measuring with pressure and temperature:

For this version, the ERZ 2000 or ERZ 2000 NG cannot be connected
via the DZU protocol (RS 485-1).
107
Version 4: Maximum assignment

½” and ¾” sealing fitting
Fig. 8.10: ½“ and ¾“ sealing fittings with up to 31 wires of size AWG 18
3 Connect ¾” sealing fitting with 20 wires of size AWG 18 (permitted, max. 20;
Killark type ENY-2TM) and ½” cable gland with 11 wires of size AWG 18 (per-
mitted, max. 11; Killark type ENY-1TM).
All connections are routed to the outside and can be connected and used.
Not used cables need to be isolated or connected to any unused

free terminals.

8 Installation
8.3.1 Connecting the power supply
108
2 Stromversorgung an den Klemmen 24 VDC
1 Connect the power supply to the terminals 24 VDC (2).

Figure 8-16 on page 94.
8.3.2 Digital interfaces of USM-GT400
2 Digital interface RS485-0
3 Digital interface RS 485-1
4 Digital interface RS 485-2
Fig. 8.12: Digital interfaces RS 485-0,1 und 2

8 Installation
The interfaces RS 485-0, RS 485-1 and RS 485-2 are basically equal and can be
set for all possible connections. However, there are minor differences. These are
taken into account in the recommended connections and make it easier to connect
the recommended devices or the PC if they are followed.
109
Notice
Please use the connections as recommended below. If connections are
used differently additional, extensive settings may become necessary.
Recommended connections at the digital outputs.
RS 485-0 RS 485-1 RS 485-2

Proto- RMGViewUSM IGM-protocol Instanz-F
col, DZU-protocol
(service) 2nd ERZ ,
device
ERZ2000, Flow computer
ERZ2400, other suppliers
ERZ2000-NG,
ERZ2000-DI
fea- no parameterizable no parameterizable Modbus-Master, can
tures byte byte handle IGM- and
sequence for sequence for DZU-protocol, too,
data types Long data types Long parameterizable
and Float
and Float byte sequence for
data types Long and
Float

8 Installation
8.3.3 Connecting the computer for RMGViewUSM
110
2 Service connection
1 Connect the computer to the terminals RS 485-0 (1).
In order to connect, you need an interface converter from USB to RS 485.

(please see recommendations in chapter 8.3.4).
8.3.4 Connecting the flow computer
1 Ex-de according to ATEX and IECEx

Fig. 8.14: Connection box types

8 Installation
The flow computer is connected to the terminal strip of the external connection
box (1).
1. Open the cover of the connection box.

111
“Open the connection box (Ex-de) ” on page 102
▪ Connecting the flow computer from RMG
Connection via data cable for ERZ 2000

Use the following cable:
• twisted pair and shielded cable
• maximum length 500 m / 1640 ft
• line cross-section min. 2 × 2 × 0.75 mm2
2 Connection flow computer 1
3 Connection flow computer 2
The 2 interfaces RS 485-1 and RS485-2 are equivalent and you may change in
the following 1 to 2 (and 2 to 1) freely.
The difference is that the RS 485-1 interface does not have a parameterizable byte sequence for
the long and float data types. This interface is particularly suitable for communication using the
DZU protocol. The RS 485-2 is intended for communication via the manufacturer-independent In-
stance-F protocol, as this interface offers a parameterizable byte sequence.
1 Connect the first flow computer to the terminals RS 485-1 (2).
2 Connect the second flow computer to the terminals RS 485-1 (3).

8 Installation
Connecting a flow computer from third-party manufacturers
112
2 Connection Warning messages
3 Connection Warning messages
4 Connection Pulse 1
5 Connection Pulse 2
6 Connection RS 485-1
7 Connection RS 485-2
Flow computers from third-party manufacturers can be connected to RS 485-1 or

RS 485-2 terminals. This interface communicates via a Modbus protocol.
All diagnosis functions can be made available via a configuration of the Modbus.
Flow computers from third-party manufacturers can also be connected to the
terminals Pulse 1 and Pulse 2. When parameterizing, take care that the maximum
possible gas flow rate is assigned to a maximum frequency of 2 kHz. All diagnosis
functions are not available.
1 Connect the flow computer to terminals RS 485-1 (6) or RS 485-2 (7) or

Pulse 1 (4) and 2 (5).
Warning and alarm messages are also available. You also have to connect a
direction contact for bi-directional operation.
2 Connect the terminal Warn (2) for warning messages.
3 Connect the terminal Alarm (3) for alarm messages.

8 Installation
8.3.5 Connection of external DSfG-Device-F via Modbus

The intension to connect Ultrasonic gas meters comparable to an electronic evalu-
ations unit via the same protocol arises due to the wish to transfer "all" data deter-
mined by an ultrasonic gas meter, i. e. measured values as well as status infor- 113
mation or diagnostic data. Therefore, the connection via DSfG-device-F has be-
come the standard in Germany.
Since the USM GT400 does not have its own DSfG bus access, its DSfG-in-
stance-F protocol is implemented externally via a flow computer, the ERZ 2000-
NG, which has this access. To realize the access the necessary data are trans-
ferred between the ERZ 2000-NG and USM GT400 via Modbus, which is often
referred to as Instance-F, although it only provides the data required for DSfG
Instance-F.
1 ERZ 2000NG with external DSfG device F

2 USM-GT-400 Ultrasonic flow rate meter for gas
Fig. 8.17: Data exchange between ERZ 2000 NG and USM-GT-400
The corresponding settings can be found in the VK Modbus Master USM menu in
the ERZ2000-NG. The corresponding register expressions can be found in the VJ
register expressions menu. In the USM GT400, the Modbus registers of instance F
are listed in column BA.

8 Installation
Electrical connection
The following figure shows the rear panel of the ERZ2000-NG.

The USM GT400 is connected to the serial interface COM6.
114
Fig. 8.18: Connection of the USM‘s Modbus interface to COM 6
USM GT400 terminal compartment
Three serial interfaces for Modbus communication are available on the USM
GT400. For instance F Modbus communication, the RS 485-2 is provided with
terminal 21 (GND), terminal 22 (Data +) and terminal 23 (Data -).
Fig. 8.19: Connection of the RS 485-2 (22 +, 23 -) at the USM GT400

8 Installation
Configuration for COM6 and COM7
For communication with ultrasonic gas meters via instance F the optional interface
COM 6 for the ERZ2000-NG is necessary. The DIL switches are located on the
115
option card required for this purpose. The jumpers for the RS 485 require a setting
that is shown in the following Figure. After that, the option card is to be placed into
the COM6 and 7 slots, which is the first one from the right looking from the display
1 Square solder joint is to be aligned bottom left

2 Square solder joint is to be aligned bottom left
3 On top 485, below 232
4 On top 485, below 232
Fig. 8.20: Configuration of the option card to be used as COM 6 and 7 of the
ERZ 2000-NG

8 Installation
116
Fig. 8.21: Slot for the option card with COM 6 and 7 of the ERZ 2000-NG
Operating mode of the ERZ 2000-NG
If the button "DSfG: F-instance COM6/7" in the menu GB Flow rate parameter is
activated, the further necessary settings are suggested in this menu (light yellow-
green background):
• GB16 Volume transducer mode -> „DZU“ mode

• GB51 Device type -> „USM GT400“
• GB53 Meter type -> „USZ“ (or “USM”)

8 Installation
117
Fig. 8.22: Selection of DZU in Vol.transd. mode GB16
The proposal must then be "entered", i. e. accepted.
Protocol type in menu VJ Register Expressions
After the selection of "DZU" in Volume transducer mode the protocol type "DSfG:
F-instance" must be defined in the menu VJ register expressions by button se-
lection. The corresponding registers for the Modbus communication are thus sug-
gested.

8 Installation
118
Fig. 8.23: Selection of DSfG: F-Instanz in VJ98
The proposal must then be "entered", i. e. adopted. In the complete menu you can
see that many other parameters are transferred in addition to the flow rate.
The connection and selection of all other ultrasonic gas meters listed below are
also possible due to legal metrology purposes.
Coordinate VJ98 selected button is used to enter which suggestion was entered.
Notice
Attention:
Even if in the same field with the same register, e. g. the information "swirl" is
transmitted, the value is "swirl" is dependent form the device and path
configuration used. It might be (significantly) different for the various devices.
The same applies to all device-specific parameters.

8 Installation
Interface configuration COM6
For communication via Instance-F, the serial interface COM6 must be operated
with parameters 38400 baud, 8 bits, parity None and 1 stop bit as well as the oper-
119
ating mode Universal Modbus master. These can be found in IB serial interfaces in
coordinates IB31 to IB33.
Fig. 8.24: Interface configuration COM6
Notice
COM6 is then no longer available for communication with a gas chromato-
graph. Therefore, the Modbus Master communication for GC1 and GC2 in
the coordinates IL50 and IL51 must be realized via the serial interface
COM7.
It has to be deactivated if no Modbus IP is used.
Fig. 8.25: Operating mode: Modbus serial C7
Fig. 8.26: Operating mode: OFF

8 Installation
Configuration VK Modbus according to instance F
For communication via DSfG Instance-F, VK Modbus Master USM must be

parameterized according to the DSfG Instance-F specification as shown in the
120
following figure.
Fig. 8.27: Configuration of Modbus Master USM due to Instanz-F
The Modbus address in VK52 must be assigned with the address of the USM
GT400 are the same. They can be found in J-31. Selection values in VK58 and
VK59 are irrelevant because these data types are not included in the instance
protocol.
Configuration USM GT400 for Instance F
Serial interface RS 485-2 (opt. Ser2)
If the ERZ2000-NG is configured according to the DSfG Instance-F specification

as described in the previous chapter, the USM GT400 must be connected to the
RS 485-2 serial interface. This is defined in the coordinates J-25 to J-37 under the
indication "Opt. Ser2 ". Here these are to parameterize, too. The Modbus address
in J-31 can be freely selected and must be set identically in VK52 in the
ERZ2000-NG.

8 Installation
121
Fig. 8.28: Parameterization of RS 485-2 for Modbus according to instance F
Serial interface RS 485-1 (Serial-1)
The serial interface RS 485-1 may be used as well but requires a different setting
due to fixed deviating Byte order. It will not be treated here, in case it is required
you may have a look into the German manual of the USM GT400.
Modbus Registers for Device-F
The Modbus registers for device-F can be found in chapter 18 the Appendix with
the List of parameters. In the last part of this appendix, you may find the relevant
Modbus registers 32768 to 33022 including the name, a short description a the
type of the registers.
Additional Registers
The following Modbus registers contain additional USM-GT-400 data which are not
included in the tables above. A connected ERZ 2000-NG needs this information so
that its DSfG Device-F can be used.
9086 DSfG-Status
Register 9086 is linked to USM coordinate BA-1.

8 Installation
122 Fig. 8.29: Additional register
This register contains 16 USM status bits.
• Bit-0 = 1: The unit “Volume” is set unequal „m3“.

• Bit-1 = 1: The unit “Flow” is set unequal „m3/h“.
• Bit-2 = 1: The unit “Speed” is set unequal „m/s“.
If one of these three bits equals 0 the requesting ERZ 2000-NG gets the message
that the data of the registers 8000 to 80CE are invalid and may not be used for the
external DSfG instance F. In this case the USM is mis-configured and the device-F
will not work. Bits 3 to 15 are currently not in use.
9084 Qt
Register 9084 is linked to USM coordinate D-24.
Fig. 8.30: Additional register
This register contains a characteristic value of the USM which is dependent from
Qbmax and Qbmin.
• Qt = 0,20 x Qbmax If 00 <= (Qbmax / Qbmin) < 30

• Qt = 0,15 x Qbmax If 30 <= (Qbmax / Qbmin) < 50
• Qt = 0,10 x Qbmax If 50 <= (Qbmax / Qbmin)
• Qt = 0,10 x Qbmax If Qbmin = 0
32792 signal acceptance
Register 32792 is linked with USM coordinate C-6 Performance.
Calculating the signal acceptance
The signal acceptance in BA-13 is equal to meter performance, which is given

from coordinate C-6. This term is defined in chapter 4, Section 4.1 General
description.

8 Installation
The value specifies how many values - of a maximum possible determinable quan-
tity - could be taken into account. If one of ten measurements within a measure-
ment cycle for a path is wrong (i.e. 9 valid measurements) the DSP provides 90%
valid measurements, and the path performance is 90%.
123
The overall performance is the average of the performance of all individual paths
(L-6 to Q-6, valid measurement G1 - G6) for the last n measurements (n = moving
average in E-09; the default is 10 measurements).
Notice
The USM-GT-400 keeps its calibrated accuracy even if up to 2 measurement
paths fails! The value “signal acceptance“ falls down to 66% then.
Exceptions:
• If | Vw | <VwUg (the speed is below the minimum speed), then the path perfor-
mance and the overall performance goes to 100%.
Additional documentation/literature Modbus
• Modicon Modbus Protocol Reference Guide, PI-MBUS-300 Rev. J, June 1996
DSfG
• Gas Information Nr. 7 – 4. Überarbeitung 10 / 2009
Technische Spezifikation für DSfG-Realisierungen
Teil 1 Grundlegende Spezifikation
• Gas Information Nr. 7 – 4. Überarbeitung 10 / 2009

Technische Spezifikation für DSfG-Realisierungen
Teil 2 Abbildung der DSfG auf die IEC 60870-5-101
und -104
• DSfG-Datenelementeliste
DSfG Dellist 23-10-09 Teil3
ERZ 2000-NG
• Bedienungsanleitung Flow Computer Serie ERZ 2000-NG

• Operating Instructions Flow Computer Series ERZ 2000-NG

8 Installation
Instance-F: measured values and register addresses in ERZ2000-NG
In the ERZ2000-NG, with the calibration switch locked, the measured values and
status information are displayed; if the calibration switch is open, the Modbus ad-
124 dresses can be seen (see below).
Detailed information including hourly averages and deviations of the individual val-
ues from the mean value can be found in the higher-level Instance-F menu V,
whose subdirectories VA to VI are structured according to measured value catego-
ries.
Fig. 8.31: Modbus register list in ERZ2000-NG with locked (left) and open (right)
calibration switch
8.3.6 Interface converter

In this chapter you get some information about interface converters that have been
tested and approved for operation with USM-GT-400.
Interface converter from Ethernet (PC) to RS 485 (USM GT400)
Here Phoenix module FL COMSERVER UNI 485-2313452 may be used. Link:
https://www.phoenixcontact.com/online/portal/de?uri=pxc-oc-
itemdetail:pid=2313452&library=dede&pcck=P&tab=1
Fig. 8.32: Interface converter from USB to RS485 (USM-GT-400)

8 Installation
There are 3 recommendations:
1 I-7561 U-G CR unter: http://www.icpdas-europe.com

125
Fig. 8.33: Type ICP Con I-7561U-G CR
2 USB-RS485-WE-1800-BT (1,8 m cable length) and USB-RS485-WE-5000-BT

(5,0 m cable length) at: http://rs-online.com
Fig. 8.34: Type USB-RS485-WE-1800-BT 687-7834 (1,8 m) or Type USB-RS485-

WE-5000-BT 730-0164 (5,0 m)
3 USB-RS485-Converter / part number: 0202047 at: http://www.ipcas.com
Fig. 8.35: Type 0202047
You may find more details of the interface converters and their product information
at the given links.

8 Installation
8.3.7 Connecting the device to earth

In this chapter you will receive information on connecting the device to earth and
the protection of the device.
126
The PA connection must be at least 4.0 mm2
Danger
Mortal danger from incorrect earthing
When the device is not correctly connected to earth so that electrostatic
discharge can lead to spark formation, there is a risk of an explosion.
• Connect the device to earth as described in the instructions.
For ultrasonic gas meters DN150 (6") and DN100 (4")
1 Earthing srew M6
2 Earthing srew M6
3 Earthing cable
Fig. 8.36: Connect to earth – Ultrasonic meters DN150 (6") and DN100 (4")
1 Fasten the customers earthing to the earthing screw (1).

8 Installation
For Ultrasonic meters DN200 (8")
127
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 8.37: Connect to earth – Ultrasonic meters DN200 (8")
1 Fasten the customers earthing to the earthing screw (1).
Cable specifications
From a cable length of 1 m, you must use a screened cable for the data and net-
work cable. The screen must be applied on both sides or only on one side (meter
or control room).
Transducer
The transducers are metallic connected to the meter housing. You do not have to
earth the transducer separately. You must ensure that the conductive connection
with the pipeline of the measuring system is established.

8 Installation
8.4 Installing the pressure connection
Malfunctions from too small pressure connections

128
The cylindrical diameter of the pressure connection must be selected as
≥3 mm according to ISO 17089.
1 USM up to DN150 with shut-off valve

2 USM from DN200 with shut-off valve
3 USM up to DN150 without shut-off valve
4 USM from DN200 without shut-off valve
Fig. 8.38: Device with and without a shut-off valve
The pressure connection can be equipped with a shut-off valve (1 and 2) or with-
out a shut-off valve (3 and 4). If the device is ordered without a shut-off valve, the
connection is provided with a union nut (clamping screw connection) or a female
thread.

8 Installation
▪ Establish connection with the clamping screw connection
129
1 Union nut with clamping screw connection Ø 6 mm

2 Blind plug (plugged)
Fig. 8.39: Connection options of the pressure connection with clamping screw
connection
1 Unscrew the union nut of the clamping screw connection (1).

2 Remove the blind plug (2).
3 Push the union nut and clamping rings onto the pipe.
4 Push the pipe into the clamping screw connection until the stop.
5 Tighten the union nut in order to fix and seal the pipe.
Usually, Swagelok screw connections (or similar) are used here.
6 Tighten the Swagelok screw connection hand tight.
7 Tighten the Swagelok screw connection using a spanner (wide across flats
14) by a further ¼ turn.

8 Installation
▪ Establish connection at the female thread
130
1 Female thread ¼"

2 Blind plug (screwed)
Fig. 8.40: Connection options of the pressure connection with female thread
1 Unscrew the blind plug (2).

2 Seal the connection in the female thread (1).
8.5 Outdoor installation

The USM-GT-400 may be installed outdoor, too. Doing this requires some
important considerations and advices:
1. Please pay attention to the ambient temperature, it must not exceed the range
from -40°C to 55°C.
2. Please prevent any contact of the USM-GT-400 with chemically aggressive
gases and vapors. These gases and vapors may not damage the protective
coating nor the materials used. The materials used can be found below in the
section "Technical data".
3. The USM-GT-400 may not be completely buried or submerged in water.
4. The display must not be exposed to direct sunlight for a longer period of time
(> 5 minutes). In this case please use the recommended sun
protection (see next picture), that can be supplied from RMG service.

8 Installation
131
Fig. 8.41: Sun protection for the US electronic
5. If you expect higher temperatures than 55°C, then the USM-GT-400 has to be
protected under a large sunshield (weather protection roof or similar).

9 Start Up
9 Start Up
In this chapter you will receive information on start up after installation.
132
Content
9.1 Comparing meter parameters 132

9.2 Checking functions of the USM 132
9.3 Reading out speed of sound 133
9.1 Comparing meter parameters

After installing the meter and completing the electrical connections, the meter
parameters must be compared with the values of the calibration certificate or test
certificate. Example:
• Path lengths
• Axial distances
• Limit values
They are listed in an alphabetical order of their corresponding matrix coordinates

and can be found using the operating display. As an alternative, they can be read
out of the USE09 directly using the operating software RMGViewUSM.
9.2 Checking functions of the USM

The functions can be checked as soon as the meter is exposed to pressure.
For this purpose, the content of the valid measurements (in %) are checked in the
coordinates L-6 to Q-6. They should be 100% at zero flow and should also not fall
below 70% under difficult flow conditions, for example, with high flow rates.
If the operating pressure is not reached, a functional check is only possible to a

limited extent.
In this case, contact RMG services.

9 Start Up
9.3 Reading out speed of sound

The slightly different speeds of sound are also readable (coordinate L-9 to Q-9).
133
The values of the individual paths should differ only by a little (< 0.5 m/s). An accu-
rate comparison with the nominal speed of sound of the media is limited within the
operating conditions.
Temperature stratification within a pipeline

If no flow is possible when start up, temperature stratification may occur
within the pipeline so that speed of sound of paths with different measuring
levels may deviate significantly from one another.
Convenient function checks with ERZ 2000 (-NG)
If an ERZ 2000 (-NG) is available, the content of valid measuring values (in
%) and the measured speed of sound can also be checked in the column
FH (ultrasonic diagnosis) for each path.
In case the speed of sound is not plausible, troubleshooting with RMGViewUSM is

possible. If one individual path has failed, then there is probably an error in the
wiring or with the transducers of this path.
Further information can be found at:
Chapter 12, „Alarm and warning messages“ on page 176

10 Operation
10 Operation
This chapter provides you with information for working with parameters, lists and
134 measurement values.
Content
10.1 Measuring values and parameters 135

10.1.1 Input protection for parameters 135
10.1.2 Parameter and measuring values with variable units 135
10.1.3 Calibration and Service Switch 136
10.1.4 Interfaces to converters and controllers 136
10.1.5 Interface for service and parameterization 137
10.1.6 Adaptation of the DZU protocol to ERZ 2400 138
10.2 Calling up and changing the parameters via the ultrasonic electronics
139
10.2.1 Calling up the value of a parameter 140
10.2.2 Entering data 141
10.2.3 Changing the parameters of protection E and S 144
10.3 Parameterize the USM interface 149
10.3.1 Interface 0 149
10.4 Modbus communication in detail 161
10.4.1 Codes supported 161
10.4.2 Data types 161
10.5 Configuration of the current output 163
10.6 List of the measurement values and
parameters 163

10 Operation
10.1 Measuring values and parameters

The measuring values and parameters are arranged in a matrix structure where
the columns are designated with letters and the lines with figures.
135
Operation of the entire system is carried out via the display of the USE09 with
magnetic pin operation or via the service and parameterization software
"RMGViewUSM".
10.1.1 Input protection for parameters

The following table describes the column designation.
Terms Input protection

A: Display values that cannot be changed.
C: User data that can be changed using the user password.
E: Data subject to calibration that can only be changed with
opened calibration switch.
F: Free parameters without protection.
S: Especially protected parameters that can only be changed
via the user password and calibration switch.
10.1.2 Parameter and measuring values with variable units

The units are variable with several parameters and measuring values. The units of
the variable parameters and measuring values can be changed via a central entry
under a coordinate. This change has an effect on all parameters and measuring
values for which the variable units have been defined.
The variable units are marked with an &.
Example:
Several parameters and measuring values have the entry &v: for a variable unit.
The unit m/s is currently set for this variable. All parameters and measuring values
with this variable unit should be converted to ft/s.

10 Operation
Under coordinate AG-32 the value for the unit m/s is converted to ft/s. All parame-
ters and measuring values with this variable unit &v: are converted to ft/s.
136 Possible variable units
Column Coordinates Data type
&v: AG-32 m/s or ft/s (flow velocity)
&Q: AG-33 m³/h or acfh (flow)
&Z: AG-34 m³ or acf (meter)
&P: AG-35 P/m³ or P/cf (puls factor)
10.1.3 Calibration and Service Switch

There are several values / parameters which are protected against any change as
long as the calibration switch is locked. The protection applies to the input from the
keypad as well as to inputs via the Modbus - interface. The service switch extends
the possibility of settings of the coordinate matrix for the service. The service
switch prevents or allows to initialize the device parameters in case of failure with
default values (CRC - error of Ferro - RAM see below).
Notice
• Calibration and service switch must always be closed in custody
transfer operation!
10.1.4 Interfaces to converters and controllers

USM-GT-400 can be connected directly to a USZ 9000 or at an ERZ 2000 USC,
the communication protocol used is IGM compatible. USZ 9000 or ERZ 2000 USC
cannot transmit any data to USM-GT-400 via this interface.

10 Operation
The USM-GT-400 - IGM - interface is non-reactive!
For direct connection to a volume corrector either digital signals

or serial protocols may be used.
137
Digital signals are:
• Two frequency outputs for the actual flow
• Two outputs for two flow directions
• Alarm and warning contacts
Serial protocols are:

• DZU
• DZU-DIAG
• DZU-X
• IGM und USE09
• VO
• DZU-SLAVE
10.1.5 Interface for service and parameterization

For parameterization of the USM-GT-400 different protections are available:
• sealable calibration switch
• individual user codeword
• sealable calibration switch and input of the individual user codeword
• freely programmable
For parameterization of the USM-GT-400 the interfaces "RS485-0", "RS485-1",

"RS485-2" or keypad input and display are used. Protocol is Modbus - RTU or
Modbus - ASCII. These protocols follow the protections noted above, means, if the
calibration switch is closed, the corresponding parameters can not be changed.
Also when using keyboard and display parameter can only be changed after the
protections are unblocked. Display and keyboard do not effect the device further,
i.e. it does not matter whether the display is available or not. Therefore it can be
plugged or removed during operation. The Parameter setting can be changed to
other protocols; but the parameters themselves can‘t be changed using them. In-
terface "RS485-0" can be used to update (to flash) the firmware. To flash a new
firmware the software „HEXLoad“ is necessary at the PC. To initiate the update -
function the calibration switch needs to be activated and the power needs to
switched off / and on, too. An eventually newly flashed firmware can be clearly

10 Operation
identified via its firmware version and its checksum (CRC-16). Therefore, for
matching checksum and version number is deposited at the PTB (registration au-
thority). The checksum itself can be verified via the display or via Modbus.
138
10.1.6 Adaptation of the DZU protocol to ERZ 2400

DZU protocol (DZU slave) becomes bus-capable adjusting the coordinates of the
bus address:
1. J-01 mode serial 0 (extended menu: DZU-Slave)

2. J-12 DZU-0 address
3. J-14 mode serial 1 (extended menu: DZU slave)
4. J-23 DZU-1 Address
5. J-25 opt. ser2 mode (extended menu: DZU-Slave)
6. J-37 DZU-2 address
Notice
This mode can be used only in areas where the MID is applied!

10 Operation
10.2 Calling up and changing the parameters via

the ultrasonic electronics
This chapter provides you with information for operating the ultrasonic electronics 139
via the display with a control panel.
The parameters can be called up and changed via the display with control
panel or RMGViewUSM.
Software instructions RMGViewUSM (separate document)
1 Switch point
2 Magnet
Fig. 10.1: Magnet for operating the buttons
When the cover of the ultrasonic electronics is closed, the buttons can be operated
using the magnets supplied. In order to operate the buttons with the magnets (2),
the magnet must be placed on the glass in the position with the switching point (1)
of the button.

10 Operation
10.2.1 Calling up the value of a parameter
▪ Select the column in the coordinate system

140
Select the column of the coordinate on the control panel of the
ultrasonic electronics using the button.
The button has been allocated with the following functions for
navigating:
• Press the button briefly: one column to the right, e.g., from
A to B.
• Press the button longer: depending on the duration of
pressing the button:
- one column to the left, e.g., from B to A.
- continuously column by column to the left, e.g., from
U to F.
1 Press the button to select the desired column.
▪ Select the line in the coordinate system
Select the line of the coordinate on the control panel of the ul-
trasonic electronics using the button.
The buttons have been allocated with the following functions

for navigating:
• Press the button briefly: one column down, e.g., from

E-01 to E-02.
• Press the button longer: continuously line by line down-
wards.
• Press the button briefly: one column up, e.g., from

E-02 to E-01.
• Press the button longer: continuously line by line upwards.
1 Press the buttons to select the desired line.
The coordinates (column and line) of the parameter are selected. The value of the
parameter is shown on the display.

10 Operation
10.2.2 Entering data
Observe the designations of the columns and the rights assigned. 141
“Input protection for parameters” on page 135
A parameter that is entered in the protection E or S can only be changed
when the calibration switch is open. For a value / parameter / measure-
ment value S, the code word also has to be entered for the ultrasonic elec-
tronics.
If this parameter is changed then the device is no longer considered as cal-
ibrated.
• Only carry out these tasks if you are authorized.
“Changing the parameters of protection E and S” on page 144
Depending on the type of data, you are offered different selection options when
making entries.
In order to change data, the coordinate of the parameter must be selected.
“Calling up the value of a parameter” on page 140
▪ Example for data type Float (F)

Data type Example
Float (F) A-06 p-Max value
1. Press the button until the next value is marked in the display.
2. Press the button to select a value from the list.

Possible value of the list.: 0 /…/ 9 / - / + / . / E / _
3. Press the button to confirm the value.
The value is stored.

10 Operation
▪ Example for data type Integer (I) and Long integer (L)
Data type Example
Integer (I) D-10 Qb-min time
142
Long integer (L) AF-02 electronic no.

Possible value of the list: 0 /…/ 9 / - / _.

▪ Example for data type Text (T)
Data type Example

Text (T) AU-01 User Test-1

Possible value of the list: 0 /…/ 9 / - / + / . / _ / A /…/ Z

Notice
The data type text is not a text in the actual sense, but a bit combination.

10 Operation
▪ Example for data type Menu (M)

Data type Example
Menu (M) A-17 p-mode
143

▪ Example for data type Time (U)

Data type Example
Time (U) D-23 Qb-S time 2
1. Press the button until the next value is marked in the display


10 Operation
10.2.3 Changing the parameters of protection E and S
This chapter provides you with information for changing parameters that are pro-
144 tected by the calibration switch and also by the code word of the ultrasonic elec-
tronics. This affects all parameters that are stored in the coordinates for columns E
and S. For a parameter in column S, the code word also has to be entered for the
ultrasonic electronics.
Danger
Danger to life from opening the device
If the cover or the housing of the device is opened in an area with a potentially
explosive environment, then the device is no longer suitable to be used in the
area with a potentially explosive environment. Risk of explosion!
• Open the device only when the device is voltage free.
Mortal danger from damaged components
If threaded holes, bolts or the sealing surfaces of the housing are damaged, the
spark protection gap can no longer be guaranteed. Sparks resulting may lead to
an explosion.
• Proceed with care when working with the bolt connections.
• Replace damaged components with new ones.
• Make sure that no parts of the housing are damaged.
Please note that for this task the official seal must be broken. The device
must not be used for calibrated operation if the official seal is broken.
If the task is carried out by RMG service, the device does not have to be
calibrated by a testing institute. The device is provided with a new official
seal by RMG service.
• Führen Sie diese Arbeiten nur aus, wenn Sie dazu befugt sind.

10 Operation
▪ Opening the cover of the ultrasonic electronics

1 Switch off the system power supply.
145
1 Threaded pin
2 Boreholes for inserting the special tools
3 Special tool (2 pieces)
Fig. 10.2: Opening the cover
2 Unscrew threaded pin (1) out of the housing.

3 Insert the special tools into the boreholes.
4 Release the cover with the special key.
1 Cover
Fig. 10.3: Opening the cover
5 Screw the cover off with both hands.

10 Operation
▪ Setting the ultrasonic electronics for configuration
146
1 Calibration switch
Fig. 10.4: Opening the calibration switch
1 Press calibration switch (1) upwards to open it.
▪ Screw down the cover of the ultrasonic electronics
1 Cover
2 Position O-ring
Fig. 10.5: Screw down the cover
1 Each time you open the ultrasonic electronic you have to expect that the O-
ring is damaged. Therefore, this damaged O-ring has to be replaced with a
new one in general. (RMG provides a replacement kit with O-ring, grease, ...
sales number: 38.03.001.00)
2 Screw the cover on with both hands.
3 Insert the special tools into the boreholes.
4 Tighten the cover with the special tools.
5 Screw in threaded pin hand tight.
6 Switch on the system.

10 Operation
▪ Entering the code word of the ultrasonic electronics
If you do not have the password for the ultrasonic electronics, request the 147
code word from RMG Service.
1 Enter the code word for the ultrasonic electronics under coordinate AG-4.
▪ Changing the value of the protected parameters
1 Calibration LED
Fig. 10.6: Check LED
AG-4 user code:

Standard setting: 9999 9999
• This value can be changed when the calibration switch is opened.
Note:
• During start up, this value can be set to customer requirements under
the supervision of a calibration inspector.
1 Check LED.
The Calibration lights up. The calibration switch has been
opened correctly.
2 Change the parameter values.
“Changing the parameters of protection E and S” on page 144
An open lock must be shown in the third line of the display to

allow the value of the protected parameters to be changed.

10 Operation
If the lock is not shown as open, check the switch position of

the calibration switch.
3 Activate the button with the magnet.

148 The value of the parameter can be changed.
Figure 10-1 on page 139
4 Activate the button with the magnet in order to position the cur-
sor on the value of the parameters to be changed.
5 Activate the button with the magnet in order to set the desired
value.
6 Activate the button with the magnet in order to confirm the

desired value.
When the parameter is changed, you have to move the

calibration switch back to the closed position.
▪ Conclude work
1 Switch off the system power supply.
2 Open the cover of the ultrasonic electronics.
“Opening the cover of the ultrasonic electronics” on page 145
3 Press calibration switch (A) downwards to close it.
4 Close the cover of the ultrasonic electronics.
“Screw down the cover of the ultrasonic electronics” on page 146
1 Calibration switch
Fig. 10.7: Close the calibration switch

10 Operation
10.3 Parameterize the USM interface

The ultrasonic gas meter has three serial interfaces that can be used for Modbus
communication. The parameterization is carried out in column "J Serial Ports" of
149
the coordinate matrix.
10.3.1 Interface 0
• Is reserved for service purposes or RMGViewUSM.

• The parameterization is carried out using the coordinates J-1 to J-13.
Coordinates Name Value Unit Modbus Address
J-01 Serial 0 modus Modbus 2099
J-02 Serial 0 baud rate 38400 baud 2100
J-03 Seriell 0 bits 8 2101
J-04 Serial 0 parity NONE 2102
J-05 Modbus 0 protocol RTU 2103
J-06 Modbus 0 HW mode RS485 2104
J-07 Modbus 0 adresse 1 2105
J-08 Modbus 0 reg.offset 0 2106
J-09 Modbus 0 gap time 45 2118
J-10 Pressure application OFF 2116
J-11 Lpt interval 10 2117
J-12 DZU-0 adress 1 2283
J-13 Serial 0 status 10 760

10 Operation
10.3.2 Interface 1
• Is intended for exchanging data with volume conversions.

150
J-14 Serial 1 mode DZU X-FRAME 2107
J-15 Serial 1 baud rate 9600 baud 2108
J-16 Serial 1 bits 8 2109
J-17 Serial 1 parity NONE 2110
J-18 Modbus-1 protocol
J-19 Not available
J-20 Modbus-1 address
J-21 Modbus-1 reg.offset
J-22 Modbus-1 gap time
J-23 DZU-1 address 2 2284
J-24 Serial 1 Status 10 770
10.3.3 Interface 2
• Is intended for communication with a Modbus Master.


10 Operation
J-25 Opt. Ser2 modus Modbus 2112

151
J-26 Opt. Ser2 baud rate 38400 baud 2113
J-27 Opt. Ser2 bits 8 2114
J-28 Opt. Ser2 parity NONE 2115
J-29 Modbus-2 protocol RTU 2178
J-30 Modbus-2 HW-mode RS485 2179
J-31 Modbus 2 address 1 2180
J-32 Modbus 2 reg. offset 0 2181
J-33 Modbus 2 gap time 45 2182
J-34 Long Byte order NORMAL 2251
J-35 Float Byte order NORMAL 2252
J-36 Double Byte order NORMAL 2253
J-37 DZU-2 Address 3 2285
J-38 seriel 2 Status
J-39 DZU Interval 100 tics 2111
J-40 DZU Checksum Preset 0x00 2255
• Interface 2 can be configured as RS232 or RS485.

• Factory setting or default is RS485.

10 Operation
152
1 DIP switch RS232 configuration

2 DIP switch RS485 configuration
Fig. 10.8: Configuring interface with DIP switch
• The configuration is carried out via software (coordinate J-30) and hardware
(switch).
• The DIP switch is located on the optional card in the ultrasonic electronics
housing.
Communication as Modbus master
J-25 Mode Opt. Serial 2
To activate the Modbus Master, the mode must be set to Modbus master.
Fig. 10.9: Activation as Modbus master
Coordinates AW-08 and AW-09 indicate the time since of the last AGA10 calcula-
tion respectively the time of last update of the gas components.

10 Operation
153
Fig. 10.10: Status information of the AGA-10 calculation
Using the coordinates AZ-01 Formula Methane to AZ-50 Formula Status the USM-
input variables are linked to the PGC gas data.
USM-GT-400 Coordinates Name Value Unit

USM_Ob AZ-01 Formula Methane F8252
USM_Ob AZ-02 Formula Methane
USM_Ob AZ-03 Formula Ethane F8256
USM_Ob AZ-04 Formula Ethane
USM_Ob AZ-05 Formula Propane F8258
USM_Ob AZ-06 Formula Propane
USM_Ob AZ-07 Formula I-Butane F8260
USM_Ob AZ-08 Formula I-Butane
USM_Ob AZ-09 Formula N-Butane F8262
USM_Ob AZ-10 Formula N-Butane
USM_Ob AZ-11 Formula Neo-Pentane 0
USM_Ob AZ-12 Formula Neo-Pentane
USM_Ob AZ-13 Formula I-Pentane F8266
USM_Ob AZ-14 Formula I-Pentane
USM_Ob AZ-15 Formula l N-Pentane F8268
USM_Ob AZ-16 Formula N-Pentane
USM_Ob AZ-17 Formula Hexane+ 0
USM_Ob AZ-18 Formula Hexane+
USM_Ob AZ-19 Formula Oxygen F8280
USM_Ob AZ-20 Formula Oxygen
USM_Ob AZ-21 Formula Helium F8282
USM_Ob AZ-22 Formula Helium
USM_Ob AZ-23 Formula Hydrogene F8284
USM_Ob AZ-24 Formula Hydrogene
USM_Ob AZ-25 Formula Argon 0
USM_Ob AZ-26 Formula Argon
USM_Ob AZ-27 Formula Nitrogen F8250
USM_Ob AZ-28 Formula Nitrogen
USM_Ob AZ-29 Formula CO2 F8254
USM_Ob AZ-30 Formula CO2
USM_Ob AZ-31 Formula Hexane 0
USM_Ob AZ-32 Formula Hexane
USM_Ob AZ-33 Formula Heptane 0

10 Operation
USM_Ob AZ-34 Formula Heptane

USM_Ob AZ-35 Formula Octane 0
USM_Ob AZ-36 Formula Octane
USM_Ob AZ-37 Formula Nonane 0
154
USM_Ob AZ-38 Formula Nonane
USM_Ob AZ-39 Formula Decane 0
USM_Ob AZ-40 Formula Decane
USM_Ob AZ-41 Formula H2S 0
USM_Ob AZ-42 Formula H2S
USM_Ob AZ-43 Formula H2O 0
USM_Ob AZ-44 Formula H2O
USM_Ob AZ-45 Formula CO 0
USM_Ob AZ-46 Formula CO
USM_Ob AZ-47 Formula Ethene 0
USM_Ob AZ-48 Formula Ethene
USM_Ob AZ-49 Formula Propene 0
USM_Ob AZ-50 Formula Propene
USM_Ob AZ-51 Formula Status u1038==0
USM_Ob AZ-52 Formula Status
USM_Ob AZ-55 MB Pause 20 s
USM_Ob AZ-56 MB Timeout 1000 ms
USM_Ob AZ-57 MB Int16Order 21
USM_Ob AZ-58 MB Int32Order 4321
USM_Ob AZ-59 MB FloatOrder 4321
USM_Ob AZ-60 MB DoubleOrder 43218765
The USM-GT-400 combines the information of the PGC-register 8252 (= Register

address component methane) with the coordinate AZ-01. Data type F8252 means
that methane is delivered as a single-precision floating-point number (Float).
There are different data types: double-precision floating point = D (Double float),
simple-precision floating point = F (Float), 32-bit unsigned integer = U (Long) and
16-bit unsigned integer = u (short).

10 Operation
155
Fig. 10.11: Gas component
Unit Conversion
An implemented formulary offers additional options for a conversion. Values from

the PGC can be converted according to the requirements. For example to multiply
the methane concentration (0.94) with 100 (94%) in coordinate AX-46 has to be
selected F8252 * 100.
Fig. 10.12: Applying the unit conversion
Rules for distributing the gas components
Not all possible gas components can be filled. Then these gas components are to
be distributed according to the distribution rules.
“Treatment of the gas data” on page 32

It might be possible that there is no input field in the USM-GT-400 for a measured
gas component from the PGC, for example, Neo-pentane (register 8264). Neo -
pentane will then be added to N-pentane (register 8268). Coordinate AZ-15 then
has to be formulated as F8264 + F8268.
Fig. 10.13: Applied distribution rule

10 Operation
Rule for splitting gas components
If components as hexane, heptane, octane, nonane and decane are not given indi-
vidually, but as a sum of hexane plus higher alkanes, eg Register in F8272, this
156
sum can be split according to the rule of thirds to the components. Hexane, hep-
tane, octane, nonane and decane are then distributed to 81: 27: 9: 3: 1. Normal-
ized this results in 81/121: 27/121: 9/121: 3/121: 1/121. The coordinates AZ-31 to
AZ-40 become to:
Fig. 10.14: Applied splitting rule
Beside addition and multiplication other mathematical rules such

as division and bracket rules can be applied, too.
Constants
It might be possible that components required from the USM-GT-400 are not given
from the PGC, for example water and hydrogen sulfide. These can be set to 0:
Fig. 10.15: Adjusting gas components

10 Operation
Remarks to the coordinates AZ-01 to AZ-50
The input of a coordinate, for example, AZ-01 can have a maximum

of 20 characters. To specify more complex expressions two
157
coordinate per gas component may be used, for example
methane
• AZ-01 Formula_Methane0 (less significant)

• AZ-02 Formula_Methane1 (highly significant)
An expression with more than 20 characters begins with the less significant coordi-
nate AZ-01 and then continues with one with higher significant AZ-02. Unused
high-order coordinates are filled with spaces.
The formulas combining the USM-GT-400 input variables with the PGC data may
not exceed a maximum of 60 Modbus registers.
AZ-51 Formula Status to AZ-54 Formula Status
For the PGC status could be required for example:
• Value = 1 The PGC measures without error

• Value = 0 The PGC is in alarm
• Value = 0 The PGC is in revision
It is possible that a PGC is not providing its status in this form. Instead, there may
be:
Register 10: It shows the number of pending alarms. When showing 0 the PGC
is free of alarms. It is a 16-bit integer register.
Register 2: It is a bit coded information. In the measuring mode of the PGC the
bit is set to 4. It is a 32-bit integer register.
The following considerations help to formulate the state-formation in coordinate
AZ51:
• The first part of a 16-bit integer registers will be imported. The number of pend-
ing alarms shows the data type of an unsigned integer (unsigned short int). The
prefix is a small u. The register address is 10, therefore, the value u10 should
be requested.

10 Operation
• The value is checked to be 0. The first term is found to be u10 == 0. The result
is true if u10 contains a 0.
• For the second part, a 32-bit integer registers is imported. This value has to be
158 read bitwise. It is a 32-bit unsigned integer (unsigned long int). The prefix is a
large U. Register address is 2; the value U2 must be
requested.
• Now it is checked whether any bit is set to 4. As operator the bitwise "and" has
to be used (&). The second part of the expression results to U2 & 4. The result
is 0 when the bit with the value 4 is not set and a value other than 0 is set. Bits
with other values then 4 do not affect the result.
• The two partial expressions are joined via a logical "and" (&&). Following the
bracket rules both subexpressions have to be put in brackets. The complete ex-
pression for AZ-51 is found to be (u10== 0)&&(U2&4).
Arithmetic Operators Comparison Opera- Logical Operators Bitwise Operators

tors
Addition + greater > Logical And && Bitwise And &
Subtraction - smaller < baud Bitwise Or |
Multiplication * greater or equal >= Logical Or || exclusive or ^
Division / less or equal <= Not! Bitwise negation
Modulo % equal ==
Sign - not equal to =!
Terms may be
• a?b:c means: if a then b else c
• brackets: ()
• constants:
Integers, for example, 42
Floating point, for example, 1.234
Exponential, for example, 1.2345E-3
unsigned, the sign is realized by the operator sign
Information to the status of the PGC

The input field of coordinate AZ-51 accommodates a maximum of 20 characters.
If this is insufficient for the formulation of a more complex expression, there are a
total of four coordinates for the status.

10 Operation
AX-51 Formula Status (lowest significance)

AX-52 Formula Status (low significance)
AX-53 Formula Status (high significance)
159
AX-54 Formula Status (highest significance)
Entering a formula with more than 20 characters starts with the lowest order coor-
dinate AZ-51 and then continues in the higher- AZ-52, AZ-53 and AZ-54. If the
higher order coordinates are not needed, they are to be filled with spaces.
AX-92 MB_Pause: The requests of the USM-GT-400 to the PGC are summarized
in a block. Between two blocks will be an interval. AX92 coordinate indicates the
interval time.
AX-93 MB_Timeout: Maximum time between a PGC request and the associated
response.
AX-94 MB_Int16Order: Adjustment of the byte order of 16-bit integers. A 16-bit

value consists of two bytes, the least significant byte and the most significant byte.
There are two settings: 12 and 21.
AX-95 MB_Int32Order: Adjustment of the byte order of 32-bit integers. A 32-bit

value consists of four bytes. Common sequences are: 1234/2143/3412 / 4321.
However, all other options can be set, too. For example, 4123.
AX-96 MB_FloatOrder: Adjustment of the byte order of single precision floating

point numbers. A single-precision floating-point number consists of four bytes.
Common sequences are: 1234/ 2143/3412 / 4321. However, all other options can
be set, too. For example, 3124.
AX-97 MB_DoubleOrder: Adjustment of the byte order of double- precision float-

ing point numbers. A double-precision floatingpoint number consists of eight bytes.
Consistent Sequences are:
12345678/21436587/34127856/43218765/56781234/65872143/78563412 /
87654321. However, all other options can be set, too.For example, 81,726,354.
Note to the coordinates AX94 to AX97: The numbers represent the significance.
It increases with the value of the byte. The sequence is read from left to right.

10 Operation
160
Fig. 10.16: Significance of the coordinates
AY-46 telegram counter: Here all correct PGC answers are counted.
AY-49 MB timeouts: Here the timeouts detected on the Modbus are counted. The
counter is incremented when no PGC-answer arrives within the time set in AX-93.
AY-50 MB error-counter: Here all incorrect PGC answers are counted.
AY-51 MB error register: If an unexpected answer from the PGC arrives, this co-
ordinate indicates the related Modbus register.
AY-52 MB error answer: Here the PGC answers are counted with exception
code.
AY-55 MB_ErrorBits: This coordinate informs about problems occurring during
the link of the USM-input variables with the PGC data. However displayed is a
three-digit hexadecimal number instead of any bit combination.
Bit 0 - 7: If a link was formulated incorrectly, a coded number here indicates the
first failed formula. Examples:
0 = formula methane is faulty
1 = formula nitrogen is faulty
6 = formula H2S is faulty
Bit 8: Reserved
Bit 9: 0 = no error.
1 = Error for the formulation.
Bit 10: Reserved
Bit 11: Reserved
Bit 12: In the formulas for linking the USM input variables with the PGC data more
than 60 Modbus registers were used in total.
AY-56 MB_InStatus: Here the evaluation result of the status formula (AZ-51 to
AZ-54) is given.

10 Operation
10.4 Modbus communication in detail

10.4.1 Codes supported
161
The ultrasonic electronics supports the following codes:
Function Code Code Description

03 Hex Read Holding Registers
06 Hex Preset Single Register
10 Hex Preset Multiple Registers
08 Hex Diagnostic
00 Hex Return Query Data
Exception Code Code Description

03 Illegal Function
03 Illegal Data Address (Register nicht vorhan-

den)
03 Illegal Data Value (Register nicht beschreibbar
oder Wert falsch)
10.4.2 Data types
Data type Register Value Byte Byte Byte Byte Byte Byte Byte Byte
1 2 3 4 5 6 7 8
float 2 273,15 0x93 0x33 0x43 0x88
text 10 USM 0x53 0x55 0x30 0x5A 0x2D 0x38 0x50 0x36
GT400
0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00
0x00 0x00 0x00 0x00
intd 1 44067 0xAC 0x23
double 4 14,2740 0x13 0x58 0x8A 0xCF 0x8C 0x4C 0x40 0x2C
long 2 100000 0x86 0xA0 0x00 0x01

10 Operation
Example (question / answer)
Question Modbus - ASCII Modbus - RTU

Start Char :
162
Slave Address 01 01
Function 03 03
Starting Address Hi 0F 0F
Starting Address Lo A2 A2 Register = 4002 (0FA2)
No. of Points Hi 00 00
No. of Points Lo 01 01 Amount = 0001 (0001)
LRC / CRC 42 26
carriage return CR FC
line feed LF
Reply:
Start Char :
Slave Address 01 01
Function 03 03
Byte Count 02 02
Data Hi (Reg 2000) A8 A8
Data Lo (Reg 2000) 01 01 Wert = A801
LRC 51 06
carriage return CR 44
line feed LF

10 Operation
10.5 Configuration of the current output

The connection of external devices to the current output of the meter is to be car-
ried out as described in chapter 8.3 Connecting the device electrically.
163
The parameters are then set in column 'I Current Output' of the coordinate matrix
as follows:
1. Enter the code number.

2. Look up the Modbus address of the physical quantity (measured or calculated
value) to be output in the parameter list or with the RMGViewUSM operating soft-
ware under "Values". Then enter this Modbus address in coordinate I-06 (c-
out select).
3. In coordinate I-07 (c-out mode), select the operating mode of the current out-
put (0-20mA or 4-20mA). With "SET VALUE" a constant current can be output,
the value of which is set in coordinate I-05 (c-out set value).
4. In coordinate I-03 (c-out min.), enter the minimum value for the physical quan-
tity at which 0 or 4 mA should be output.
5. In coordinate I-04 (c-out max.), enter the maximum value for the physical
quantity at which 20 mA should be output.
6. In I-08 (c-out err mode) it can then be determined whether the minimum value,
the maximum value or 0 should be output in the event of an error.
The damping value in I-09 can be used to specify how quickly the output current
reacts to a change in the physical quantity. The fastest possible reaction occurs
with the value of 0.
10.6 List of the measurement values and

parameters
The lists for parameter and measured values are in appendix 18.

11 Maintenance
11 Maintenance
164 In this chapter, you are provided with information as to how you can extend the
service life of the device through maintenance. You can only protect the device
against premature wear when observing the maintenance schedules described
here.
Content
11.1 Maintenance schedule 165

11.2 Checking the device for leaks 165
11.3 Checking the device for any signs of damage 166
11.4 Changing the battery 166
11.5 Changing the transducer 166
11.6 Changing the ultrasonic electronics 167
11.7 Cleaning the device 167
11.8 Check the official seal 168
11.9 Decommissioning and disposal 168

11 Maintenance
11.1 Maintenance schedule

The maintenance schedule specifies the intervals in which the maintenance work
has to be carried out in order to maintain the function of the device.
165
Interval Activity
Weekly • Check that the official seal has not been tampered with (this
time interval can be extended to a meaningful length).
As required • Clean the device.
• Check the plug connections and screw connections for
leaks and tight fit, where necessary, replace the seals.
Every 5 to 10 • Check the device for leaks. Please perform a leakage check
Years each time the device has been physical touched.
On consulta- • Check the device for leaks. The leak tightness of the device
tion with RMG. may be limited if non-approved gas types are used. In these
cases, please contact RMG.
11.2 Checking the device for leaks

For safe operation, the device must be sent back to RMG every 5 to 10 years to
check for leaks.
In the course of a recalibration from RMG, the device will also be checked
for leaks at the same time.
If the device is used with the permitted gases, the service life of the seals is
unlimited.
Chapter 13.2, “Approved gas types” on page 180
If other gases are used, please contact RMG.

RMG service will provide you with an interval for the leak test for the inter-
action with the ultrasonic gas meter and the gas type used.
1 Pack the device for transport and shipping to RMG correctly.

Chapter 6.2, „Packing the device for transportation“ on page 73

11 Maintenance
11.3 Checking the device for any signs of damage

The device must only be used in a technically sound state.
166
▪ Checking the device
1 Perform a visual check of the ultrasonic electronics viewing window.
The viewing window must be free of cracks and complete.
2 Perform a visual check of the transducer covers.
The covers must be free of cracks and breaking points.
3 Perform a visual check of the ultrasonic gas meter housing.
The housing must be free of damage resulting from mechanical influences.
11.4 Changing the battery

The ultrasonic electronics contains a battery which keeps date and time when no
power is available. If the battery is empty, the setting for the time and date are lost.
1 Have the empty battery changed by the RMG service.
Notice
Recommendation: The battery should be changed on the regular base of
recalibration but latest each 10 years.
11.5 Changing the transducer

Danger
Mortal danger from incorrect replacement of the transducer
If transducers of a system under pressure are not changed correctly, this may
cause an explosion. Escaping gas may lead to intoxication.
• Change the transducer only if you have obtained a training from RMG for
this activity.
• Observe the separate service instructions for changing the transducer.

11 Maintenance
The special tool from RMG must be used for changing the transducers.
You can find out more about changing the transducers with the tool here:
Service manual for changing the transducers and ultrasonic electronics (sepa- 167
rate document)
11.6 Changing the ultrasonic electronics

Danger
If transducers of a system under pressure are not changed correctly, this may
cause an explosion. Escaping gas may lead to intoxication.
this activity.
• Observe the separate service instructions for changing the transducer.
You can find out more about changing the ultrasonic electronics here:
Service manual for changing the transducers and ultrasonic electronics (sepa-
rate document)
11.7 Cleaning the device

Notice
Malfunction from soiling
If the device is soiled on the inside, it cannot function correctly. This may lead to
incorrect measuring values or a failure.
• Have a device that is contaminated on the inside only cleaned by RMG ser-
vice or by personnel that have been especially trained by RMG.
Damage to the device from incorrect cleaning agent
If the device is cleaned with cleaning agent containing solvents or other unsuita-
ble agents, the paint or plastic parts become brittle, for example.
• Use gentle cleaning agents that are suitable for glass surfaces, metal and
plastic.

11 Maintenance
▪ Performing cleaning
1 Free the device from rough and lose dirt with a soft brush.
2 Clean the viewing window of the ultrasonic electronics with a moist cloth.
168
11.8 Check the official seal

The official seals must be available and must not be damaged for calibrated
operation.
▪ Perform a visual check of the official seals

1 Check that the official seals are intact and complete in a visual inspection.
The positions of the official seals can be found here:
Chapter 13.7, “Official seal diagram” on page 192
11.9 Decommissioning and disposal

Danger
Mortal danger from disassembly in potentially explosive environment.
If the device is disassembled in a potentially explosive environment for
disposal, resulting sparks may lead to an explosion.
• Disassemble the device only in an explosion-proof area.
Warning
Risk of injury from work carried out incorrectly
During decommissioning and removal work, there is a risk of severe injuries
from components under pressure and highly explosive atmospheres if the sys-
tem has not been correctly disconnected from the gas supply network and the
power supply in advance.
• Before starting work, switch off the device and secure it against being
switched back on.
• Depressurize the device.
• Only specialist personnel are allowed to undertake the decommissioning.

11 Maintenance
Observe the applicable national and local guidelines for disposal. Ask your
local authorities about the legal guidelines at your company location as well
169
as about the regional disposal companies or collecting points.
The device mainly comprises materials that can be disposed of as old metal. In the
following we shall specify the components that may not be disposed of as old
metal.
Ultrasonic electronics
Electric components are contained in the housing of the ultrasonic electronics that
must be disposed of as electric waste. In order to remove the ultrasonic electron-
ics, you have to remove the cover of the ultrasonic electronics.
Chapter 10.2.3, “Opening the cover of the ultrasonic electronics” on page 145
Battery
The battery is attached to the PCB of the ultrasonic electronics. In order to remove
the battery, you have to remove the cover of the ultrasonic electronics.
Chapter 10.2.3, “Opening the cover of the ultrasonic electronics” on page 145
Transducer
The transducer comprises titanium, plastic and heavy metals (e.g., lead in piezo
crystal). The transducers must be disposed of according to the applicable national
and local guidelines.
In order to remove the transducers, RMG service shall inform you of the proce-
dure.
„Manufacturer“ on the inside cover

12 Alarm and warning messages

In this chapter, you will find out which information, alarm and warning messages
170 can be displayed. In this chapter, you will also find out how to eliminate problems
with the RMG components.
Content
12.1 Alarm messages 171
12.2 Warning messages 172
0

Notes 175
12.4 Troubleshooting 175
Active warning messages are displayed with a + in front of the message number. 171
Warning messages that can be acknowledged are displayed with a - in front of the
message number.
12.1 Alarm messages

No. Message Explanation
0 No errors Trouble-free operation
1 Power failure Temporary power failure
2 FPGA FPGA communication: FPGA does not answer
Timeout
3 FPGA CRC FPGA-communication: faulty checksum
4 DSP-SPI DSP-communication: Serial Peripheral Interface (Databus) of the digital
Timeout Signal processor does not respond.
5 DSP-SPI CRC DSP-communication: faulty checksum at SPI
6 DSP no data No DSP measuring data arrives
7 DSP R-length DSP-communication: Telegram length invalid
8 DSP Critical DSP fault. Faulty bits can be read-off separately with DSP faults
9 FPGA Critical FPGA fault. Faulty bits can be read-off separately with FPGA
faults
10 COM-0 Fault with data transmission via interface COM-0
14 AD converter Fault at analog digital converter of the option card 2
15 Option card Fault at the option card 1
16 Meter invalid Meter invalid
17 Replacement Replacement value of the path reconstruction invalid
value invalid
18 F-RAM invalid Checksum of the F-RAM telegram invalid
19 F-RAM length Length of the F-RAM telegram invalid
20 opt. Data crc Checksum of the data from the option card invalid
21 ADCData crc Checksum of the data from the AD converter invalid
22 Iout min/max Min/Max limits of the power output violated
23 Send level min Send level too low
24 DSP version DSP SW version not compatible with M32 SW version
25 FPGA version FPGA version not compatible with M32 SW version
26 LOGP invalid Parameter in log memory invalid
30 Path 1 failure Measuring path 1 failed


172
36 Path 7 failure Measuring path 7 failed (spare)
37 Path 8 failure Measuring path 8 failed (spare)
38 max. path Maximum permissible number of path failures exceeded
40 Replacement Replacement value for failed path could not be calculated
value not cal.
41 USE09 Timeout No valid measurement, all measuring paths have failed.
42 ADC ADCfault temperature input
temperature
43 ADC pressure ADC fault pressure input
45 I1 Out min/max Power outlet outside the min. / max. limits
47 Temp. min/max Temperature outside the min. / max. limits
48 Pressure Pressure outside the min. / max. limits
min/max
50 DSP path 1 Critical path error. Error bits can be read-off separately in Path 1 error
54 DSP path 5 Critical path error. Error bits can be read-off separately in Path 5error
(spare)
(spare)
60 P1 AGC limit Amplification factor for path 1 outside the permissible limits
66 P7 AGC limit Amplification factor for path 7 outside the permissible limits (spare)
67 P8 AGC limit Amplification factor for path 8 outside the permissible limits (spare)
77 QVb min. Operating volume flow below Qmin
Grenze
78 QVb max. limit Operating volume flow above Qmax
99 Wrong Parm. Parameter entered is invalid
12.2 Warning messages

No. Messages Explanation
100 Path1 Warn. Proportion invalid measurements for path 1 too high


173
106 Path7 Warn. Proportion invalid measurements for path 7 too high (spare)
107 Path8 Warn. Proportion invalid measurements for path 8 too high (spare)
108 RTC Hardware Hardware fault to the real time clock
109 Ext. Warning External warning
110 P1 V min/max Flow velocity from path 1 outside the min./max. limits
116 P7 V min/max Flow velocity from path 7 outside the min./max. limits (spare)
117 P8 V min/max Flow velocity from path 8 outside the min./max. limits (spare)
118 work.mode test Counter runs in test mode
120 P1 C min/max Speed of sound from path 1 outside the min./max. limits
126 P7 C min/max Speed of sound from path 7 outside the min./max. limits (spare)
127 P8 C min/max Speed of sound from path 8 outside the min./max. limits (spare)
130 P1.1 amplitude Amplitude of the signal from sensor 1.1 too small
136 P7.1 amplitude Amplitude of the signal from sensor 7.1 too small (spare)
150 Pfad1 delta c Deviation from the speed of sound in path 1 from the average speed of
sound too large


sound too large
174 sound too large
sound too large
sound too large
sound too large
sound too large (spare)
sound too large (spare)
170 P1 AGC delta Deviation from the amplification factor in path 1 from the average
amplification factor too large
amplification factor too large (spare)
amplification factor too large (spare)

12.3 Notes
181 Sys. Temp Min System temperature to low
175
182 Sys. Temp Max System temperature to high
183 Rawdata len Length of the raw data telegram wrong
184 Rawdata crc Checksum of the raw data telegram wrong
185 P-LOG full Parameter log memory full
186 DSP-info len Length of the DSP info telegram wrong
187 DSP-info crc Checksum of the DSP info telegram wrong
188 SoS calc. status Status of the SoS calculation
12.4 Troubleshooting
If you cannot find a solution to your problem with the RMG component in
the table below, then please contact the RMG service.
„Manufacturer“ on the inside cover
If problems cannot be eliminated, please contact RMG service.
• Note the active message (number and text) in order to be able to dis-
cuss the problem with RMG service.
No. Description
45 The current output is freely configurable (is only code word protected). Violating the
limit value may occur in an otherwise trouble-free operation if the limits are selected
too close together. In this case, the limits can simply be adjusted. The limits are set
ex-factory in such a manner that they correspond with the limit values of the assigned
measured values, e.g., flow. A limit value violation occurs at the current outlet only if
the meter, for example, is run-over and thus also reports a QVb max error (No.78).
60-65 AGC limits can be violated if an actual fault is at hand on the sensors or it is simply
caused by the operating conditions. In order to limit the cause, one should compare
the values of all paths in L-16/17 to Q-16/17. If only the AGC value of a single path
deviates then one has to expect a defect. If all paths are affected then the cause may
be contamination or condensation deposits on the transducer heads or, also an oper-
ating pressure that is simply too low if, for example, the system has not been applied
yet. If the actual operating pressure deviates significantly from that previously speci-
fied, the parameters must be adjusted by the service. For extremely fluctuating oper-
ating conditions, there is an option for switching the attenuator on and off automati-
cally here, which does not always lead to an optimum setting of the gain as this is
only a 2-point regulation

No. Description
78 QVb max limit appears when the meter is actually run. Then all measuring paths in L-
7 to Q-7 should supply respectively high flow velocities. If only one values stands sig-
nificantly out here then it is probably a malfunction of the path affected.
176 100-105 Path errors occur if one or more of the criterion monitored are violated permanently
so that the content of valid measurement falls below the permitted limit value. If all
measuring paths are affected at the same time, the cause for this is usually due to
unsuitable operating conditions. If, for example, high-pressure gas is not applied to
the system, but it is filled with nitrogen at atmospheric pressure, path error messages
are activated as the limit value for the gain (AGC limit) is exceeded as well as the
speed of sound may fall short or the signal leaves the permissible range of the evalu-
ation window. Change the operating conditions or have the parameters adapted to
the desired mode of operation (service deployment)! Contamination or the accumula-
tion of condensation may also be a possibility. Errors on an individual path typically
indicate a malfunction or a defect of the affected transducer or the corresponding wir-
ing. Check the wiring and plug connectors! Only qualified personnel must change the
transducer!
110-115 The flow velocity of the single paths measured are monitored at the limit values ± 50
m/s. If this is a tangible exceeding of the limit value by the actual flow velocity or it is
a malfunction of an individual path, can be determined by comparing the single meas-
urements in L-7 to Q-7. A subsequent error is no. 78.
120-125 The speed of sound of the single paths measured are monitored at the limit values ±
500 m/s. When using a gas (e.g., hydrogen) that deviates strongly with regard to the
speed of sound, a parameterization must be carried out (service). If strongly deviating
speed of sound are to be expected, the function "Signal Tracking" can also be acti-
vated in AI-27 that then adjusts the respective speed of sound range of the evaluation
window. In case of a path error 100-105, the speed of sound is set to 0 so that the
path can also be clearly identified as faulty on the basis of the measuring value, even
if the reconstructed path velocity with the aid of the replacement-value function ap-
pears plausible.
130-135 These additional messages are helpful in faulty path cases (100-105) in order to de-
und termine the defective transducer of the path affected. Naturally, these error messages
are also triggered if the evaluation electronics were defective, but then, all at the
140-145 same time.
150-155 The monitoring of individual paths with regard to their deviation from the average val-
und ues with respect to measuring variable such as speed of sound and gain (AGC = au-
tomatic gain control) serves the premature recognition of possible irregularities. Thus,
170-175 one has the option to already identify conspicuous paths when the limit values rele-
vant for the calibration have not been violated for the validity of the measurement yet.
Possible causes are identical with those described in 100 -125.

13 Technical specifications
In this chapter you will receive information on the performance data of the device.
177
Content
13.1 Performance data 178

13.2 Approved gas types 180
13.2.1 Suitability and safety for natural gas containing H2 180
0

Approved measuring range according to MID 181

13.4 Type plate 182
13.4.1 Type plate ATEX / IECEx 183
178
13.4.2 Type plate NEC (CSA) 184
13.5 Weights and dimensions 184
13.5.1 NEC (CSA) 185
13.5.2 ATEX / IECEx 186
Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle
konnte nicht gefunden werden. Fehler! Textmarke nicht definiert.
13.6 Inner diameter of connecting spool pieces 189
13.7 Official seal diagram 192
13.7.1 Type plate 192
13.7.2 Ultrasonic electronics 193
13.7.3 Ultrasonic gas meter 195
13.8 Transducer types 197
13.1 Performance data

Power supply Measuring element: 24 VDC
Power consumption Measuring element: typical 7-9 W;

with heated display, typically 12 W;
max. 15 W
Protection class IP 66
Interfaces RS 485 0 (for RMGViewUSM): 9600 / 19200 / 38400 / 57600 Baud
RS 485 1 9600 / 19200 / 38400 / 57600 Baud

(for Modbus ASCII, RTU or Flow
Computer)
RS 485 2 9600 / 19200 / 38400 / 57600 Baud

(for Modbus ASCII, RTU or Flow
Computer)

Current output Umax= 16 V Load resistance: max. 400 Ω
Pulse output Umax= 30 V fmax= 5 kHz

179
Sensor frequency 200 kHz (DN100 / 4“ and DN150 /
6“) or 120 kHz (DN200 / 8“ and
larger)
Flow velocity -40 to + 40 m/s
Gas temperature range -40 C to +80 C

(-40 F to 176 F)
Maximum operating observe the details on the type

pressure plate.
Ambient conditions -40 C to +55 C

(-40 F to 131 F)

13.2 Approved gas types

The device must only be operated with the following gas types.
180 Safe operation is only guaranteed with the gas types specified:
• gases of class 1
The components of the gases must be within the concentration limits for test
gases according to EN 437:2009 or similar national standards.
The national standards of other countries demand similar gas type specifications.
Notice
In general, the gas to be measured must not build any condensates in the
operating range of the USM (flow, pressure and temperature range) and
must be free of corrosive and aggressive components, liquids and solids.
In case of deviating conditions a suitable operation has to be agreed with
the RMG service.
13.2.1 Suitability and safety for natural gas containing H2

The USM GT400 can be used in hydrogen-containing natural gas. There are no
safety-related concerns for this use.
Notice
In accordance with the German TR-G19 – the USM GT400 is suitable and
approved for use in custody transfer applications –
in natural gases with a maximum hydrogen content of 10 mol-% without a
loss of the accuracy.
Since there are currently no certified test rigs in Germany to calibrate meters with
higher hydrogen-containing gases, an accuracy above 10 mol-% cannot be tested
or certified.
Not custody transfer measurements are of course possible in natural gases with a
hydrogen content above 10 mol%. However, a reduced measuring range must be
taken into account if applicable. Please contact RMG for further information.

13.3 Approved measuring range according to MID

Nominal diameter Measuring range (m³/h) / (acfh) Extended measuring range (m³/h) /
(acfh) *1 181
mm inches Qmax Qmin Qmin
l780 3 77650 / 23000 5 / 175 (2,5 / 88) abi in preparation
100 4 1000 / 35320 8 / 208 (4 / 140) abcd in preparation
150 6 2400 / 84760 20 / 700 (10 / 350) bci in preparation
200 8 4200 / 148350 32 / 1130 16 / 560
250 10 6600 / 233100 50 / 1750 25 / 880
300 12 9400 / 332000 70 / 2450 35 / 1240
350 12 11400 / 403000 I90 / 3180 45 / 1590
400 16 15000 / 530000 120 / 4230 60 / 2120
450 12 19000 / 670700 150 / 1750 75 / 2650
500 20 23500 / 830000 180 / 6350 90 / 3180
600 24 34000 / 1201000 260 / 9175 130 / 4590
650 26 45000 / 1588000 340 / 12010 170 / 6000
700 28 52000 / 1834800 420 / 14335 210 / 7400
750 30 60000 / 2115000 460 / 16230 320 / 8100
800 32 68000 / 2399000 550 / 19250 550 / 19250
900 36 86000 / 3030000 700 / 24500 700 / 24500
1000 40 108000 / 3800000 850 / 29750 850 / 29750
*1 The extended measuring range only effects Qmin. It can be

used at pressures above p ≥ 4 bar / p ≥ 60 psi.
For meters with a full bore inner diameter according to Di-2 in the table at the end of chapter 13.5,
the table values for Qmin and Qmax are to be increased by a factor of 1.1.
The number of acoustic paths is 6 for all variants.

13.4 Type plate
182
1 Type plate
Fig. 13.1: Position of the type plate
The following details can be found on the type plate:

13.4.1 Type plate ATEX / IECEx
183
Fig. 13.2: Type plate ATEX / IECEx

13.4.2 Type plate NEC (CSA)
184
Fig. 13.3: Type plate NEC (CSA / FM)
13.5 Weights and dimensions
In this chapter you will receive information on the dimensions for the versions NEC
and ATEX /IECEx.
ANSI pressure stages: The flange connecting dimensions comply with the
standard ASME B 16.5.
DIN pressure stages: The flange connecting dimensions comply with the
standard DIN EN 1092.

13.5.1 NEC (CSA)
185
1 Front view
2 Side view
3 Top view
Space requirements for sensor exchange
S0: at non pressure flowmeter
S1: Flowmeter under pressure (with special tool)
Fig. 13.4: Weights and dimensions NEC
The version NEC and version ATEX / IECEx have identical dimensions. The table
of the versions can be found on the following location:
Fehler! Verweisquelle konnte nicht gefunden werden.188

13.5.2 ATEX / IECEx
186
1 Front view
2 Side view
3 Top view
Space requirements for sensor exchange
S0: at non pressure flowmeter
S1: Flowmeter under pressure (with special tool)
Fig. 13.5: Weights and dimensions NEC

187
1 Threaded blind hole

Fig. 13.6: Weights and dimensions DN80
Due to the different sizes of the individual components, the device in DN80 is
shown separately.

Dimensions - Version NEC and ATEX / IECEx

DN L L Di-1 Di-2 T1 H2 B2 B2 SO2 S12 Weight3 Weight3
ANSI900 ANSI 900 ANSI 900
188 80 240 - 73.7 77.9 82.5 450 450 - 225 - 75 -

(3) (9.5) (2.9) (3.07) (3.25) (17.72) (17.72) (8.86) (165)
100 300 400 97.2 102.3 107.1 330 595 415 250 - 100 125
(4) (11.81) (15.75) (3.83) (4.03) (4.22) (12.99) (23.43) (16.34) (9.84) (220) (276)
150 450 450 146.4 154.1 159.3 340 470 470 300 - 160 180
(6) (17.72) (17.72) (5.76) (6.07) (6.27) (13.39) (18.5) (18.5) (11.81) (353) (397)
200 600 800 193.7 202.7 207.3 360 530 565 375 1520 300 380
(8) (23.62) (31.5) (7.63) (7.98) (8.16) (14.17) (20.87) (22.24) (14.76) (59.84) (661) (838)
250 750 1000 242.8 254.5 260.4 380 650 615 400 1550 450 560
(10) (29.53) (39.37) (9.56) (10.02) (10.25) (14.96) (25.59) (24.21) (15.75) (61.02) (992) (1235)
300 900 900 288.8 303.2 309.7 395 700 660 425 1575 550 670
(12) (35.43) (35.42) (11.37) (11.94) (12.19) (15.55) (27.56) (25.98) (16.73) (62.01) (1213) (1477)
350 1050 - 284-348 333.5 - 420 730 - 450 1600 700 -

(11.2-13.7)
(14) (41.34) (14.31) (16.54) (28.74) (17.72) (62.99) (1543)
400 1200 1200 363.5 381.0 292.2 500 750 750 475 1620 950 1050
(16) (47.24) (47.24) (14.31) (15.0) (11.50) (19.69) (29.53) (29.53) (18.70) (63.78) (2094) (2315)
450 1350 - 367-449 428.7 - 530 820 - 500 1650 1000 -

(16) (53.15) (14.4-17.7) (16.88) (20.87) (32.28) (19.69) (64.96) (2205)
500 1500 1500 455.6 477.8 493.8 550 900 860 525 1670 1500 1650
(20) (59.06) (59.06) (17.94) (18.81) (19.44) (21.65) (35.43) (31.5) (20.67) (65.75) (3307) (3638)
600 1200 1500 547.7 574.7 595.8 550 1000 1045 600 1725 1550 2500
(24) (47.24) (59.06) (21.56) (22.63) (23.46) (21.65) (39.37) (41.14) (23.62) (67.91) (3417) (5512)
650 1200 - 632-648 - 680 1040 - 610 1740 1650 -

(24.9-25-5)
(26) (47.24) (26.77) (40.94) (24.02) (68.5) (3638)
700 1200 - 679-699 - 700 1050 - 615 1750 1800 -

(26.8-27.5)
(28) (47.24) (27.56) (41.34) (24.21) (68.9) (3968)
750 1500 - 730-749 - 800 1100 - 650 1780 1900 -

(28.8-29.5)
(30) (59.06) (31.5) (43.31) (25.59) (70.08) (4189)
800 1500 - 778-800 - 850 1150 - 675 1800 2200 -

(30.6-31.5)
(32) (59.06) (33.46) (45.28) (26.57) (70.87) (4850)
900 1500 - 876-902 - 1000 1300 - 750 1875 2600 -

(34.5-35.5)
(36) (59.06) (39.37) (51.18) (29.53) (73.82) (5732)
1000 1500 - 978-1000 - 1200 1400 - 800 1930 3000 -

(38.5-39.4)
(40) (59.06) (47.24) (55.12) (31.5) (75.98) (6614)
Dimensions are in mm (inch); weight in kg (lbs)

The given values are for pressure level ANSI 600, respectively ANSI900 (speci-
fied).

Di-1 = inner diameter (tapered, schedule 80)

Di-2 = inner diameter full bore (schedule 40)
1
Maximum diameter at the flange, depending on tapering. 189
2
Approximate dimension.
3
Approximate values. Weights can vary due to casting tolerances.
An angle of 7° is used for tapering.
13.6 Inner diameter of connecting spool pieces

Connection diameter at tapering of the USM GT400
(= inner diameter for inlet and outlet spool pieces)
Maximum deviation from meter to piping:
+/- 1% acc. MID
For calibrated spool pieces belonging to the measuring instrument, the deviation
may be up to +/- 3%. For the full-bore version, generally +5% / -2% are allowed re-
gardless of the use during calibration.
The blue marked inner diameters for every ANSI pressure rating are to be under-
stood as a recommendation if no inner diameter is specified by the customer.
Meter Pressure Inner Min. ID Max. ID Schedule

size class Diameter of spools of spools
in DN
/ Inch
80 ANSI150 73,7 73 74,4 80
80 ANSI150 77,9 77,2 78,7 40
80 ANSI300 73,7 73 74,4 80
80 ANSI300 77,9 77,2 78,7 40
80 ANSI600 73,7 73 74,4 80
80 ANSI600 77,9 77,2 78,7 40
100 ANSI150RF 97.2 96.2 98.2 80
100 ANSI150RF 102.3 101.3 103.3 40
100 ANSI300RF 97.2 96.2 98.2 80
100 ANSI300RF 102.3 101.3 103.3 40
100 ANSI600RF 97.2 96.2 98.2 80
100 ANSI600RF 102.3 101.3 103.3 40
100 ANSI600RTJ 97.2 96.2 98.2 80
100 ANSI600RTJ 102.3 101.3 103.3 40
150 ANSI150RF 146.4 144.9 147.9 80
150 ANSI150RF 154.1 152.6 155.6 40


in DN
/ Inch
190 150 ANSI300RF 146.4 144.9 147.9 80
150 ANSI300RF 154.1 152.6 155.6 40
150 ANSI600RF 146.4 144.9 147.9 80
150 ANSI600RF 154.1 152.6 155.6 40
150 ANSI600RTJ 146.4 144.9 147.9 80
150 ANSI600RTJ 154.1 152.6 155.6 40
200 ANSI150RF 193.7 191.8 195.6 80
200 ANSI150RF 198.5 196.5 200.5 60
200 ANSI150RF 202.7 200.7 204.7 40
200 ANSI300RF 193.7 191.8 195.6 80
200 ANSI300RF 198.5 196.5 200.5 60
200 ANSI300RF 202.7 200.7 204.7 40
200 ANSI600RF 193.7 191.8 195.6 80
200 ANSI600RF 198.5 196.5 200.5 60
200 ANSI600RF 202.7 200.7 204.7 40
200 ANSI600RTJ 193.7 191.8 195.6 80
200 ANSI600RTJ 198.5 196.5 200.5 60
200 ANSI600RTJ 202.7 200.7 204.7 40
250 ANSI150RF 242.8 240.4 245.2 80
250 ANSI150RF 247.6 245.1 250.1 60
250 ANSI150RF 254.4 251.9 256.9 40
250 ANSI300RF 242.8 240.4 245.2 80
250 ANSI300RF 247.6 245.1 250.1 60
250 ANSI300RF 254.4 251.9 256.9 40
250 ANSI600RF 242.8 240.4 245.2 80
250 ANSI600RF 247.6 245.1 250.1 60
250 ANSI600RF 254.4 251.9 256.9 40
250 ANSI600RTJ 242.8 240.4 245.2 80
250 ANSI600RTJ 247.6 245.1 250.1 60
250 ANSI600RTJ 254.4 251.9 256.9 40
300 ANSI150RF 288.8 285.9 291.7 80
300 ANSI150RF 295.3 292.3 298.3 60
300 ANSI150RF 303.2 300.2 306.2 40
300 ANSI300RF 288.8 285.9 291.7 80
300 ANSI300RF 295.3 292.3 298.3 60
300 ANSI300RF 303.2 300.2 306.2 40
300 ANSI600RF 288.8 285.9 291.7 80
300 ANSI600RF 295.3 292.3 298.3 60
300 ANSI600RF 303.2 300.2 306.2 40
300 ANSI600RTJ 288.8 285.9 291.7 80


in DN
/ Inch
300 ANSI600RTJ 295.3 292.3 298.3 60 191
300 ANSI600RTJ 303.2 300.2 306.2 40
400 ANSI150RF 363.5 359.9 367.1 80
400 ANSI150RF 373.1 369.4 376.8 60
400 ANSI150RF 381 377.2 384.8 40
400 ANSI300RF 363.5 359.9 367.1 80
400 ANSI300RF 373.1 369.4 376.8 60
400 ANSI300RF 381 377.2 384.8 40
400 ANSI600RF 363.5 359.9 367.1 80
400 ANSI600RF 373.1 369.4 376.8 60
400 ANSI600RF 381 377.2 384.8 40
400 ANSI600RTJ 363.5 359.9 367.1 80
400 ANSI600RTJ 373.1 369.4 376.8 60
400 ANSI600RTJ 381 377.2 384.8 40
500 ANSI150RF 455.6 451.0 460.2 80
500 ANSI150RF 466.8 462.1 471.5 60
500 ANSI150RF 477.8 473.0 482.6 40
500 ANSI300RF 455.6 451.0 460.2 80
500 ANSI300RF 466.8 462.1 471.5 60
500 ANSI300RF 477.8 473.0 482.6 40
500 ANSI600RF 455.6 451.0 460.2 80
500 ANSI600RF 466.8 462.1 471.5 60
500 ANSI600RF 477.8 473.0 482.6 40
500 ANSI600RTJ 455.6 451.0 460.2 80
500 ANSI600RTJ 466.8 462.1 471.5 60
500 ANSI600RTJ 477.8 473.0 482.6 40
600 ANSI300RF 547.7 542.2 553.2 80
600 ANSI300RF 560.4 554.8 566.0 60
600 ANSI300RF 574.6 568.9 580.3 40
600 ANSI600RF 547.7 542.2 553.2 80
600 ANSI600RF 560.4 554.8 566.0 60
600 ANSI600RF 574.6 568.9 580.3 40

13.7 Official seal diagram

In this chapter you will receive information at which location the official seals are
attached to the device.
192
The device must not be used for a calibrated operation if the official seal is
broken.
13.7.1 Type plate
1 Seal
Fig. 13.7: Position of the official seal on the type plate

13.7.2 Ultrasonic electronics
193
Representation of the device with DN 150 (6“)

1 Side view
2 Top view
3 Seal
Fig. 13.8: Official seal diagram according to AEX / IECEx

194
Representation of the device with DN 150 (6“)

1 Side view
2 Top view
3 Seal
Fig. 13.9: Official seal diagram according to NEC

13.7.3 Ultrasonic gas meter
195
Fig. 13.10: Devices DN 80 (3”), DN 100 (4“) and DN 150 (6“)

196
1 Front view 2 Side view

3 Top view 4 View without cover
5 Seal 6 Type plate
Fig. 13.11: Devices DN 200 (8 ") and larger
Seals of the measuring element of type USM-GT-400
Valid for sizes DN 200 upwards
Representation: DN 200

13.8 Transducer types

Danger
197
If transducers of a device under pressure are not changed correctly, this may
cause an explosion. Escaping gas mixtures may lead to intoxication.
this activity.
• Observe the separate service instruction for changing the transducer.
1 TNG 10-CP / -CHP

Fig. 13.12: Trancducer type TNG 10-CP / -CHP
1 TNG 20-SP / -SHP

Fig. 13.13: Trancducer type TNG 20-SP / -SHP

Transducer Operating fre- Operating pressure Ambient temperature Gas temper-

type quency (kHz) range bar (psi) °C (°F) ature °C (°F)
198
TNG 10-CP 120 1–150 -40 to +55 °C to +80 °C
(14,5 to 2175.57) (55 to 131 °F) (176 °F)
TNG 10-CHP 120 1–300 -40 to +55 °C to +80 °C

(14,5 to 4351.13) (55 to 131 °F) (176 °F)
TNG 20-SP 200 1–150 -40 to +55 °C to +80 °C

(14,5 to 2175.57) (55 to 131 °F) (176 °F)
TNG 20-SHP 200 1–300 -40 to +55 °C to +80 °C

(14,5 to 4351.13) (55 to 131 °F) (176 °F)

14 Spare parts and accessories

Order number Description
199
Electronics
98800-14400 USE 09, complete electronics
98800-13352 USE 09, display circuit board
98800-13512 USE 09, Options card 1 (RS485 and pulse outputs)
98800-13762 USE 09, Options card 2 (P&T inputs)
98800-13020 USE 09, Multiplexer (4 channels)
00.66.197.00 Magnetic pin, complete with holder
External elements
00.65.142.00 Weather protection cover for electronics housing
00.64.923.00 Complete grill element DN 100 (4”)
00.64.855.00 Complete grill element DN 150 (6”)
00.64.811.00 Transducer cover for DN 80 (3”) to DN 150 (6”)
00.64.798.00 Grill element DN 200 (8”)
00.64.860.00 Grill element DN 250 (10”)
00.64.862.00 Grill element DN 300 (12”)
00.64.864.00 Grill element DN 400 (16”)
00.64.866.00 Grill element DN 500 (20”)
00.64.868.00 Grill element (middle level) DN 600 (24”)
00.64.926.00 Grill element (outer levels) DN 600 (24”)
87.06.050.00 Cable bushing M20x1.5 (Ø 3‐9)
87.06.051.00 Cable bushing M20x1.5 (Ø 6‐12)
84.08.023.00 Shut-off valve NV2F-4N-R-K 2x1/4NPT inn.H.

Pipe bundles
00.64.767.01 Pipe bundle for DN 100 (4”)
200
Transducers
00.64.758.00 USM-transducer type TNG 20-SP (3”-6”), 200 kHz, up to 150 bar(a)
00.65.000.00 USM-transducer type TNG20-SHP (3”-6”), 200 kHz, up to 300 bar(a)
00.64.757.00 USM-transducer type TNG 10-CP (8”-40”), 120 kHz, up to 150 bar(a)
00.64.839.00 USM-transducer type TNG10-CHP (8”-40”), 120 kHz, up to 300 bar(a)
Tools for transducer replacement

00.64.669.00 Special tool for transducer replacement DN200 (8”)
38.00.014.00 Special tool pair d=7x10 for USE-09
00.61.128.00 Special tool for transducer replacement under pressure (from DN 200)
Interface converter
30.00.212.00 RS 485 to USB converter for top hat rail (I‐7561U‐G CR)
35.00.023.00 RS 485 to Ethernet converter (FL Comserver)

15 Lists of parameters and measured values
15 Lists of parameters and measured

values 201
The following tables show the parameters that can be shown and edited using the
RMGViewUSM software or via the display with control panel.
With different versions of the device software, individual parameters may

have different coordinates.
The abbreviations in the Type and Protection (Prot.) columns have the following
meanings:
Type Protection
F Float R Reading Value
M Menu S Official Key
I Integer F free programmable
U Unixtime C Codeword
L Long Int. CS Code and Official Key
T Text
D Double
C Code
(d) to the right of a menu option means “default value”.

Pressure
Coord. Value Reg. No. Type Prot. Unit Description
202 A-01 Pressure 6252 2 F R → Units: Pressure a Shows the measured pressure
A-03 Current Input 6254 2 F R mA Shows the input value in mA
A-05 p min value 1392 2 F S → Units: Pressure a Measuring pressure min. value
A-06 p max value 1394 2 F S → Units: Pressure a Measuring pressure max. value
A-09 p set value 1396 2 F S → Units: Pressure a Measuring pressure default value
A-11 p at base cond. 1398 2 F S → Units: Pressure a base pressure
A-12 curr. inp. gradient 1400 2 F S Gradient (correction of the mA value)
A-13 curr. inp. offset 1402 2 F S Offset (correction of the mA value)
A-14 p err. min 1404 2 F S → Units: Pressure a Lower error limit of measuring pressure
A-15 p err. max 1406 2 F S → Units: Pressure a Upper error limit of measuring pressure
A-17 p mode 4078 1 M S Operating mode of measuring pressure
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 4-20mA
0x0003 4-20mA_ERR
Temperature

B-01 temperature 6256 2 F R → Units: Temp. PT100-input
B-03 PT100 resistance 6258 2 F R Ohm PT100-input
B-09 T set value 1408 2 F S → Units: Temp. PT100-input
B-11 T at base cond. 1410 2 F S → Units: Temp. base temperature
B-12 T gradient 1412 2 F S Gradient (correction of the Ohm value)
B-13 T offset 1414 2 F S Offset (correction of the Ohm value)
B-14 T err. min 1416 2 F S → Units: Temp. Lower error limit of measuring tempera-
ture
B-15 T err. max 1418 2 F S → Units: Temp. Upper error limit of measuring tempera-
ture
B-17 T mode 4079 1 M S Operating mode of measuring tempera-
ture
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 PT100
0x0003 PT100_ERR

USE09-C Meas. Val.

C-01 vw 6220 2 F R → velocity unit weighted gas velocity
C-02 vwc 6222 2 F R → velocity unit corrected weighted gas velocity 203
C-03 Qm 6224 2 F R → flow unit Intermediate result for Qm (with pre-
ceding sign)
C-04 Qmb 6238 2 F R → flow unit Intermediate result for Qmb (with pre-
ceding sign)
C-05 Qmc 6226 2 F R → flow unit Intermediate result for Qmc (with pre-
ceding sign)
C-06 performance 6268 1 I R % Performance
USE09-C Qm

D-01 vol. Flow rate Qm 730 10 T R → flow unit Volumetric flow rate Qm after all cor-
rections (as amount) with up-
stream/downstream identification
D-02 vol. flow rate Qm 6230 2 F R → flow unit Volumetric flow rate Qm after all cor-
rections (Qm lower limit will be ob-
served)
D-03 Qm damped 6264 2 F R → flow unit Volumetric flow rate Qm damped (Qm
lower limit will be observed)
D-04 Qm min. 1320 2 F S → flow unit Qm min. limit
D-05 Qm max. 1322 2 F S → flow unit Qm max. limit
D-06 vw factor d1 1324 2 F S [1] Constant Kv direction 1
D-07 vw factor d2 1436 2 F S [1] Constant Kv direction 2
D-08 vw lower limit 1326 2 F S → Calib. units: v vw lower limit (creeping quantity before
apply. polynomial)
D-09 Qm lower limit 1328 2 F S → flow unit Qm lower limit (creeping quantity)
D-10 Qm-min time 2120 1 I S s Time below Qm min
D-15 Qm damping 1446 2 F C Damping for Qmc-D (0.0=off, 1.0=max)
D-16 pipe diameter 1334 2 F S → Calib. units: Pipe diameter
Length
D-17 geometry correct- 2258 1 M S Correction of the effects of press. and
ing temp.
0x0000 OFF (d)
0x0001 ON
D-18 temp. coefficient 1450 2 F S Temperature coefficient
D-19 pressure coeff. 1452 2 F S Pressure coefficient
D-20 Qm-max value 1 1330 2 F C → flow unit Qm max. value of direction 1
D-21 Qm-max time 1 2580 2 U C Time of Qm max. value 1
D-22 Qm-max value 2 1332 2 F C → flow unit Qm max. value of direction 2
D-23 Qm-max time 2 2582 2 U C Time of Qm max. value 2
D-24 Qt 9084 2 F R Transition flow Qt

Parameters

E-01 USE09 working 2090 1 M S USE09 operating mode
204 mode
0x0000 IGM (d)
0x0001 USE09C
0x0002 SIMU
0x0003 SIMU_K
0x0004 SIMU_N
0x0005 SIMU_EW
E-02 path select 690 10 T S Select activated paths (path 1.1, path
1.2 … path 4.2)
E-03 max. path RV 2121 1 I S Maximum number of used replacement
values
E-04 fault time 2122 1 I S s Time limit for IGM timeout
E-05 error per cent 2123 1 I S % A measurement quality below this level
will cause a path error
E-09 moving average 2125 1 I C Number of measured values for the
cnt moving average, V, SoS
E-15 SoS mode 2240 1 M C Speed of Sound mode
0x0000 STANDARD (d)
0x0001 EXTENDED
0x0002 CALIBRATION
0x0003 STATISTIC OFF
E-16 delta SoS mode 2091 1 M C Delta SoS observing ON / OFF
0x0000 OFF
0x0001 ON (d)
E-17 delta SoS limit 1344 2 F C % Limit for Delta SoS
E-18 std. SoS corr-fac- 1370 2 F S [1] Standard SoS correction-factor
tor
E-19 adv. SoS corr-fac- 9068 2 F S [1] Advanced SoS correction-factor
tor
E-20 std. SoS v factor 1372 2 F S [1] Standard SoS v correction-factor
E-21 adv. SoS v factor 9070 2 F S [1] Advanced SoS v correction-factor
E-22 delta AGC limits 1438 2 F C dB Max. deviation between path-AGC and
AGC-mean
E-23 Tw correct 2281 1 M S Correct TWs
0x0000 OFF (d)
0x0001 SET
E-24 Tw damping 1518 2 F C Damping for TW adjustment
USE09-C polynom-B

Flow correction

G-01 error curve lin. 2093 1 M S Error curve linearization mode
0x0000 OFF (d) 205
0x0001 POLYNOMIAL
0x0002 piecewise lin.
G-02 const m2 d.1 1276 2 F S [1] Error polynomial for direction 1
G-04 const 0 d.1 1280 2 F S [1] Error polynomial for direction 1
G-20 dir. 1: flowrate 1 1600 2 F S → Calib. units: Q Linear interpolation direction 1: flow
rate 1
G-21 dir. 1: error 1 1602 2 F S % Linear interpolation direction 1: error 1
rate 2
rate 3
rate 4
rate 5
rate 6
rate 7
rate 8
rate 9
rate 10

rate 11
206 rate 12
rate 1
rate 2
rate 3
rate 4
rate 5
rate 6
rate 7
rate 8
rate 9
rate 10
rate 11
rate 12

Freq.,Pulse Outputs

H-01 fo base value 6248 2 F R → flow unit Measured value of the frequency out-
put 207
H-02 frequency value 6250 2 F R Hz Frequency value of the frequency out-
put (in Hz)
H-03 fo corr. factor 1386 2 F S Correction factor of the frequency out-
put
H-04 corr. frequency 6266 2 F R Hz Correction of the frequency value of the
frequency output (in Hz)
H-05 fo base max. 1388 2 F S → Calib. units: Q Upper range value of the frequency out-
put (physical value)
H-06 fo freq. max. 1444 2 F S Hz Maximum value of the frequency out-
put (in Hz)
H-07 pulse value 6262 2 F R → pulse unit Indication of the calculated pulse value
of the frequency output
H-08 fo set value 1390 2 F S Hz Calibration frequency
H-09 fo select 2161 1 M C Selection of the measured value for the
frequency output
0x0000 QMC (d)
0x0001 QMC-D
H-10 fo mode 2162 1 M S Operating mode of the frequency out-
put
0x0000 OFF
0x0001 SET VALUE
0x0002 ON (d)
0x0003 TEST
H-11 fo2 error mode 2163 1 M S Frequency-2 mode if a fault occurs
0x0000 F2 STOP (d)
0x0001 F2 ACTIVE
0x0002 CRYSTAL TEST
H-12 ferr waveform 6260 2 F R Hz Frequency delta
gen.
H-15 IO-1 mode 2165 1 M C Mode for IO-1
0x0000 OFF
0x0001 DIRECTION (d)
0x0002 DIRECTION
INV.
0x0003 INPUT
0x0004 TEST
0x0005 WARN-INPUT
HIGH
0x0006 WARN-INPUT
LOW
H-16 IO-2 mode 2166 1 M C Mode for IO-2
0x0000 OFF
0x0001 DIRECTION (d)

0x0002 DIRECTION
INV.
0x0003 INPUT
0x0004 TEST
208 0x0005 CPU
H-17 mode ext. warn- 2186 1 M C Mode in the case of external warning
ing
0x0000 OFF (d)
0x0001 LOW_POWER
H-20 Test Alarm a. 1 M C Tests the warning and alarm contacts
Warn 4081
0x0000 OFF (d)
0x0001 TEST
Current Output

I-01 c-out physical val. 6244 2 F R Current output, physical value
I-02 c-out value 6246 2 F R mA Current output in mA
I-03 c-out min. 1374 2 F C Current output, physical minimum value
I-04 c-out max. 1376 2 F C Current output, physical maximum
value
I-05 c-out set value 1378 2 F C mA Current output, set value
I-06 c-out select 2158 1 I C Current output, selection of the meas-
ured value (Modbus reg.)
I-07 c-out mode 2159 1 M C Current output, operating mode
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 0-20mA
0x0003 4-20mA
I-08 c-out err mode 2160 1 M C Current output, operating mode if a
fault occurs
0x0000 OFF (d)
0x0001 MIN
0x0002 MAX
I-09 c-out damping 1380 2 F C Current output, damping (0.0=OFF,
1.0=max)
I-10 c-out gradient 1382 2 F S Current output, gradient
I-11 c-out offset 1384 2 F S Current output, offset
Serial Ports

J-12 DZU-0 address 2283 1 I F Serial interface -1 DZU slave ID (ASCII:
00-99)
J-13 serial-0 status 760 10 T R Serial interface -1 status

J-14 serial-1 mode 2107 1 M F Serial interface -1 mode

0x0000 OFF (d)
0x0001 IGM
0x0002 USE09
209
0x0003 DZU
0x0004 DZU-DIAG
0x0005 DZU X-FRAME
0x0006 VO
0x0007 DZU-SLAVE
0x0008 Modbus
J-15 serial-1 baud rate 2108 1 M F baud Serial interface -1 baud rate
0x0000 2400
0x0001 4800
0x0002 9600
0x0003 19200 (d)
0x0004 38400
0x0005 57600
J-16 serial-1 bits 2109 1 M F Serial interface -1 number of bits
0x0000 7
0x0001 8 (d)
J-17 serial-1 parity 2110 1 M F Serial interface -1 parity
0x0000 NONE (d)
0x0001 EVEN
0x0002 ODD
00-99)
J-24 serial-1 status 770 10 T R Serial interface -1 status
J-25 opt. ser2 mode 2112 1 M F Optional serial interface -2 mode
0x0000 OFF
0x0001 Modbus (d)
0x0002 IGM
0x0003 USE09
0x0004 DZU-SLAVE
0x0005 RMGBus
0x0006 Modbus mas-
ter
J-26 opt. ser2 baud 2113 1 M F baud Optional serial interface -2 baud rate
rate
0x0000 2400
0x0001 4800
0x0002 9600
0x0003 19200
0x0004 38400 (d)

0x0005 57600
J-27 opt. ser2 bits 2114 1 M F Optional serial interface -2 number of
bits
0x0000 7
210 0x0001 8 (d)
J-28 opt. ser2 parity 2115 1 M F Optional serial interface -2 parity
0x0000 NONE (d)
0x0001 EVEN
0x0002 ODD
J-29 Modbus-2 proto- 2178 1 M F Optional serial interface -2 Modbus op-
col erating mode (Off, Ascii or RTU)
0x0000 OFF
0x0001 RTU (d)
0x0002 ASCII
J-30 Modbus-2 hw- 2179 1 M F Optional serial interface -2 Modbus
mode hardware (RS232 or RS485)
0x0000 RS232
0x0001 RS485 (d)
J-31 Modbus-2 ad- 2180 1 I F Optional serial interface -2 Modbus ad-
dress dress (ID)
J-32 Modbus-2 reg.off- 2181 1 I F Optional serial interface -2 Modbus reg-
set ister offset
J-33 Modbus-2 gap 2182 1 I F Optional serial interface -2 Modbus
time turn-off time
J-34 Long Byte Order 2251 1 M F Ser-2 Modbus byte order with long:
(1,0)(3,2) or (3,2)(1,0)
0x0000 NORMAL
0x0001 SWAPPED (d)
J-35 Float Byte Order 2252 1 M F Ser-2 Modbus byte order with float:
(1,0)(3,2) or (3,2)(1,0)
0x0000 NORMAL
0x0001 SWAPPED (d)
J-36 Double Byte Or- 2253 1 M F Ser-2 Modbus byte order with double:
der (1,0)(3,2)(5,4)(7,6) or (7,6)(5,4)(3,2)(1,0)
0x0000 NORMAL (d)
0x0001 SWAPPED
00-99)
J-38 serial-2 status 780 10 T R Optional serial interface -2 status
J-39 DZU Interval 2111 1 I S tics Optional serial interface -2 DZU-interval
J-40 DZU Checksum 2255 1 M F Serial interface -1, initial DZU checksum
Preset value
0x0000 0x00 (d)
0x0001 0x7F

DSP,FPGA values

K-20 DSP status 4004 1 I R hex DSP status (bit encoded)
K-21 DSP error 4003 1 I R hex DSP error (bit encoded) 211
K-22 DSP bytes re- 7034 1 I R Counts the receive telegrams from DSP
ceived
K-23 FPGA status 4006 1 I R hex FPGA status (bit encoded)
K-24 FPGA error 4005 1 I R hex FPGA error (bit encoded)
Path1 Meas. Values

L-01 p1.1 time of flight 6100 2 F R us Path 1.1 time of flight
L-02 p1.2 time of flight 6120 2 F R us Path 1.2 time of flight
L-03 path-1 delta-t 6140 2 F R us Path 1 time difference
L-04 p1 delta-t corr. 6540 2 F R us Path 1 corrected time difference
L-06 Valid samples G1 7000 1 I R % Path 1 valid measuring values in %
L-07 path-1 velocity 6000 2 F R → velocity unit Path 1 path velocity
L-08 velocity vc1 6200 2 F R → velocity unit Path 1 corrected path velocity vc
L-09 SoS1 6020 2 F R → velocity unit Path 1 Speed of Sound
L-10 path-1 delta SoS 6080 2 F R % Path 1 Path-SoS / Mean-SoS
L-12 path-1 fault 4030 1 I R hex Path 1 path error
L-13 path-1 status 4040 1 I R hex Path 1 path status
L-14 p1.1 Amplitude 7010 1 I R % Path 1.1 amplitude in per cent
L-15 p1.2 Amplitude 7020 1 I R % Path 1.2 amplitude in per cent
L-16 p1.1 AGC-level 6040 2 F R dB Path 1.1 Automated Gain Control
L-17 p1.2 AGC-level 6060 2 F R dB Path 1.2 Automated Gain Control
L-18 p1.1 snr 6640 2 F R dB Path 1.1 signal-to-noise ratio
L-19 p1.2 snr 6660 2 F R dB Path 1.2 signal-to-noise ratio
L-20 path-1 fault (X) 2270 1 I R hex Path 1 path error (3X-measurement)
L-21 p1.1 AGC-level (X) 6680 2 F R dB Path 1.1 Automated Gain Control (3X-
measurement)
L-22 p1.2 AGC-level (X) 6700 2 F R dB Path 1.2 Automated Gain Control (3X-
measurement)
L-23 p1.1 snr (X) 6720 2 F R dB Path 1.1 signal-to-noise ratio (3X-meas-
urement)
L-24 p1.2 snr (X) 6740 2 F R dB Path 1.2 signal-to-noise ratio (3X-meas-
urement)
L-26 path-1 turbulence 6776 2 F R % Path 1 turbulence

Path2 Meas. Values

M-01 p2.1 time of flight 6102 2 F R us Path 2.1 time of flight
212 M-02 p2.2 time of flight 6122 2 F R us Path 2.2 time of flight
M-03 path-2 delta-t 6142 2 F R us Path 2 time difference
M-04 p2 delta-t corr. 6542 2 F R us Path 2 corrected time difference
M-06 Valid samples G2 7001 1 I R % Path 2 valid measuring values in %
M-07 path-2 velocity 6002 2 F R → velocity unit Path 2 path velocity
M-08 velocity vc2 6202 2 F R → velocity unit Path 2 corrected path velocity vc
M-09 SoS2 6022 2 F R → velocity unit Path 2 Speed of Sound
M-10 path-2 delta SoS 6082 2 F R % Path 2 Path-SoS / Mean-SoS
M-12 path-2 fault 4031 1 I R hex Path 2 path error
M-13 path-2 status 4041 1 I R hex Path 2 path status
M-14 p2.1 Amplitude 7011 1 I R % Path 2.1 amplitude in per cent
M-15 p2.2 Amplitude 7021 1 I R % Path 2.2 amplitude in per cent
M-16 p2.1 AGC-level 6042 2 F R dB Path 2.1 Automated Gain Control
M-17 p2.2 AGC-level 6062 2 F R dB Path 2.2 Automated Gain Control
M-18 p2.1 snr 6642 2 F R dB Path 2.1 signal-to-noise ratio
M-19 p2.2 snr 6662 2 F R dB Path 2.2 signal-to-noise ratio
M-20 path-2 fault (X) 2271 1 I R hex Path 2 path error (3X-measurement)
M-21 p2.1 AGC-level (X) 6682 2 F R dB Path 2.1 Automated Gain Control (3X-
measurement)
M-22 p2.2 AGC-level (X) 6702 2 F R dB Path 2.2 Automated Gain Control (3X-
measurement)
M-23 p2.1 snr (X) 6722 2 F R dB Path 2.1 signal-to-noise ratio (3X-meas-
urement)
M-24 p2.2 snr (X) 6742 2 F R dB Path 2.2 signal-to-noise ratio (3X-meas-
urement)
M-26 path-2 turbulence 6778 2 F R % Path 2 turbulence
Path3 Meas. Values

N-01 p3.1 time of flight 6104 2 F R us Path 3.1 time of flight
N-02 p3.2 time of flight 6124 2 F R us Path 3.2 time of flight
N-03 path-3 delta-t 6144 2 F R us Path 3 time difference
N-04 p3 delta-t corr. 6544 2 F R us Path 3 corrected time difference
N-06 Valid samples G3 7002 1 I R % Path 3 valid measuring values in %
N-07 path-3 velocity 6004 2 F R → velocity unit Path 3 path velocity
N-08 velocity vc3 6204 2 F R → velocity unit Path 3 corrected path velocity vc
N-09 SoS3 6024 2 F R → velocity unit Path 3 Speed of Sound
N-10 path-3 delta SoS 6084 2 F R % Path 3 Path-SoS / Mean-SoS
N-12 path-3 fault 4032 1 I R hex Path 3 path error

N-13 path-3 status 4042 1 I R hex Path 3 path status

N-14 p3.1 Amplitude 7012 1 I R % Path 3.1 amplitude in per cent
N-15 p3.2 Amplitude 7022 1 I R % Path 3.2 amplitude in per cent
N-16 p3.1 AGC-level 6044 2 F R dB Path 3.1 Automated Gain Control
213
N-17 p3.2 AGC-level 6064 2 F R dB Path 3.2 Automated Gain Control
N-18 p3.1 snr 6644 2 F R dB Path 3.1 signal-to-noise ratio
N-19 p3.2 snr 6664 2 F R dB Path 3.2 signal-to-noise ratio
N-20 path-3 fault (X) 2272 1 I R hex Path 3 path error (3X-measurement)
N-21 p3.1 AGC-level (X) 6684 2 F R dB Path 3.1 Automated Gain Control (3X-
measurement)
N-22 p3.2 AGC-level (X) 6704 2 F R dB Path 3.2 Automated Gain Control (3X-
measurement)
N-23 p3.1 snr (X) 6724 2 F R dB Path 3.1 signal-to-noise ratio (3X-meas-
urement)
N-24 p3.2 snr (X) 6744 2 F R dB Path 3.2 signal-to-noise ratio (3X-meas-
urement)
N-26 path-3 turbulence 6780 2 F R % Path 3 turbulence
Path4 Meas. Values

O-01 p4.1 time of flight 6106 2 F R us Path 4.1 time of flight
O-02 p4.2 time of flight 6126 2 F R us Path 4.2 time of flight
O-03 path-4 delta-t 6146 2 F R us Path 4 time difference
O-04 p4 delta-t corr. 6546 2 F R us Path 4 corrected time difference
O-06 Valid samples G4 7003 1 I R % Path 4 valid measuring values in %
O-07 path-4 velocity 6006 2 F R → velocity unit Path 4 path velocity
O-08 velocity vc4 6206 2 F R → velocity unit Path 4 corrected path velocity vc
O-09 SoS4 6026 2 F R → velocity unit Path 4 Speed of Sound
O-10 path-4 delta SoS 6086 2 F R % Path 4 Path-SoS / Mean-SoS
O-12 path-4 fault 4033 1 I R hex Path 4 path error
O-13 path-4 status 4043 1 I R hex Path 4 path status
O-14 p4.1 Amplitude 7013 1 I R % Path 4.1 amplitude in per cent
O-15 p4.2 Amplitude 7023 1 I R % Path 4.2 amplitude in per cent
O-16 p4.1 AGC-level 6046 2 F R dB Path 4.1 Automated Gain Control
O-17 p4.2 AGC-level 6066 2 F R dB Path 4.2 Automated Gain Control
O-18 p4.1 snr 6646 2 F R dB Path 4.1 signal-to-noise ratio
O-19 p4.2 snr 6666 2 F R dB Path 4.2 signal-to-noise ratio
O-20 path-4 fault (X) 2273 1 I R hex Path 4 path error (3X-measurement)
O-21 p4.1 AGC-level (X) 6686 2 F R dB Path 4.1 Automated Gain Control (3X-
measurement)
O-22 p4.2 AGC-level (X) 6706 2 F R dB Path 4.2 Automated Gain Control (3X-
measurement)
O-23 p4.1 snr (X) 6726 2 F R dB Path 4.1 signal-to-noise ratio (3X-meas-
urement)

O-24 p4.2 snr (X) 6746 2 F R dB Path 4.2 signal-to-noise ratio (3X-meas-
urement)
O-26 path-4 turbulence 6782 2 F R % Path 4 turbulence
214
Path5 Meas. Values

P-01 p5.1 time of flight 6108 2 F R us Path 5.1 time of flight
P-02 p5.2 time of flight 6128 2 F R us Path 5.2 time of flight
P-03 path-5 delta-t 6148 2 F R us Path 5 time difference
P-04 p5 delta-t corr. 6548 2 F R us Path 5 corrected time difference
P-06 Valid samples G5 7004 1 I R % Path 5 valid measuring values in %
P-07 path-5 velocity 6008 2 F R → velocity unit Path 5 path velocity
P-08 velocity vc5 6208 2 F R → velocity unit Path 5 corrected path velocity vc
P-09 SoS5 6028 2 F R → velocity unit Path 5 Speed of Sound
P-10 path-5 delta SoS 6088 2 F R % Path 5 Path-SoS / Mean-SoS
P-12 path-5 fault 4034 1 I R hex Path 5 path error
P-13 path-5 status 4044 1 I R hex Path 5 path status
P-14 p5.1 Amplitude 7014 1 I R % Path 5.1 amplitude in per cent
P-15 p5.2 Amplitude 7024 1 I R % Path 5.2 amplitude in per cent
P-16 p5.1 AGC-level 6048 2 F R dB Path 5.1 Automated Gain Control
P-17 p5.2 AGC-level 6068 2 F R dB Path 5.2 Automated Gain Control
P-18 p5.1 snr 6648 2 F R dB Path 5.1 signal-to-noise ratio
P-19 p5.2 snr 6668 2 F R dB Path 5.2 signal-to-noise ratio
P-20 path-5 fault (X) 2274 1 I R hex Path 5 path error (3X-measurement)
P-21 p5.1 AGC-level (X) 6688 2 F R dB Path 5.1 Automated Gain Control (3X-
measurement)
P-22 p5.2 AGC-level (X) 6708 2 F R dB Path 5.2 Automated Gain Control (3X-
measurement)
P-23 p5.1 snr (X) 6728 2 F R dB Path 5.1 signal-to-noise ratio (3X-meas-
urement)
P-24 p5.2 snr (X) 6748 2 F R dB Path 5.2 signal-to-noise ratio (3X-meas-
urement)
P-26 path-5 turbulence 6784 2 F R % Path 5 turbulence
Path6 Meas. Values

Q-01 p6.1 time of flight 6110 2 F R us Path 6.1 time of flight
Q-02 p6.2 time of flight 6130 2 F R us Path 6.2 time of flight
Q-03 path-6 delta-t 6150 2 F R us Path 6 time difference
Q-04 p6 delta-t corr. 6550 2 F R us Path 6 corrected time difference
Q-06 Valid samples G6 7005 1 I R % Path 6 valid measuring values in %
Q-07 path-6 velocity 6010 2 F R → velocity unit Path 6 path velocity

Q-08 velocity vc6 6210 2 F R → velocity unit Path 6 corrected path velocity vc
Q-09 SoS6 6030 2 F R → velocity unit Path 6 Speed of Sound
Q-10 path-6 delta SoS 6090 2 F R % Path 6 Path-SoS / Mean-SoS
Q-12 path-6 fault 4035 1 I R hex Path 6 path error
215
Q-13 path-6 status 4045 1 I R hex Path 6 path status
Q-14 p6.1 Amplitude 7015 1 I R % Path 6.1 amplitude in per cent
Q-15 p6.2 Amplitude 7025 1 I R % Path 6.2 amplitude in per cent
Q-16 p6.1 AGC-level 6050 2 F R dB Path 6.1 Automated Gain Control
Q-17 p6.2 AGC-level 6070 2 F R dB Path 6.2 Automated Gain Control
Q-18 p6.1 snr 6650 2 F R dB Path 6.1 signal-to-noise ratio
Q-19 p6.2 snr 6670 2 F R dB Path 6.2 signal-to-noise ratio
Q-20 path-6 fault (X) 2275 1 I R hex Path 6 path error (3X-measurement)
Q-21 p6.1 AGC-level (X) 6690 2 F R dB Path 6.1 Automated Gain Control (3X-
measurement)
Q-22 p6.2 AGC-level (X) 6710 2 F R dB Path 6.2 Automated Gain Control (3X-
measurement)
Q-23 p6.1 snr (X) 6730 2 F R dB Path 6.1 signal-to-noise ratio (3X-meas-
urement)
Q-24 p6.2 snr (X) 6750 2 F R dB Path 6.2 signal-to-noise ratio (3X-meas-
urement)
Q-26 path-6 turbulence 6786 2 F R % Path 6 turbulence
Path7 Meas. Values

R-01 p7.1 time of flight 6112 2 F R us Path 7.1 time of flight
R-02 p7.2 time of flight 6132 2 F R us Path 7.2 time of flight
R-03 path-7 delta-t 6152 2 F R us Path 7 time difference
R-04 p7 delta-t corr. 6552 2 F R us Path 7 corrected time difference
R-06 Valid samples G7 7006 1 I R % Path 7 valid measuring values in %
R-07 path-7 velocity 6012 2 F R → velocity unit Path 7 path velocity
R-08 velocity vc7 6212 2 F R → velocity unit Path 7 corrected path velocity vc
R-09 SoS7 6032 2 F R → velocity unit Path 7 Speed of Sound
R-10 path-7 delta SoS 6092 2 F R % Path 7 Path-SoS / Mean-SoS
R-12 path-7 fault 4036 1 I R hex Path 7 path error
R-13 path-7 status 4046 1 I R hex Path 7 path status
R-14 p7.1 Amplitude 7016 1 I R % Path 7.1 amplitude in per cent
R-15 p7.2 Amplitude 7026 1 I R % Path 7.2 amplitude in per cent
R-16 p7.1 AGC-level 6052 2 F R dB Path 7.1 Automated Gain Control
R-17 p7.2 AGC-level 6072 2 F R dB Path 7.2 Automated Gain Control
R-18 p7.1 snr 6652 2 F R dB Path 7.1 signal-to-noise ratio
R-19 p7.2 snr 6672 2 F R dB Path 7.2 signal-to-noise ratio
R-20 path-7 fault (X) 2276 1 I R hex Path 7 path error (3X-measurement)

R-21 p7.1 AGC-level (X) 6692 2 F R dB Path 7.1 Automated Gain Control (3X-
measurement)
R-22 p7.2 AGC-level (X) 6712 2 F R dB Path 7.2 Automated Gain Control (3X-
measurement)
R-23 p7.1 snr (X) 6732 2 F R dB Path 7.1 signal-to-noise ratio (3X-meas-
216 urement)
R-24 p7.2 snr (X) 6752 2 F R dB Path 7.2 signal-to-noise ratio (3X-meas-
urement)
R-26 path-7 turbulence 6788 2 F R % Path 7 turbulence
Path8 Meas. Values

S-01 p8.1 time of flight 6114 2 F R us Path 8.1 time of flight
S-02 p8.2 time of flight 6134 2 F R us Path 8.2 time of flight
S-03 path-8 delta-t 6154 2 F R us Path 8 time difference
S-04 p8 delta-t corr. 6554 2 F R us Path 8 corrected time difference
S-06 Valid samples G8 7007 1 I R % Path 8 valid measuring values in %
S-07 path-8 velocity 6014 2 F R → velocity unit Path 8 path velocity
S-08 velocity vc8 6214 2 F R → velocity unit Path 8 corrected path velocity vc
S-09 SoS8 6034 2 F R → velocity unit Path 8 Speed of Sound
S-10 path-8 delta SoS 6094 2 F R % Path 8 Path-SoS / Mean-SoS
S-12 path-8 fault 4037 1 I R hex Path 8 path error
S-13 path-8 status 4047 1 I R hex Path 8 path status
S-14 p8.1 Amplitude 7017 1 I R % Path 8.1 amplitude in per cent
S-15 p8.2 Amplitude 7027 1 I R % Path 8.2 amplitude in per cent
S-16 p8.1 AGC-level 6054 2 F R dB Path 8.1 Automated Gain Control
S-17 p8.2 AGC-level 6074 2 F R dB Path 8.2 Automated Gain Control
S-18 p8.1 snr 6654 2 F R dB Path 8.1 signal-to-noise ratio
S-19 p8.2 snr 6674 2 F R dB Path 8.2 signal-to-noise ratio
S-20 path-8 fault (X) 2277 1 I R hex Path 8 path error (3X-measurement)
S-21 p8.1 AGC-level (X) 6694 2 F R dB Path 8.1 Automated Gain Control (3X-
measurement)
S-22 p8.2 AGC-level (X) 6714 2 F R dB Path 8.2 Automated Gain Control (3X-
measurement)
S-23 p8.1 snr (X) 6734 2 F R dB Path 8.1 signal-to-noise ratio (3X-meas-
urement)
S-24 p8.2 snr (X) 6754 2 F R dB Path 8.2 signal-to-noise ratio (3X-meas-
urement)
S-26 path-8 turbulence 6790 2 F R % Path 8 turbulence

Path1 Sig. Analysis

T-01 p1.1 tw offset 6600 2 F R us Path 1.1 corrected delay time
T-02 p1.2 tw offset 6620 2 F R us Path 1.2 corrected delay time 217
T-03 p1 Tw damped 6830 2 F R us Path 1 delay time TwD
Path2 Sig. Analysis

U-01 p2.1 tw offset 6602 2 F R us Path 2.1 corrected delay time
U-02 p2.2 tw offset 6622 2 F R us Path 2.2 corrected delay time
U-03 p2 Tw damped 6832 2 F R us Path 2 delay time TwD
Path3 Sig. Analysis

V-01 p3.1 tw offset 6604 2 F R us Path 3.1 corrected delay time
V-02 p3.2 tw offset 6624 2 F R us Path 3.2 corrected delay time
V-03 p3 Tw damped 6834 2 F R us Path 3 delay time TwD
Path4 Sig. Analysis

W-01 p4.1 tw offset 6606 2 F R us Path 4.1 corrected delay time
W-02 p4.2 tw offset 6626 2 F R us Path 4.2 corrected delay time
W-03 p4 Tw damped 6836 2 F R us Path 4 delay time TwD
Path5 Sig. Analysis

X-01 p5.1 tw offset 6608 2 F R us Path 5.1 corrected delay time
X-02 p5.2 tw offset 6628 2 F R us Path 5.2 corrected delay time
X-03 p5 Tw damped 6838 2 F R us Path 5 delay time TwD
Path6 Sig. Analysis

Y-01 p6.1 tw offset 6610 2 F R us Path 6.1 corrected delay time
Y-02 p6.2 tw offset 6630 2 F R us Path 6.2 corrected delay time
Y-03 p6 Tw damped 6840 2 F R us Path 6 delay time TwD

Path7 Sig. Analysis

Z-01 p7.1 tw offset 6612 2 F R us Path 7.1 corrected delay time
218 Z-02 p7.2 tw offset 6632 2 F R us Path 7.2 corrected delay time
Z-03 p7 Tw damped 6842 2 F R us Path 7 delay time TwD
Path8 Sig. Analysis

AA-01 p8.1 tw offset 6614 2 F R us Path 8.1 corrected delay time
AA-02 p8.2 tw offset 6634 2 F R us Path 8.2 corrected delay time
AA-03 p8 Tw damped 6844 2 F R us Path 8 delay time TwD
USE09 meas. val.

AB-01 SoS average 6228 2 F R → velocity unit Average Speed of Sound over all paths
AB-02 p.1 AGC average 6056 2 F R dB Path x.1 average AGC over all paths
AB-03 p.2 AGC average 6076 2 F R dB Path x.2 average AGC over all paths
USE09 Diagnosis

AC-01 Vz plane-1 6560 2 F R → velocity unit Velocity Vz of plane 1
AC-05 Vx plane-1 6568 2 F R → velocity unit Velocity Vx of plane 1
AC-09 Ve plane-1 6576 2 F R → velocity unit Velocity V of plane 1
AC-15 Swirl Angle Plane- 6584 2 F R ° Swirl angle of plane 1
1
2
3
4

AC-20 Profile PFY1 6800 2 F R Profile factor PFY1

AC-22 Profile PFY 6804 2 F R Profile factor PFY
219
AC-27 Profile PFX 6814 2 F R Profile factor PFX
AC-28 Profile PFX12 6816 2 F R Profile factor PFX12
AC-29 Profile PFX56 6818 2 F R Profile factor PFX56
AC-30 Profile Factor 6820 2 F R Diagnosis: Profile factor
AC-31 Symmetry X 6822 2 F R Symmetry X
AC-32 Symmetry Y 6824 2 F R Symmetry Y
AC-33 Symmetry 6826 2 F R Symmetry
Time and Date

AD-01 time 2560 2 U F date and time
USE09-C Totalizers

AE-01 Tot. Volume d.1 3000 4 D CS → volume unit Actual volume counter for direction 1
AE-02 Tot. Volume d.2 3004 4 D CS → volume unit Actual volume counter for direction 2
AE-04 Tot. VolumeErr 3008 4 D CS → volume unit Actual disturbed volume counter for di-
d.1 rection 1
AE-05 Tot. VolumeErr 3012 4 D CS → volume unit Actual disturbed volume counter for di-
d.2 rection 2
AE-07 Tot. VolumeSum 3016 4 D CS → volume unit Actual summarized volume counter for
d.1 direction 1
AE-08 Tot. VolumeSum 3020 4 D CS → volume unit Actual summarized volume counter for
d.2 direction 2
AE-09 Total Volume 3024 4 D CS → volume unit Total volume totalizer for volume at
measurement conditions, both direc-
tions
AE-10 tot. Error-mode 2096 1 M S Error mode of Vm and test totalizers
0x0000 STOP (d)
0x0001 RUN
AE-11 Total Volume 2098 1 M S Mode of the total volume totalizer (VO)
mode
0x0000 D1 - D2 (d)
0x0001 DIRECTION_1
0x0002 DIRECTION_2
AE-20 test-tot. mode 2097 1 M F Start/stop of the Vm test totalizers

0x0000 STOP (d)

0x0001 RUN
AE-21 Vm-dir.1 test sum 3040 4 D R → volume unit Actual volume test-counter for direction
1
220 AE-22 Vm-dir.2 test sum 3044 4 D R → volume unit Actual volume test-counter for direction
2
AE-23 time for test sum 6242 2 F R s Duration of on-the-fly calibration
AE-30 Unit LF-Volumes 2217 1 M F Unit (factor) for totalizers of type LONG
0x0000 x1 (d)
0x0001 x 0.1
0x0002 x 0.01
AE-31 L: Tot. Volume d.1 2600 2 L R → Unit LF-Volumes Copy of Vm totalizer, direction 1 (with
factor in Long format)
AE-32 L: Tot. Volume d.2 2602 2 L R → Unit LF-Volumes Copy of Vm totalizer, direction 2 (with
AE-34 L: Tot. Vol.Err d.1 2604 2 L R → Unit LF-Volumes Copy of disturbing Vm totalizer, direc-
tion 1 (with factor in Long format)
AE-35 L: Tot. Vol.Err d.2 2606 2 L R → Unit LF-Volumes Copy of disturbing Vm totalizer, direc-
tion 2 (with factor in Long format)
AE-37 L: Tot. Vol.Sum 2608 2 L R → Unit LF-Volumes Copy of total volume totalizer
d.1 (Vm+VmD), direction 1 (with factor in
Long format)
AE-38 L: Tot. Vol.Sum 2610 2 L R → Unit LF-Volumes Copy of total volume totalizer
d.2 (Vm+VmD), direction 2 (with factor in
Long format)
AE-39 L: Total Volume 2612 2 L R → Unit LF-Volumes Copy of Vm total volume totalizer (with
ID

AF-01 electronic type 500 10 T S ID: Device type
AF-02 electronic no 2564 2 L S ID: Device No.
AF-03 unit type 510 10 T S ID: Type of measuring element
AF-04 unit no 2562 2 L S ID: Measuring element No.
AF-05 manufacturer 2151 1 M S ID: Manufacturer of the USE09
0x0000 RMG (d)
AF-06 model (year) 2152 1 I S ID: Year of construction of the USE09
(DZU interface)
AF-07 meter size 520 10 T S ID: Meter size
AF-08 nominal diameter 2210 1 I S → Calib. units: ID: Nominal diameter DN
DN Length
AF-09 pressure rating 740 10 T S ID: Pressure rating
AF-10 pipe flange type 2211 1 M S ID: Flange standard
0x0000 PN (d)
0x0001 ANSI
AF-11 pipe flange value 2212 1 I S ID: Flange value
AF-12 Qmin 1346 2 F S → flow unit ID: q-min

AF-13 Qmax 1348 2 F S → flow unit ID: q-max

AF-14 pmin 1350 2 F S → Units: Pressure g ID: Calibration pressure min
AF-15 pmax 1352 2 F S → Units: Pressure g ID: Calibration pressure max
AF-16 meas.press. min 1520 2 F S → Units: Pressure a ID: Measuring pressure min
221
AF-17 meas.press. max 1522 2 F S → Units: Pressure a ID: Measuring pressure max
AF-18 Tmin 1354 2 F S → Units: Temp. ID: T-min
AF-21 Tmax 1356 2 F S → Units: Temp. ID: T-max
AF-23 gas type 2154 1 M S ID: Gas type
0x0000 NATURAL GAS (d)
AF-24 p type 2155 1 M S ID: P-type
0x0000 3051CA (d)
0x0001 G1151Ap
0x0002 G1151
0x0003 2088A
AF-25 p no. 2566 2 L S ID: P-No.
AF-26 T type 2156 1 M S ID: T-type
0x0000 AGG-EX (d)
0x0001 Q-4407
0x0002 PT100
0x0003 F-56
0x0004 F-57
AF-27 T no 2568 2 L S ID: T-No.
AF-28 Transducer type 9072 10 T S ID: Transducer type
AF-29 Transducer 1.1 no. 530 10 T S ID: transducer 1/1 No.
AF-30 Transducer 1.1 1524 2 F S → Calib. units: ID: transducer 1/1 length
len. Length
AF-31 Transducer 1.1 2291 1 I S ID: transducer 1/1 year of manufacture
built
len. Length
built
len. Length
built
len. Length
built
len. Length


built
222 len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built

len. Length
built
AF-77 serial number 790 10 T S ID: serial number USE09
USE09 223
AF-78 version 100 2 F R ID: M32C software version
AF-79 CPU CRC 201 1 I R hex ID: M32C CRC-16
AF-80 Matrix version 200 1 I R ID: M32C Matrix version
AF-81 DSP version 102 2 F R ID: DSP software version
AF-82 DSP CRC 202 1 I R hex ID: DSP CRC-16
AF-83 FPGA version 104 2 F R ID: FPGA software version
AF-84 FPGA CRC 203 1 I R hex ID: FPGA CRC-16
AF-85 fiscal par. CRC 204 1 I R hex ID: fiscally parameters crc-16
AF-86 piecewise lin. CRC 205 1 I R hex ID: piecewise linearization parameters
crc-16
Mode

AG-04 codeword 750 10 C F Entry of codeword
AG-26 test working 2185 1 M S Test mode for debugging the DSP
mode
0x0000 OFF (d)
0x0001 DEBUG
0x0002 WD
AG-27 Display, LED test 65535 10 T R Display test, bottom
AG-28 Test LEDs 4080 1 M C Tests the LEDs on the front panel
0x0000 OFF (d)
0x0001 TEST
AG-30 language 2094 1 M C Selection of language
0x0000 GERMAN (d)
0x0001 ENGLISH
AG-31 units 2095 1 M CS Selection of units
0x0000 METRICAL- (d)
UNITS
0x0001 IMPERIAL-
UNITS
AG-32 velocity unit 7030 1 M R Unit: Velocities
0x0000 m/s
0x0001 ft/s
AG-33 flow unit 7031 1 M R Unit: Flow rate
0x0000 m3/h
0x0001 acfh
AG-34 volume unit 7032 1 M R Unit: Totalizers

0x0000 m3
0x0001 acf
AG-35 pulse unit 7033 1 M R Unit: Pulse value
0x0000 Imp/m3
224
0x0001 Imp/cf
AG-36 Units: Temp. 7035 1 M S Unit: temperature
0x0000 °C (d)
0x0001 °F
0x0002 K
0x0003 °Ra
AG-37 Units: Pressure 7036 1 M S Unit: pressure
0x0000 bar (d)
0x0001 psi
AG-38 Units: Pressure a 7037 1 M R Unit: absolute pressure
0x0000 bar_a
0x0001 psi_a
AG-39 Units: Pressure g 7038 1 M R Unit: relative pressure
0x0000 bar_g
0x0001 psi_g
AG-40 Calib. units: 7039 1 M S Calibration unit: length
Length
0x0000 mm (d)
0x0001 in
AG-41 Calib. units: v 7040 1 M S Calibration unit: speed
0x0000 m/s (d)
0x0001 ft/s
AG-42 Calib. units: Q 7041 1 M S Calibration unit: flow
0x0000 m3/h (d)
0x0001 acfh
Faults

AH-01 fault message 710 10 T R Fault message as rolling text
AH-02 fault time 7500 2 U R Date and time of the fault
AH-03 clear fault 2126 1 M F Clear fault
0x0000 NO (d)
0x0001 YES
AH-04 fault mode 2127 1 M S Fault mode below Qm-min
0x0000 NORMAL (d)
0x0001 ALL

AH-05 fault display 2128 1 M S Fault display mode active: Shows all cur-
mode rently active faults
0x0000 NORMAL (d)
0x0001 ACTIVE
AH-06 path error mode 2129 1 M S Error mode in the case of a path failure 225
0x0000 WARNING (d)
0x0001 ALARM
AH-07 fault,warn contact 2254 1 M F Mode for alarm and warning contact
0x0000 NORMAL (d)
0x0001 5_SECONDS
0x0002 HOLD
AH-09 path ok 700 10 T R Indication of the path status (path moni-
toring is considered)
AH-10 hint status 4008 1 M R Current hint status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-11 warning status 4001 1 M R Current warning status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-12 warn contact 4120 1 M R Current warning contact
0x0000 OFF
0x0001 ON
AH-13 fault status 4000 1 M R Current alarm status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-14 fault contact 4121 1 M R Current alarm contact
0x0000 OFF
0x0001 ON
AH-15 USE09 device sta- 4002 1 I R hex USE09 device status
tus
AH-16 Fault bit 0-15 4010 1 I R hex Active faults (bit-coded) 0-15

226
DSP Parameters

AI-09 number of 2136 1 I C Number of batches
batches
AI-10 Relay delay time 2137 1 I S ms Relay delay time (RDT)
AI-11 sample frequency 2138 1 M S MHz Sample frequency in MHz
0x0000 1
0x0001 1,25
0x0002 1,67
0x0003 2
0x0004 2,5
0x0005 3,33
0x0006 4
0x0007 5 (d)
0x0008 6,67
0x0009 10
AI-12 fifo size 2139 1 M S Size of the receiving memory
0x0000 512
0x0001 1024
0x0002 2048 (d)
AI-13 FPGA testpin ctrl. 2214 1 I F hex Hexadecimal control word for the FPGA
test pins
AI-14 transmission level 2140 1 I S % Transmission level control in %
AI-15 send mux time 1364 2 F S ms Response time of transmit multiplexer
in ms
AI-16 receive mux time 1366 2 F S ms Response time of receive multiplexer in
ms
AI-17 Attenuator mode 2141 1 M S Operating mode of the attenuator
0x0000 OFF (d)
0x0001 ON
0x0002 TEST
0x0003 AUTO_SEPA-
RATE
AI-18 Attenuator on 2142 1 I S dB Limit for the attenuator ON
AI-19 Attenuator off 2143 1 I S dB Limit for the attenuator OFF
AI-20 Attenuator HV 2144 1 I S dB Limit for the attenuator HV mode
AI-21 amp. regulator 2145 1 M C Operating mode of amplitude control
mode
0x0000 SET VALUE
0x0001 ON (d)

0x0002 HOLD
AI-22 amp. regulator 2146 1 I C % Min. range for amplitude control
min
AI-23 amp. regulator 2147 1 I C % Max. range for amplitude control
max 227
AI-24 amp. damping 1448 2 F C Damping for amplitude control
AI-25 theoretical SoS 1368 2 F S → velocity unit Theoretical speed of sound of the fluid
AI-26 ADC gain 2164 1 M S FPGA AD gain 0 dB, +6 dB, -6 dB
0x0000 1 (d)
0x0001 2
0x0002 0.5
AI-27 signal tracking 2169 1 M C Switches signal tracking on or off
0x0000 ON
0x0001 OFF (d)
AI-28 max. track. Offset 2187 1 I C Tics Max. size of the tracking window
AI-37 corr. mode 2256 1 M S Correlation mode
0x0000 OFF (d)
0x0001 FADE_IN
AI-38 corr. length 2189 1 I S Length of the correlation window
AI-39 Batch: amp. min. 2279 1 I S % Batch: Minimum amplitude
AI-47 AmplitudeMin 2000 1 I S % Limit for the input signal (Low)
AI-48 AmplitudeMax 2010 1 I S % Limit for the input signal (High)
AI-49 Vmin 1000 2 F S → Calib. units: v Lower limit for the flow velocity
AI-50 Vmax 1020 2 F S → Calib. units: v Upper limit for the flow velocity
AI-51 Cmin 1040 2 F S → Calib. units: v Lower limit for the speed of sound
AI-52 Cmax 1060 2 F S → Calib. units: v Upper limit for the speed of sound
DSP Parameters 3X

AJ-07 corr. mode (X) 2257 1 M S Correlation mode (3X measurement)
0x0000 OFF (d)
0x0001 FADE_IN
AJ-09 Batch: amp. min. 2280 1 I S % Batch: Minimum amplitude (3X meas-
urement)

Path1 Parameters

AK-09 p1 f-trans set val 2500 2 L S Hz Path 1 transmit frequency intended
228 value in Hz
AK-10 path-1 trans. freq. 2520 2 L R Hz Path 1 transmit frequency actual value
in Hz
AK-11 path-1 band limits 2190 1 I S % Path 1 limits to observe
AK-12 path-1 2040 1 I S Path 1 number of transmit pulses
trans.pulses
AK-13 p1 filter selection 2170 1 M S kHz Path 1 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AK-14 path-1 tw 1080 2 F S us Path 1 delay time
AK-16 path-1 DAC-G1 2050 1 I S Path 1 DAC-G1 command register
cmd
AK-17 path-1 DAC-G1 val 2060 1 I S Path 1 DAC-G1 data register
AK-18 path-1 DAC-G2 2070 1 I S Path 1 DAC-G2 command register
cmd
AK-19 path-1 DAC-G2 val 2080 1 I S Path 1 DAC-G2 data register
AK-20 p1 blanking delay 1100 2 F R us Path 1 blanking delay
AK-21 p1 blanking count 2540 2 L R tic Path 1 blanking count
AK-22 path-1 decay time 1120 2 F S ms Path 1 pulse decay time
AK-23 path-1 path 1140 2 F S → Calib. units: Length Path 1 path length
length
AK-24 path-1 axial dist. 1160 2 F S → Calib. units: Length Path 1 smallest path distance
AK-25 p1 assembly an- 1500 2 F S ° Path 1 assembly angle
gle
AK-26 p1 delta-t offset 1420 2 F S us Path 1 time difference offset
AK-29 const w1 1240 2 F S [1] Path 1 weigthing factor w1
AK-30 p1 tic offset 2200 1 I S tic Path 1 tic offset
AK-31 p1 tic offset (X) 2260 1 I S tic Path 1 tic offset (3X-measurement)
AK-32 p1 AGC-limit 2220 1 I S dB Path 1 AGC limit
AK-34 p1 no. of f- 2312 1 I C Path 1 no. of measurement (FBatches)
batches

Path2 Parameters

AL-09 p2 f-trans set val 2502 2 L S Hz Path 2 transmit frequency intended
value in Hz 229
AL-10 path-2 trans. freq. 2522 2 L R Hz Path 2 transmit frequency actual value
in Hz
AL-11 path-2 band limits 2191 1 I S % Path 2 limits to observe
AL-12 path-2 2041 1 I S Path 2 number of transmit pulses
trans.pulses
AL-13 p2 filter selection 2171 1 M S kHz Path 2 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AL-14 path-2 tw 1082 2 F S us Path 2 delay time
AL-16 path-2 DAC-G1 2051 1 I S Path 2 DAC-G1 command register
cmd
AL-17 path-2 DAC-G1 val 2061 1 I S Path 2 DAC-G1 data register
AL-18 path-2 DAC-G2 2071 1 I S Path 2 DAC-G2 command register
cmd
AL-19 path-2 DAC-G2 val 2081 1 I S Path 2 DAC-G2 data register
AL-20 p2 blanking delay 1102 2 F R us Path 2 blanking delay
AL-21 p2 blanking count 2542 2 L R tic Path 2 blanking count
AL-22 path-2 decay time 1122 2 F S ms Path 2 pulse decay time
AL-23 path-2 path 1142 2 F S → Calib. units: Length Path 2 path length
length
AL-24 path-2 axial dist. 1162 2 F S → Calib. units: Length Path 2 smallest path distance
AL-25 p2 assembly an- 1502 2 F S ° Path 2 assembly angle
gle
AL-26 p2 delta-t offset 1422 2 F S us Path 2 time difference offset
AL-29 const w2 1242 2 F S [1] Path 2 weigthing factor w2
AL-30 p2 tic offset 2201 1 I S tic Path 2 tic offset
AL-31 p2 tic offset (X) 2261 1 I S tic Path 2 tic offset (3X-measurement)
AL-32 p2 AGC-limit 2221 1 I S dB Path 2 AGC limit
AL-34 p2 no. of f- 2313 1 I C Path 2 no. of measurement (FBatches)
batches

Path3 Parameters

AM-09 p3 f-trans set val 2504 2 L S Hz Path 3 transmit frequency intended
230 value in Hz
AM-10 path-3 trans. freq. 2524 2 L R Hz Path 3 transmit frequency actual value
in Hz
AM-11 path-3 band limits 2192 1 I S % Path 3 limits to observe
AM-12 path-3 2042 1 I S Path 3 number of transmit pulses
trans.pulses
AM-13 p3 filter selection 2172 1 M S kHz Path 3 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AM-14 path-3 tw 1084 2 F S us Path 3 delay time
AM-16 path-3 DAC-G1 2052 1 I S Path 3 DAC-G1 command register
cmd
AM-17 path-3 DAC-G1 val 2062 1 I S Path 3 DAC-G1 data register
AM-18 path-3 DAC-G2 2072 1 I S Path 3 DAC-G2 command register
cmd
AM-19 path-3 DAC-G2 val 2082 1 I S Path 3 DAC-G2 data register
AM-20 p3 blanking delay 1104 2 F R us Path 3 blanking delay
AM-21 p3 blanking count 2544 2 L R tic Path 3 blanking count
AM-22 path-3 decay time 1124 2 F S ms Path 3 pulse decay time
AM-23 path-3 path 1144 2 F S → Calib. units: Length Path 3 path length
length
AM-24 path-3 axial dist. 1164 2 F S → Calib. units: Length Path 3 smallest path distance
AM-25 p3 assembly an- 1504 2 F S ° Path 3 assembly angle
gle
AM-26 p3 delta-t offset 1424 2 F S us Path 3 time difference offset
AM-29 const w3 1244 2 F S [1] Path 3 weigthing factor w3
AM-30 p3 tic offset 2202 1 I S tic Path 3 tic offset
AM-31 p3 tic offset (X) 2262 1 I S tic Path 3 tic offset (3X-measurement)
AM-32 p3 AGC-limit 2222 1 I S dB Path 3 AGC limit
AM-34 p3 no. of f- 2314 1 I C Path 3 no. of measurement (FBatches)
batches

Path4 Parameters

AN-09 p4 f-trans set val 2506 2 L S Hz Path 4 transmit frequency intended
value in Hz 231
AN-10 path-4 trans. freq. 2526 2 L R Hz Path 4 transmit frequency actual value
in Hz
AN-11 path-4 band limits 2193 1 I S % Path 4 limits to observe
AN-12 path-4 2043 1 I S Path 4 number of transmit pulses
trans.pulses
AN-13 p4 filter selection 2173 1 M S kHz Path 4 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AN-14 path-4 tw 1086 2 F S us Path 4 delay time
AN-16 path-4 DAC-G1 2053 1 I S Path 4 DAC-G1 command register
cmd
AN-17 path-4 DAC-G1 val 2063 1 I S Path 4 DAC-G1 data register
AN-18 path-4 DAC-G2 2073 1 I S Path 4 DAC-G2 command register
cmd
AN-19 path-4 DAC-G2 val 2083 1 I S Path 4 DAC-G2 data register
AN-20 p4 blanking delay 1106 2 F R us Path 4 blanking delay
AN-21 p4 blanking count 2546 2 L R tic Path 4 blanking count
AN-22 path-4 decay time 1126 2 F S ms Path 4 pulse decay time
AN-23 path-4 path 1146 2 F S → Calib. units: Length Path 4 path length
length
AN-24 path-4 axial dist. 1166 2 F S → Calib. units: Length Path 4 smallest path distance
AN-25 p4 assembly an- 1506 2 F S ° Path 4 assembly angle
gle
AN-26 p4 delta-t offset 1426 2 F S us Path 4 time difference offset
AN-29 const w4 1246 2 F S [1] Path 4 weigthing factor w4
AN-30 p4 tic offset 2203 1 I S tic Path 4 tic offset
AN-31 p4 tic offset (X) 2263 1 I S tic Path 4 tic offset (3X-measurement)
AN-32 p4 AGC-limit 2223 1 I S dB Path 4 AGC limit
AN-34 p4 no. of f- 2315 1 I C Path 4 no. of measurement (FBatches)
batches

Path5 Parameters

AO-09 p5 f-trans set val 2508 2 L S Hz Path 5 transmit frequency intended
232 value in Hz
AO-10 path-5 trans. freq. 2528 2 L R Hz Path 5 transmit frequency actual value
in Hz
AO-11 path-5 band limits 2194 1 I S % Path 5 limits to observe
AO-12 path-5 2044 1 I S Path 5 number of transmit pulses
trans.pulses
AO-13 p5 filter selection 2174 1 M S kHz Path 5 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AO-14 path-5 tw 1088 2 F S us Path 5 delay time
AO-16 path-5 DAC-G1 2054 1 I S Path 5 DAC-G1 command register
cmd
AO-17 path-5 DAC-G1 val 2064 1 I S Path 5 DAC-G1 data register
AO-18 path-5 DAC-G2 2074 1 I S Path 5 DAC-G2 command register
cmd
AO-19 path-5 DAC-G2 val 2084 1 I S Path 5 DAC-G2 data register
AO-20 p5 blanking delay 1108 2 F R us Path 5 blanking delay
AO-21 p5 blanking count 2548 2 L R tic Path 5 blanking count
AO-22 path-5 decay time 1128 2 F S ms Path 5 pulse decay time
AO-23 path-5 path 1148 2 F S → Calib. units: Length Path 5 path length
length
AO-24 path-5 axial dist. 1168 2 F S → Calib. units: Length Path 5 smallest path distance
AO-25 p5 assembly an- 1508 2 F S ° Path 5 assembly angle
gle
AO-26 p5 delta-t offset 1428 2 F S us Path 5 time difference offset
AO-29 const w5 1248 2 F S [1] Path 5 weigthing factor w5
AO-30 p5 tic offset 2204 1 I S tic Path 5 tic offset
AO-31 p5 tic offset (X) 2264 1 I S tic Path 5 tic offset (3X-measurement)
AO-32 p5 AGC-limit 2224 1 I S dB Path 5 AGC limit
AO-34 p5 no. of f- 2316 1 I C Path 5 no. of measurement (FBatches)
batches

Path6 Parameters

AP-09 p6 f-trans set val 2510 2 L S Hz Path 6 transmit frequency intended
value in Hz 233
AP-10 path-6 trans. freq. 2530 2 L R Hz Path 6 transmit frequency actual value
in Hz
AP-11 path-6 band limits 2195 1 I S % Path 6 limits to observe
AP-12 path-6 2045 1 I S Path 6 number of transmit pulses
trans.pulses
AP-13 p6 filter selection 2175 1 M S kHz Path 6 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AP-14 path-6 tw 1090 2 F S us Path 6 delay time
AP-16 path-6 DAC-G1 2055 1 I S Path 6 DAC-G1 command register
cmd
AP-17 path-6 DAC-G1 val 2065 1 I S Path 6 DAC-G1 data register
AP-18 path-6 DAC-G2 2075 1 I S Path 6 DAC-G2 command register
cmd
AP-19 path-6 DAC-G2 val 2085 1 I S Path 6 DAC-G2 data register
AP-20 p6 blanking delay 1110 2 F R us Path 6 blanking delay
AP-21 p6 blanking count 2550 2 L R tic Path 6 blanking count
AP-22 path-6 decay time 1130 2 F S ms Path 6 pulse decay time
AP-23 path-6 path 1150 2 F S → Calib. units: Length Path 6 path length
length
AP-24 path-6 axial dist. 1170 2 F S → Calib. units: Length Path 6 smallest path distance
AP-25 p6 assembly an- 1510 2 F S ° Path 6 assembly angle
gle
AP-26 p6 delta-t offset 1430 2 F S us Path 6 time difference offset
AP-29 const w6 1250 2 F S [1] Path 6 weigthing factor w6
AP-30 p6 tic offset 2205 1 I S tic Path 6 tic offset
AP-31 p6 tic offset (X) 2265 1 I S tic Path 6 tic offset (3X-measurement)
AP-32 p6 AGC-limit 2225 1 I S dB Path 6 AGC limit
AP-34 p6 no. of f- 2317 1 I C Path 6 no. of measurement (FBatches)
batches

Path7 Parameters

AQ-09 p7 f-trans set val 2512 2 L S Hz Path 7 transmit frequency intended
234 value in Hz
AQ-10 path-7 trans. freq. 2532 2 L R Hz Path 7 transmit frequency actual value
in Hz
AQ-11 path-7 band limits 2196 1 I S % Path 7 limits to observe
AQ-12 path-7 2046 1 I S Path 7 number of transmit pulses
trans.pulses
AQ-13 p7 filter selection 2176 1 M S kHz Path 7 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AQ-14 path-7 tw 1092 2 F S us Path 7 delay time
AQ-16 path-7 DAC-G1 2056 1 I S Path 7 DAC-G1 command register
cmd
AQ-17 path-7 DAC-G1 val 2066 1 I S Path 7 DAC-G1 data register
AQ-18 path-7 DAC-G2 2076 1 I S Path 7 DAC-G2 command register
cmd
AQ-19 path-7 DAC-G2 val 2086 1 I S Path 7 DAC-G2 data register
AQ-20 p7 blanking delay 1112 2 F R us Path 7 blanking delay
AQ-21 p7 blanking count 2552 2 L R tic Path 7 blanking count
AQ-22 path-7 decay time 1132 2 F S ms Path 7 pulse decay time
AQ-23 path-7 path 1152 2 F S → Calib. units: Length Path 7 path length
length
AQ-24 path-7 axial dist. 1172 2 F S → Calib. units: Length Path 7 smallest path distance
AQ-25 p7 assembly an- 1512 2 F S ° Path 7 assembly angle
gle
AQ-26 p7 delta-t offset 1432 2 F S us Path 7 time difference offset
AQ-29 const w7 1252 2 F S [1] Path 7 weigthing factor w7
AQ-30 p7 tic offset 2206 1 I S tic Path 7 tic offset
AQ-31 p7 tic offset (X) 2266 1 I S tic Path 7 tic offset (3X-measurement)
AQ-32 p7 AGC-limit 2226 1 I S dB Path 7 AGC limit
AQ-34 p7 no. of f- 2318 1 I C Path 7 no. of measurement (FBatches)
batches

Path8 Parameters

AR-09 p8 f-trans set val 2514 2 L S Hz Path 8 transmit frequency intended
value in Hz 235
AR-10 path-8 trans. freq. 2534 2 L R Hz Path 8 transmit frequency actual value
in Hz
AR-11 path-8 band limits 2197 1 I S % Path 8 limits to observe
AR-12 path-8 2047 1 I S Path 8 number of transmit pulses
trans.pulses
AR-13 p8 filter selection 2177 1 M S kHz Path 8 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AR-14 path-8 tw 1094 2 F S us Path 8 delay time
AR-16 path-8 DAC-G1 2057 1 I S Path 8 DAC-G1 command register
cmd
AR-17 path-8 DAC-G1 val 2067 1 I S Path 8 DAC-G1 data register
AR-18 path-8 DAC-G2 2077 1 I S Path 8 DAC-G2 command register
cmd
AR-19 path-8 DAC-G2 val 2087 1 I S Path 8 DAC-G2 data register
AR-20 p8 blanking delay 1114 2 F R us Path 8 blanking delay
AR-21 p8 blanking count 2554 2 L R tic Path 8 blanking count
AR-22 path-8 decay time 1134 2 F S ms Path 8 pulse decay time
AR-23 path-8 path 1154 2 F S → Calib. units: Length Path 8 path length
length
AR-24 path-8 axial dist. 1174 2 F S → Calib. units: Length Path 8 smallest path distance
AR-25 p8 assembly an- 1514 2 F S ° Path 8 assembly angle
gle
AR-26 p8 delta-t offset 1434 2 F S us Path 8 time difference offset
AR-29 const w8 1254 2 F S [1] Path 8 weigthing factor w8
AR-30 p8 tic offset 2207 1 I S tic Path 8 tic offset
AR-31 p8 tic offset (X) 2267 1 I S tic Path 8 tic offset (3X-measurement)
AR-32 p8 AGC-limit 2227 1 I S dB Path 8 AGC limit
AR-34 p8 no. of f- 2319 1 I C Path 8 no. of measurement (FBatches)
batches

Service

AS-01 CPU speed 2574 2 L CS Hz Actual M32 clock speed
236 AS-02 DSP speed 2576 2 L S Hz Actual DSP clock speed
AS-04 FPGA speed 2578 2 L S Hz Actual FPGA clock speed
AS-05 ext. card s.no. 2584 2 L S IO card s. No.
AS-06 ext. ADC s.no. 2586 2 L S IO-ADC card s. No.
AS-07 write opt.EEProm 2167 1 M S (Service key!) Writes paramet. in the
OPT-EEP
0x0000 NO (d)
0x0001 YES
AS-08 write ADC 2168 1 M S (Service key!) Writes paramet. in the
EEProm OPT-ADC-EEP
0x0000 NO (d)
0x0001 YES
AS-09 LCD lighting 2183 1 M F Display lighting if key is pressed or
steady light
0x0000 KEY (d)
0x0001 always
AS-10 parameter reset 2148 1 M CS Load new parameters
0x0000 NO (d)
0x0001 YES
AS-12 RV reset 2149 1 M C Clear replacement values
0x0000 NO (d)
0x0001 YES
AS-13 RV: number 2150 1 I C Number of average values for the calcu-
lation of replacement values
AS-14 RV status 720 10 T R Status for the replacement value
AS-15 RV mode 2213 1 M S Mode of replacement values
0x0000 OFF
0x0001 ON (d)
AS-16 Raw data path no. 2124 1 I F Raw data: Path selection (0=OFF)
AS-17 Raw data type 2184 1 M F Raw data: Type selection
0x0000 TEST
0x0001 RAW (d)
0x0002 FILTER
0x0003 RAW ERR
0x0004 FILTER ERR
0x0005 FFG
0x0006 RAW FFT
0x0007 FILTER FFT
AS-18 Raw data function 2215 1 I F Raw data: Trigger function (subselection)
AS-20 M32 Temperature 5000 2 F R → Units: Temp. Temperature of the M32 board

AS-21 Transmit Level 5002 2 F R % Transmission level HV analog board

AS-22 +-5V symmetry 5004 2 F R V Symmetry +-5V, analog board
AS-23 System Tempera- 5006 2 F R → Units: Temp. Temperature, baseboard
ture
AS-24 +-12V symmetry 5008 2 F R V Symmetry +-12V, analog board 237
AS-25 1V2 voltage 5010 2 F R V Voltage 1V2 DSP board
AS-26 1V5 voltage 5012 2 F R V Voltage 1V5 DSP board
AS-27 3V3 voltage 5014 2 F R V Voltage 3V3 M32 board
AS-28 adc-p binary val. 7502 2 L R Pressure input, transmitter value
AS-29 adc-t binary val. 7504 2 L R PT100 input, transmitter value
AS-30 max. sys. temp. 1440 2 F C → Units: Temp. System temperature, max. value
AS-31 time max. sys. 2588 2 U C Time of max. system temperature
temp
AS-32 min. sys. temp. 1442 2 F C → Units: Temp. System temperature, min. value
AS-33 time min. sys. 2590 2 U C Time of min. system temperature
temp
Log Data

AT-01 Log-data date 800 10 T R Data logger, date of last change
AT-02 Log-data coordi- 810 10 T R Data logger, coordinate of last change
nate
AT-03 Log-data old value 820 10 T R Data logger (old value)
AT-04 Log-data new 830 10 T R Data logger (new value)
value
AT-10 Log-data fill level 4007 1 I R % Data logger, fill level
AT-11 clear par-log 2157 1 M S Clear parameter logging list
0x0000 NO (d)
0x0001 YES
AT-12 clear event-log 2216 1 M F Clear event logging list
0x0000 NO (d)
0x0001 YES
Site Information

AU-01 User Text-1 840 10 T F User-programmable text line 1

Remote Control

AV-01 remote access 10000 1 M C Remote access
238 0x0000 NO (d)
0x0001 YES
AV-02 remote keycode 10001 1 I C Keyboard code
AV-03 lcd row 1 10010 10 T R Actual line 1 LCD
AGA-10 Values

AW-01 SoS calc. status 8000 1 I R hex Status AGA-10 calculation
AW-02 SoS 8001 2 F R → velocity unit Measured average speed of sound
AW-03 SoS calculated 8003 2 F R → velocity unit Result speed of sound AGA-10
AW-04 rel. error SoS 8005 2 F R % Relative error measured SoS to SoS cal-
culated
AW-05 abs. error SoS 8007 2 F R → velocity unit SoS measured - SoS AGA-10
AW-06 temperature 8009 2 F R → Units: Temp. Temperature: AGA-10 equation
AW-07 pressure 8011 2 F R → Units: Pressure a Pressure: AGA-10 equation
AW-08 last calculation 8013 2 U R Time of last AGA-10 calculation
AW-09 last gas comp. 8015 2 U R Time of last gas components input
AW-20 norm. methane 8040 2 F R mol-% Methane: fraction in AGA-10 equation
AW-21 norm. ethane 8046 2 F R mol-% Ethane: fraction in AGA-10 equation
AW-22 norm. propane 8048 2 F R mol-% Propane: fraction in AGA-10 equation
AW-23 norm. iso-butane 8060 2 F R mol-% I-Butane: fraction in AGA-10 equation
AW-24 norm. n-butane 8062 2 F R mol-% N-Butane: fraction in AGA-10 equation
AW-26 norm. iso-pen- 8064 2 F R mol-% I-Pentane: fraction in AGA-10 equation
tane
AW-27 norm. n-pentane 8066 2 F R mol-% N-Pentane: fraction in AGA-10 equation
AW-29 norm. oxygen 8058 2 F R mol-% Oxygen: fraction in AGA-10 equation
AW-30 norm. helium 8078 2 F R mol-% Helium: fraction in AGA-10 equation
AW-31 norm. hydrogen 8054 2 F R mol-% Hydrogen: fraction in AGA-10 equation
AW-32 norm. argon 8080 2 F R mol-% Argon: fraction in AGA-10 equation
AW-33 norm. nitrogen 8042 2 F R mol-% Nitrogen: fraction in AGA-10 equation
AW-34 norm. CO2 8044 2 F R mol-% Carbon dioxide: fraction in AGA-10
equation
AW-35 norm. n-hexane 8068 2 F R mol-% N-Hexane: fraction in AGA-10 equation
AW-36 norm. n-heptane 8070 2 F R mol-% N-Heptane: fraction in AGA-10 equation
AW-37 norm. n-octane 8072 2 F R mol-% N-Octane: fraction in AGA-10 equation

AW-38 norm. n-nonane 8074 2 F R mol-% N-Nonane: fraction in AGA-10 equation

AW-39 norm. n-decane 8076 2 F R mol-% N-Decane: fraction in AGA-10 equation
AW-40 norm. H2S 8052 2 F R mol-% Hydrogen sulfide: fraction in AGA-10
equation
AW-41 norm. water 8050 2 F R mol-% Water: fraction in AGA-10 equation 239
AW-42 norm. CO 8056 2 F R mol-% Carbon monoxide: fraction in AGA-10
equation
AGA-10 Config

AX-01 SoS calc source 8100 1 M F Source gas analysis for AGA-10
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 default air
0x0003 serial port 2
AX-02 SoS source temp. 8101 1 M F Source temperature for AGA-10
0x0000 SoS default (d)
0x0001 USE09
AX-03 SoS source press. 8102 1 M F Source pressure for AGA-10
0x0000 SoS default (d)
0x0001 USE09
AX-04 SoS temp. default 8104 2 F F → Units: Temp. Default value temperature for AGA-10
AX-05 SoS press. default 8106 2 F F → Units: Pressure a Default value pressure for AGA-10
AX-06 relative humidity 8108 2 F F % Relative humidity
AX-07 timeout max. 8110 1 I F min Timeout time for new analysis (except
default)
AX-08 RMGBus mode 8111 1 M F Selection 24 or 9 gas components via
RMGBus
0x0000 RMGBus 24 (d)
comp.
0x0001 RMGBus
AX-09 stream number 8112 1 M F Selection of the stream with RMGBus
0x0000 without indi- (d)
cation
0x0001 stream 1
0x0002 stream 2
0x0003 stream 3
0x0004 stream 4
AX-10 Modbus master 8113 1 M F Target for Modbus master
target
0x0000 RMG GC9300 (d)
0x0001 custom 1
AX-11 set gas comp. 8350 1 M F Set new components
0x0000 gas comp. are (d)
set

0x0001 set new

comp.
AX-20 default methane 8140 2 F F mol-% Methane: default value
AX-21 default ethane 8142 2 F F mol-% Ethane: default value
240 AX-22 default propane 8144 2 F F mol-% Propane: default value
AX-23 default iso-bu- 8146 2 F F mol-% iso-Butane: default value
tane
AX-24 default n-butane 8148 2 F F mol-% n-Butane: default value
AX-25 default neo-pen- 8150 2 F F mol-% neo-Pentane: default value
tane
AX-26 default iso-pen- 8152 2 F F mol-% iso-Pentane: default value
tane
AX-27 default n-pentane 8154 2 F F mol-% n-Pentane: default value
AX-28 default hexane+ 8156 2 F F mol-% Hexane+: default value
AX-29 default oxygen 8158 2 F F mol-% Oxygen: default value
AX-30 default helium 8160 2 F F mol-% Helium: default value
AX-31 default hydrogen 8162 2 F F mol-% Hydrogen: default value
AX-32 default argon 8164 2 F F mol-% Argon: default value
AX-33 default nitrogen 8166 2 F F mol-% Nitrogen: default value
AX-34 default CO2 8168 2 F F mol-% Carbon dioxide: default value
AX-35 default n-hexane 8170 2 F F mol-% n-Hexane: default value
AX-36 default n-heptane 8172 2 F F mol-% n-Heptane: default value
AX-37 default n-octane 8174 2 F F mol-% n-Octane: default value
AX-38 default n-nonane 8176 2 F F mol-% n-Nonane: default value
AX-39 default n-decane 8178 2 F F mol-% n-Decane: default value
AX-40 default H2S 8180 2 F F mol-% Hydrogen sulfide: default value
AX-41 default water 8182 2 F F mol-% Water vapour: default value
AX-42 default CO 8184 2 F F mol-% Carbon monoxide: default value
AX-43 default ethene 8186 2 F F mol-% Ethene: default value
AX-44 default propene 8188 2 F F mol-% Propene: default value
AX-45 sum of def. comp. 8190 2 F R mol-% Sum of default values
AX-92 MB_Pause 8980 1 I F s Modbus-master pause
AX-93 MB_Timeout 8981 1 I F ms Modbus-master time outs
AX-94 MB_Int16Order 8982 10 T F Int16 order
AX-95 MB_Int32Order 8992 10 T F Int32 order
AX-96 MB_FloatOrder 9002 10 T F Float32 order
AX-97 MB_DoubleOrder 9012 10 T F Float64 order

Gas Comp. RMGBus

AY-20 methane 8300 2 F F mol-% RMGBus/Modbus value methane
AY-21 ethane 8302 2 F F mol-% RMGBus/Modbus value ethane 241
AY-22 propane 8304 2 F F mol-% RMGBus/Modbus value propane
AY-23 iso-butane 8306 2 F F mol-% RMGBus/Modbus value iso-butane
AY-24 n-butane 8308 2 F F mol-% RMGBus/Modbus value n-butane
AY-25 neo-pentane 8310 2 F F mol-% RMGBus/Modbus value neo-pentane
AY-26 iso-pentane 8312 2 F F mol-% RMGBus/Modbus value iso-pentane
AY-27 n-pentane 8314 2 F F mol-% RMGBus/Modbus value n-pentane
AY-28 hexane+ 8316 2 F F mol-% RMGBus/Modbus value hexane+
AY-29 oxygen 8318 2 F F mol-% RMGBus/Modbus value oxygen
AY-30 helium 8320 2 F F mol-% RMGBus/Modbus value helium
AY-31 hydrogen 8322 2 F F mol-% RMGBus/Modbus value hydrogen
AY-32 argon 8324 2 F F mol-% RMGBus/Modbus value argon
AY-33 nitrogen 8326 2 F F mol-% RMGBus/Modbus value nitrogen
AY-34 CO2 8328 2 F F mol-% RMGBus/Modbus value carbon dioxide
AY-35 n-hexane 8330 2 F F mol-% RMGBus/Modbus value n-hexane
AY-36 n-heptane 8332 2 F F mol-% RMGBus/Modbus value n-heptane
AY-37 n-octane 8334 2 F F mol-% RMGBus/Modbus value n-octane
AY-38 n-nonane 8336 2 F F mol-% RMGBus/Modbus value n-nonane
AY-39 n-decane 8338 2 F F mol-% RMGBus/Modbus value n-decane
AY-40 H2S 8340 2 F F mol-% RMGBus/Modbus value hydrogen sulfide
AY-41 Water 8342 2 F F mol-% RMGBus/Modbus value water vapour
AY-42 CO 8344 2 F F mol-% RMGBus/Modbus value carbon monox-
ide
AY-43 ethene 8346 2 F F mol-% RMGBus/Modbus value ethene
AY-44 propene 8348 2 F F mol-% RMGBus/Modbus value propene
AY-45 sum of gas comp. 8351 2 F R mol-% Sum of components via Modbus/RMG-
Bus
AY-46 telegram counter 8126 1 I R Counter for new gas component trans-
fers
AY-47 RMGBus status 8127 1 M R Last valid status
0x0000 revision
0x0001 calibration
0x0002 analysis
0x0003 revision error
0x0004 calibration er-
ror
0x0005 analysis error
0x0006 invalid
AY-48 RMGBus stream 8128 1 I R Stream number of the last telegram
AY-49 MB timeouts 8129 1 I R Number of modbus-master time outs

AY-50 Modbus errors 8130 1 I R Number of Modbus master telegram er-

rors
AY-51 Modbus error reg. 8131 1 I R MB register of the last error
AY-52 Modbus error 8132 1 I R MB register of the last error
242 resp.
AY-53 MB_NAN_Coun- 9022 1 I R MB register of the last error
ter
AY-54 MB_SyntaxError 9023 10 T R Modbus master syntax error coordinate
AY-55 MB_ErrorBits 9033 2 L R hex Int. Modbus master error bits
AY-56 MB_InStatus 9035 1 I F Modbus master status input
Gas Comp. Modbus

AZ-01 Formula methane 8440 10 T S Formula methane
AZ-02 Formula methane 8450 10 T S Formula methane
AZ-03 Formula ethane 8460 10 T S Formula ethane
AZ-04 Formula ethane 8470 10 T S Formula ethane
AZ-05 Formula propane 8480 10 T S Formula propane
AZ-06 Formula propane 8490 10 T S Formula propane
AZ-07 Formula i-butane 8500 10 T S Formula i-butane
AZ-08 Formula i-butane 8510 10 T S Formula i-butane
AZ-09 Formula n-butane 8520 10 T S Formula n-butane
AZ-10 Formula n-butane 8530 10 T S Formula n-butane
AZ-11 Formula neo-pen- 8540 10 T S Formula neo-pentane
tane
AZ-12 Formula neo-pen- 8550 10 T S Formula neo-pentane
tane
AZ-13 Formula i-pentane 8560 10 T S Formula i-pentane
AZ-14 Formula i-pentane 8570 10 T S Formula i-pentane
AZ-15 Formula n-pen- 8580 10 T S Formula n-pentane
tane
AZ-16 Formula n-pen- 8590 10 T S Formula n-pentane
tane
AZ-17 Formula hexane+ 8600 10 T S Formula hexane
AZ-18 Formula hexane+ 8610 10 T S Formula hexane
AZ-19 Formula oxygen 8620 10 T S Formula oxygen
AZ-20 Formula oxygen 8630 10 T S Formula oxygen
AZ-21 Formula helium 8640 10 T S Formula helium
AZ-22 Formula helium 8650 10 T S Formula helium
AZ-23 Formula hydrogen 8660 10 T S Formula hydrogen
AZ-24 Formula hydrogen 8670 10 T S Formula hydrogen
AZ-25 Formula argon 8680 10 T S Formula argon
AZ-26 Formula argon 8690 10 T S Formula argon
AZ-27 Formula nitrogen 8700 10 T S Formula nitrogen

AZ-28 Formula nitrogen 8710 10 T S Formula nitrogen

AZ-29 Formula CO2 8720 10 T S Formula CO2
AZ-30 Formula CO2 8730 10 T S Formula CO2
AZ-31 Formula hexane 8740 10 T S Formula hexane
243
AZ-32 Formula hexane 8750 10 T S Formula hexane
AZ-33 Formula heptane 8760 10 T S Formula heptane
AZ-34 Formula heptane 8770 10 T S Formula heptane
AZ-35 Formula octane 8780 10 T S Formula octane
AZ-36 Formula octane 8790 10 T S Formula octane
AZ-37 Formula nonane 8800 10 T S Formula nonane
AZ-38 Formula nonane 8810 10 T S Formula nonane
AZ-39 Formula decane 8820 10 T S Formula decane
AZ-40 Formula decane 8830 10 T S Formula decane
AZ-41 Formula H2S 8840 10 T S Formula H2S
AZ-42 Formula H2S 8850 10 T S Formula H2S
AZ-43 Formula water 8860 10 T S Formula water
AZ-44 Formula water 8870 10 T S Formula water
AZ-45 Formula CO 8880 10 T S Formula CO
AZ-46 Formula CO 8890 10 T S Formula CO
AZ-47 Formula ethene 8900 10 T S Formula ethane
AZ-48 Formula ethene 8910 10 T S Formula ethane
AZ-49 Formula propene 8920 10 T S Formula propene
AZ-50 Formula propene 8930 10 T S Formula propene
AZ-51 Formula status 8940 10 T S Formula status
DSfG Instance-F

BA-01 DSfG error 9086 1 I R DSfG Error (0000 if no error)
BA-02 vol. flow rate Qm 32768 2 F R m3/h Volume flow (pos. FD1, neg. FD2)
BA-03 Gas velocity 32770 2 F R m/s Velocity of Gas (pos. FD1, neg. FD2)
BA-04 SoS 32772 2 F R m/s Speed of Sound
BA-05 Gas volume sum 32774 2 L R → Unit LF-Volumes Volume of Gas total Flow direction 1
d.1 (V_tot_d1=Vm_d1+Vm_err_d1)
BA-06 Gas volume sum 32776 2 L R → Unit LF-Volumes Volume of Gas total Flow direction 2
d.2 (V_tot_d2=Vm_d2+Vm_err_d2)
BA-07 Gas vol no err d.1 32778 2 L R → Unit LF-Volumes Volume of Gas undisturbed Flow direc-
tion 1 (Vm_d1)
BA-08 Gas vol no err d.2 32780 2 L R → Unit LF-Volumes Volume of Gas undisturbed Flow direc-
tion 2 (Vm_d2)

BA-09 Gas vol error d.1 32782 2 L R → Unit LF-Volumes Volume of Gas disturbed Flow direction
1 (Vm_err_d1)
BA-10 Gas vol error d.2 32784 2 L R → Unit LF-Volumes Volume of Gas disturbed Flow direction
2 (Vm_err_d2)
BA-11 Valence 32786 2 L R Valency
244
BA-12 Flow > Qt 32788 2 L R Flow bigger Qt (0 = no, unequal 0 = yes)
BA-13 Signal acceptance 32790 2 L R % Signal acceptance
BA-14 Meter error 32792 2 L R Meter disturbed (0 = no, unequal 0 =
yes)
BA-15 Number of Paths 32794 2 L R Number of Paths
BA-16 SoS deviation P1 32796 2 F R % Speed of Sound deviation Path 1
(SoS_1_dev = (SoS_1-SoS)/SoS*100)
BA-24 Path velocity vc1 32896 2 F R m/s Velocity of Gas Path 1
BA-25 SoS P1 32898 2 F R m/s Speed of Sound Path 1
BA-26 Signal acceptance 32900 2 F R % Signal acceptance Path 1
P1
BA-27 SNR P1 AB 32902 2 F R dB Signal-Noise-Ratio AB Path 1
BA-28 SNR P1 BA 32904 2 F R dB Signal-Noise-Ratio BA Path 1
BA-29 AGC-level P1 AB 32906 2 F R dB Automatic gain AB Path 1
BA-30 AGC-level P1 BA 32908 2 F R dB Automatic gain BA Path 1
BA-31 Path velocity vc2 32912 2 F R m/s Velocity of Gas path 2
P2
P3


P4
245
P5
P6
P7
BA-69 SNR P7 AB 32998 2 F R Signal-Noise-Ratio AB Path 7
P8

16 USM GT400 Approval

In this section, you will receive information in which fields of application the device
246 is approved. The standards, guidelines and regulations are also listed which are
applied for the development and manufacturing.
16.1 Metrological approvals

The device has the following approvals:
• MID approval (DE-14-MI002-PTB002)
• MC type approval (metrological approval of Measurement
Canada, AG-0622)
16.2 Pressure devices approval
• PED 2014/68/EU /
EU-type examination certificate (Module B)
ISG-22-14-1630
• ASME B31.3 Ed.2012
• CRN
16.3 Electromagnetic compatibility
• FS-1312-249580-001
• FS-1312-249585
16.4 Explosion protection approval
• ATEX (BVS 14 ATEX E 034X)

• IECEx (BVS 14.0029X)
• CSA (NA) C22.2 No 0.-M91, 30-M1986, 142-M1987

16.5 Standards, directives and guidelines

We, RMG Messtechnik GmbH, herewith declare that due to its design and
construction in the version brought onto the market the devices described in this
247
operating instruction conforms to the relevant fundamental health and safety re-
quirements of the applicable EC Directive.
In the event of a modification of the device is not authorized by us, this declaration
shall be rendered void.
EC guidelines
2014/68/EU EC Pressure Equipment Directive
2014/30/EU Electromagnetic Compatibility
2014/34/EU ATEX Operational Directive.
2014/32/EU MID - Measuring Instrument Directive.
2011/65/EU RoHS
Applied harmonized standards
DIN ISO 8434-1 Metallic tube connections.

(DIN 2353)
DIN ISO 17089 Measurement of fluid flow in closed conduits.
DIN EN 334:2009-07 Gas pressure regulators for inlet pressures up to 100 bar
DIN EN 14382 Safety devices for gas pressure regulating stations and installa-
tions - Gas safety shut-off devices for inlet pressures up to 100
bar
DIN IEC 60529:A1 IP protection categories.
OIML R137-1&2 1. Metrological and technical requirements.

2. Metrological controls and performance tests.
OIML R137-3 OIML Report format for type evaluation.
DIN EN and Explosive atmospheres

IEC/EN 60079-0

DIN EN and Explosive atmospheres - Part 1: Equipment protection by flame-

IEC/EN 60079-1 proof enclosures "d"
248 DIN EN and Explosive atmospheres - Part 7: Equipment protection by flame-

IEC/EN 60079-7 proof enclosures "e"
CAN C22.2 No. 30 Explosion-Proof Enclosures for Use in Class I Hazardous Loca-
tions
UL 1203 Explosion-Proof and Dust- Ignition-Proof Electrical Equipment for

Use in Hazardous Locations
USA Directives
ASME B31.3 Pressure safety

Ed. 2012
AGA report No. 9 Measurement of Gas by Multipath Ultrasonic Meters.
AGA report No. 10 Speed of Sound in Natural Gas and Other Related Hydrocarbon
Gases.
Canada Directives
PS-G-06 Provisional Specifications for the Approval, Verification, Reverifi-

cation, Installation and Use of Ultrasonic Meters.
G-16 Recognition of Test Data From Gas Meter Test Facilities.
S-EG-05 Specifications for the Approval of Software Controlled Electricity

and Gas Metering Devices.
S-G-03 Specifications for Approval of Type of Gas Meters and Auxiliary

Devices - Amendments to Measurement Canada Specification
LMB-EG-08.
S-EG-06 Specifications Relating to Event Loggers for Electricity and Gas

Metering Devices.
GEN-40 Application and Implementation of Measurement Canada's Spec-

ifications for the Approval of both Software Controlled Electricity
and Gas Meters and Event Loggers.
CRN Canadian Registration Number

17 USM GT400 Glossary
17 USM GT400 Glossary

In this chapter you will be given information on terminology.
249
Ultrasonic gas meter (USM)
The flow of the gas is measured at different levels with ultrasonic transducers.
Ultrasonic electronics (USE)

The ultrasonic electronics are mounted on the ultrasonic gas meter. The ultrasonic
electronics evaluate the data recorded by the sensors. The parameters can be dis-
played and evaluated on a computer with the USM software.
Plot
Graphic display of one or more measured values.
Meter
In der Software wird der Ultraschallzähler zum Teil als Messwerk bezeichnet.
Device
In the software the ultrasonic gas meter is sometimes called a meter.
Transducer
The transducer or sensor is built into the device. The transducer sends the oppos-
ing transducer an ultrasonic signal. Using the time measured for the ultrasonic
signal to travel the distance between the two transducers, the ultrasonic electron-
ics calculates the gas flow. 12 transducers are built into the device. They are dis-
tributed across three levels with four transducers on every level. Per level two
paths measure the gas flow. A path comprises two opposing transducers.
In the manual the transducer is called a sensor.
Sensor
Transducer
Meter
Ultrasonic gas meter (USM)

18 USM GT400 Attachment

You will find the declaration of conformity and approvals of the device in this sec-
250 tion.

251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

Contact
Technische Änderungen vorbehalten
Weitere Informationen
Wenn Sie mehr über die Produkte und
Lösungen von RMG erfahren möchten,
besuchen Sie unsere Internetseite:
www.rmg.com
oder setzen Sie sich mit Ihrer lokalen
Vertriebsbetreuung in Verbindung
RMG Messtechnik GmbH

Otto-Hahn-Straße 5
35510 Butzbach, Deutschland
Tel: +49 (0) 6033 897 – 0
Fax: +49 (0) 6033 897 – 130
Email: service@rmg.com

No. PO PO15298
REV. DATE 2023-06-06

METERING SKID
2. FLOW ALIGNER
CPA 50E Recomendaciones de Instalación
¿Cómo sabemos que nuestros acondicionadores de flujo son la solución más efectiva para
sus necesidades de acondicionamiento de flujo? Porque han sido ampliamente probados y
evaluados por laboratorios independientes y han demostrado ser superiores para estabilizar
el rendimiento aguas abajo, incluso en las situaciones más exigentes.
Eso significa que siempre obtendrá mediciones precisas, sin importar si se trata de una
aplicación de aire, gas natural, agua, petróleo, petróleo líquido o cualquier otro fluido.
Nos enorgullecemos de la entrega rápida. Tenemos modelos de cara elevada ANSI en stock y
listos para su envío inmediato, y tenemos tiempos de respuesta rápidos para diseños y
fabricación personalizados. Ofrecemos una amplia variedad de materiales y podemos
diseñar para cualquier tamaño de ½ "a 60 pulgadas, múltiples opciones de instalación, baja
temperatura, alta temperatura, NORSOK, NACE y más.
EN 10204 3.1b Se incluyen informes de prueba de materiales con cada parte, así como
cálculos de caída de presión, certificados de control de calidad y dibujos con cada pedido.
Acondicionador de flujo CPA 50E

El CPA 50E es el acondicionador de flujo más probado en la industria y está respaldado por
más de 20 años de datos de prueba por laboratorios de flujo independientes. El CPA 50E está
diseñado para producir un perfil de flujo completamente desarrollado sin remolinos,
mejorando la confiabilidad y reduciendo los errores, al tiempo que acorta el funcionamiento
del medidor.
Canada Pipeline Accessories es el único fabricante del acondicionador de flujo CPA 50E y es
la única compañía que ha verificado los datos de prueba y cumplimiento utilizando muchos
fluidos diferentes, incluidos gas natural, aire, agua, petróleo líquido y petróleo pesado. Este
extenso cuerpo de datos de prueba solo es aplicable al CPA 50E fabricado por Canada
Pipeline Accessories, y está inherentemente vinculado a los programas de fabricación,
ingeniería y calidad de CPA.
Características
• Inventario disponible para entrega rápida. Disponible en configuración de tipo A de cara
elevada ANSI, tamaños de 2 a 16 pulgadas, material 40 y 80, material de acero inoxidable
316.
• Se puede fabricar a medida para tubos de 3/8 ″ - 48 ″.
• Disponible en acero al carbono, 316SS, 304SS, aluminio, Hastelloy, dúplex, Monel, Inconel,
titanio, etc.
• Aplicable a tipos de medidores de flujo, incluidos orificios, ultrasonidos, turbinas, Coriolis y
más.
• Adecuado para su uso en todo tipo de fluidos, incluidos gas natural, petróleo, agua, vapor,
petróleo líquido y más.
• Compatible con las pestañas CPA FloAlign y CPA Paddle para ayudar a levantar, inspeccionar,
instalar y alinear.
• Los informes de calidad del material EN 10204 3.1b se incluyen con cada pedido y están
disponibles en nuestra base de datos en línea.
• ¡AGA3, AGA9, OIMLR-137 y muchos más datos están disponibles!
• Producto completo y soporte técnico de los ingenieros de CPA, incluidas las
recomendaciones de CFD, cartas de cumplimiento, etc.
CPA 50E RTJF

El CPA Tipo D está diseñado para aplicaciones que usan juntas de juntas de tipo anillo. El
acondicionador de flujo tipo D se fabrica para que coincida con la presión nominal de las
bridas y juntas.
Hay dos subtipos adicionales del acondicionador de flujo Tipo D: el RTJ hembra (RTJF) y el
RTJ macho (RTJM).
En una configuración RTJF, la instalación del acondicionador de flujo implica colocar el

acondicionador de flujo entre dos bridas de unión de tipo anillo y juntas de anillo
coincidentes.
En una configuración RTJM, las juntas están integradas en el acondicionador de flujo, por lo
que no se requieren juntas adicionales y se reduce el espacio entre bridas.
Dado que las juntas integrales en el RTJM están diseñadas para deformarse durante
la instalación, el acondicionador de flujo no debe reutilizarse si se abren las bridas.
Características
• Diseño personalizado para cada aplicación con una amplia gama de opciones de tamaño y
material.
• Disponible para clasificaciones ANSI 150 # a 2500 #, API 2000 a 20000 y brida compacta
Norsok.
• Puede ser diseñado para acomodar cáncamos forjados ASME 18.15.
• Totalmente compatible con los mínimos de espesor de pieza RTJ especificados en ASME
B16.48‐2005 y ASME B31.3‐2004.
Información de instalación de placa

En un RTJF, recomendamos que la cara de lavado se coloque contra la brida aguas abajo del
tubo del medidor.
Para un RTJM, el acondicionador de flujo debe insertarse en el tubo del medidor aguas
abajo. Este posicionamiento asegura que el acondicionador de flujo esté centrado en relación
con el medidor de flujo y aísla adecuadamente el tubo del medidor aguas arriba.
En un CPA 50E, la geometría no es direccional y el acondicionador de flujo se puede instalar

hacia atrás si es necesario sin ningún cambio en el rendimiento del medidor de flujo.
El CPA 55E y 65E tienen una dirección preferida. Están diseñados para instalarse con el
lado escalonado hacia arriba para un rendimiento adecuado.
Espesor de diseño de junta tipo anillo femenino (RTJF)
Todos los acondicionadores de flujo tipo anillo hembra (RTJF) fabricados por Canada
Pipeline Accessories están diseñados para cumplir con ASME B31.3 y ASME B16.48. Estas
normas proporcionan las dimensiones requeridas para la instalación segura de espacios en
blanco RTJ, espaciadores y persianas de línea.
Las dimensiones requeridas para un acondicionador de flujo RTJF se basan en el esfuerzo al

que se somete la pieza cuando se sujeta y atornilla. Las bridas a cada lado del RTJF deben
apretarse juntas, lo suficiente para que las juntas de anillo se deformen ligeramente y se
asienten en las ranuras. Esta es la condición de diseño dominante para la que debe diseñarse
el RTJF: debe ser lo suficientemente fuerte como para no fallar cuando se aprieta.
El grosor del RTJF es un factor importante para determinar qué tan fuerte es la pieza. A
medida que el RTJF se comprime entre sí mediante el atornillado de la brida, fuerzan a las
superficies de la ranura a separarse y someten fuertemente al material entre las ranuras. En
un RTJF con el grosor adecuado, hay suficiente material para resistir las fuerzas que separan
la brida. Si la brida RTJF es demasiado delgada, no habrá suficiente material y resistencia
para evitar que la pieza falle.
La Figura 1 a continuación muestra el resultado de un análisis de elementos finitos (FEA) en

una brida RTJF que cumple con el espesor mínimo ASME. Las áreas de color púrpura oscuro
indican regiones que están estresadas más allá del límite elástico del material y están cerca
de fallar. Se espera que ceda en el área inmediata alrededor de las ranuras RTJF, ya que las
piezas deben sujetarse lo suficientemente juntas como para deformar las juntas de anillo. Sin
embargo, tenga en cuenta que la mayoría del área de la brida RTJF está muy por debajo del
límite elástico del material y fácilmente tiene la resistencia necesaria para mantenerse unida.
Figura 1: Este gráfico visualiza el esfuerzo en una brida conforme a ASME B16.48. Las áreas
de color púrpura oscuro indican que el material está estresado más allá de los límites
aceptables y está cerca de fallar.
En la figura 2 a continuación, el grosor de la brida RTJF se ha reducido al grosor de un anillo
de purga común. Como antes, las áreas de color púrpura oscuro indican material que está
estresado más allá del rango máximo permitido y que está a punto de fallar. Debido a que la
brida en la figura 2 es más delgada, no hay suficiente material para resistir la fuerza que
mantiene juntas las bridas. El área púrpura oscura se extiende por todo el grosor de la
materia, y en este grosor, la brida RTJF está en riesgo de fallar catastróficamente.
Figura 2: Este gráfico visualiza la tensión en una brida delgada de RTJF. Los colores morados
oscuros indican material que está estresado más allá de los límites aceptables y está a punto
de fallar.
Los acondicionadores de flujo de CPA están diseñados para tener en cuenta la tensión a la
que están sometidas las bridas RTJF cuando se instalan. Para el cumplimiento adecuado de
la ingeniería, es muy importante cumplir con las dimensiones especificadas en ASME B31.3
y ASME B16.48. Los diseños más delgados estarán en riesgo de falla severa.
Orientación de placa
Para facilitar la instalación, el acondicionador de flujo CPA Tipo D tiene un marcador de
punto muerto superior grabado en la circunferencia exterior de la brida. Esta flecha grabada
está alineada con el eje de 90 grados del acondicionador de flujo y se proporciona para
ayudar con la orientación del acondicionador de flujo cuando se utilizan medidores de flujo
ultrasónicos.
La orientación del acondicionador de flujo de CPA no es aplicable al rendimiento de

medición cuando se usan otros tipos de medidores de flujo.
No. PO PO15298
REV. DATE 2023-06-06

METERING SKID
3. VALVES – 3/4"
No. PO PO15298
REV. DATE 2023-06-06

METERING SKID
4. VALVES – 8” 600#
DOC NO:NWS 0004.7
REV NO: 2014
BS/BSP/BSE series
Forged Steel Trunnion Ball Valve
Installation，Operation and Maintenance
Instruction
Translated Copy
Prepared by Lie Cai Date 2014-11-05

Reviewed by Wendong Fan Date 2014-11-05
Approved by Ian Cheng Date 2014-11-05
Translated by Ran Jing Date 2014-11-19
地址：苏州新区泰山路 666 号电话: 86-512-666-51365 传真: 86-512-666-18930-2020 邮编：215129

Add：No.666 Taishan Road, Suzhou New District, P.R. China Post Code: 215129 Tel: 86-512-666-51365
Fax: 86-512-666-18930-2020 E-Mail: neway@neway.com.cn http: //www.newayvalve.com
BS/BSP/BSE series Forged Steel
Trunnion Ball Valve Installation, DOC NO: NWS 0004.7
Operation and Maintenance Instruction REV NO: 2014
Document change records
Rev. No. Rev. identification Change Description Effective date Appro. No

2010 All First issue 2010/10/14 10230
2012 All Structure Upgrated to V5, 2012/06/01 12133
QA Was Added
Double-Piston Warning
Board Added, Draining And
2014 Red Script+Underline 2014/11/12 14138
Bleeding Valve Arranged
Separately
Page 2 of 16
BS/BSP/BSE series Forged Steel Trunnion Ball Valve

Installation，Operation and Maintenance Instruction
b) Obturate the valve passage and groove with

1. Overview connection covers to avoid sundries entering
This instruction applies to Neway 2 "~ 60" 150LB or bruise groove.
~ 2500LB BS/BSP/BSE series full port (FP) and c) If the valve need to be stored outside, please
reduced port (RP) trunnion ball valve. In order to be covered to avoid water buildup.
ensure the product be installed and operated d) If long-term storage is required, the valve
correctly, trouble obviated , please read this should use corrosion inhibitor and end
instructions carefully and keep in the archives for connection covers. Before using again , clean
future reference. care should be taken, if necessary, valve shall
Valve Instruction: be pressure tested once more.
BS: 3-pc design forged steel trunnion mounted
ball valve(double bleed seat); 3. Installing
BSP: 3-pc, double-piston design forged steel 3.1 The valve should be inspected before
trunnion mounted ball valve(both sides are installation:
double-piston seat); a) Check whether sundries in valve passage.
BSE: 3-pc bleeding, double-piston design forged b) Check whether connected surface is damaged.
steel trunnion mounted ball valve(one side bleed c) Check whether valve movement is normal.
seat, the other side is double-piston). d) Be sure the valve is in full-open position.
e) For BSE series, the accurate installation
2. Storage position is: When the valve is closed as Fig.1
The following care should be taken when storing shows, the high pressure end is seat①（bleed
valves: seat）, low pressure end is seat②(double
a) Make sure the valve is in full-opening position. piston seat).
Page 3 of 16
from the lifting devices. In difficult working

environment, sundries such as sand should
be avoid entering into valve passage.
---------------------------------------------------------------
3.3 For flange connection valve, in order to get a

Fig.1Installation Direction Indicate good sealing effect, pre-tighten the bolts in
diagonal sequence to ensure force uniformity.
---------------------------------------------------------------
Show as Fig.3:
Caution: The ball should be in full-opening
position during instalation. Failure to keep
the ball fully open during installation may
cause damage to the valve. \
---------------------------------------------------------------
Fig.3
3.2 Handling of Valves
3.4 Ensure enough space to valve operation.
1) The valve should be lifted in correct way so
that the body supports the load. ---------------------------------------------------------------
Caution: ball valve is 90 degrees rotation
-------------------------------------------------------------
operating valves, clockwise close;
2)Caution: Never use handwheel or other
counterclockwise drive open. For lever
protruding parts of the gearbox or actuator operated valves, keep enough space to
not designated for this purpose. If lifting lug operate.
is visible, please use lifting lug, if not, please ---------------------------------------------------------------
follow Fig2.
--------------------------------------------------------------- 3.5 The following care should be taken for
butt-welding valve when welding:
1) If the valve must be installed in full-close
position, please lay oil on the exposure part of
the ball to protect ball from splash welding slag.
---------------------------------------------------------------
Caution: For butt-welding valve with no
nipple pipe , never install valve when the
ball is in close position
Fig.2 lifting with end neck
---------------------------------------------------------------
3) The end protector covers should be kept in
2) During the welding of ball valve, temperature of
place on the end connections during all
handling. Remove only before installation of any point which is 3 inch(75mm) off brazing
the valve. Movement should be careful. seam should not exceed 302℉(150℃).Please
--------------------------------------------------------------- measure temperature with thermopile stick.
Caution: During handling, protect the end
connection faces and fittings against damage
Page 4 of 16
3) Before finally welding to pipe vessel, please with isolating valves, the bleed valve should be
obturate valve half bottom sealing changed to plug screw.
area(sealing between ball and valve seat and 4) Now the valve is ready to be pressure tested.
sealing between valve seat and bonnet) with 5) After pressure test, turn the valve to fully open
20mm wide bracer. In order to avoid the position before releasing the test fluid. The
sundries enter into this area. Before using or isolate valve should be in fully-opened position
pressure test, contaminant should be cleaned if it is installed on bleed hole and draining hole.
with cleaning ball in piping system. Screw off the screw plug or safety relief valve,
3.6 Hydrostatic Testing releasing the test fluid from body cavity.
When ball valves are installed in a piping 6) Screw on the screw plug or safety relief valve,
system that requires hydrostatic testing of the return the valve to fully open position or other
adjoining pipe, follow these procedures to position need to operate.
minimize any damage that could occur to the 7) For the structure of double piston on both sides,
sealing surfaces and seat seals inside the and no isolating valve on bleed hole, after pressure
valve, and reduce unnecessary leakage. testing, the plug screw should be taken down, and
1) Valve should be in the fully open position when rechange to bleed valve. For valves with bleed
the injection of test fluid begins. This will allow valve, the plug screw should also rechange to bleed
any pipeline debris to be flushed through the valve.
valve bore and out of the piping. Isolating valve 8) If medium is water, the pipe and valve cavity must
should be fully-opened if installed on bleed be dried and exhausted in time, and filling the pipe
hole or draining hole. with nitrogen, injecting grease when necessary,
2) Once the piping system has been purged of material of carbon steel should be painted
debris and the system has been filled anticorrosive oil to avoid corrosion resulting from
completely with the test fluid, the ball valve testing medium, which would affect the valve
should be placed in the partially open performance.
position(approximately 10o from the fully open
position).This allows test fluid into the body 4. Using
cavity of the valve. The isolating valve should 4.1 Products shall worked in specified conditions
be turned to middle position if it is installed on in purchase order.
bleed hole or draining hole. ---------------------------------------------------------------
3) For the structure of double piston on both sides, Caution: anything beyond the purchase
order specified working conditions (media,
and no isolating valve on bleed hole, warning
pressure, temperature, and the external
board should be installed under bleed valve,
environment etc.) are not allowed, otherwise
according to the board, bleed valve above the will produce risk.
diagonal should be taken down before ---------------------------------------------------------------
pressure test, then using the plug screw. Valve 4.2 Valve in normal working condition, should
Page 5 of 16
keep in fully open or fully closed state. Valve c) Isolating valve: handle paralleling with the
with isolating valve should be installed on channel is full-open position, vertical is full-
bleed hole or draining hole, the isolating hole closed position.
should be in full-open position, others in full-
closed position. We do not recommend that in
order to adjust the pipeline flux and make the
valve in partial open state.
4.3 Valve position observation

Whether valve be in open or not, it can be
learned through stem head to judge. Fig.6 full-open position
a) Flat trend----- Direction parallel flat trend is
the direction of ball passage. (As figure 4)
Fig.7 full-closed position
4.4 Double-block-and bleed

4.4.1 Whether valve is in fully open position or
fully close position, pressure from upstream and
downstream and be both isolated from valve
Fig.4 valve is in full-opening position
cavity by valve seat ring. Cavity release can
through valve body drain. (BSP valve usually vent
b) Unflat trend——Direction of valve location
and drain through relief valve)
direction on the top of valve stem is the
4.4.2 For 6 inches and above, both sides with
direction of ball passage.( As figure 5)
double piston structure, no isolating valve on the
relief valve, 3 by-pass valves should be installed
on the body, as shown in fig.8.
Page 6 of 16
a) Pressure relief: use appropriate hexagon ring

spanner into safety relief valve, turning
counter-clockwise direction, screw off the
gland and pressure will be released.
b) Drain: Screw off the safety relief valve directly.
Fig.8
① Relief valve. Used for pressure bleeding. 4.5 Lubricant and emergency injection
② Relief valve warning board. Used for Valve with lubricator can inject lubricant or
reminding users to change the relief valve sealing gum into valve seat or stem when
of plug screw. needed.
③ Relief valve. Bleeding pressure in cavity NEWAY RECOMMANDING：
manually. Sealing grease: DOW CORNING DC-111.
④ Plug screw. Used for draining.
Lubrication grease: DESCO 111(HS）, used
---------------------------------------------------------------
in acid or crude oil environment.
Caution: Valve cavity release in half open
position is prohibited; Valve cavity release 4.5.1 Valve Cleaning
under pressure is not suggested; Please Valve seat cavity is easy polluted for piping
ensure to wear appropriate cloth when system valve. In order to ensure the movement of
releasing valve cavity, and follow the safe valve seat, timely cleaning with approved washing
rules. Otherwise injury may occur.
liquid is suggested. Procedure refer to page 10.
---------------------------------------------------------------
4.5.2 Injection procedure please follow process on
4.4.3 Use of safety relief valve. Purpose for using page 10.
safety relief valve shall be: pressure relief and 4.5.3 Washing liquid/sealing gum using quantity
drain: refer to page 11.
Gland
5. Maintenance
5.1 Daily maintenance is the necessary for valves
in good condition. Mainly includes:
a) Check bolts, nuts fastening.
Normal draining
b) Check the sealing situation of stem, body
and bonnet all day long.
Page 7 of 16
c) Check valve corrosion situation. 5.4 Valve disassemble (refer to valve disassemble
fig 1 & fig 2)
5.2 Gearbox maintenance 5.4.1 After demounting from the piping, release
a) Inspect housing for damage and wear. the possible residual stress in the housing of
b) Check the sealing situation of gearbox and valve.
prevent from water which cause corrosion. 5.4.2 Fix valve vertically on mounting rack. Be
c) Lubricate gear box with approved lubricant careful not to damage the facing ring of
if necessary. flange, close the valve clockwise rotation.
5.4.3 Actuator
5.3 Maintenance Normal Lever:
For your safety, suggest valve repair by NEWAY. a. Remove the bolt, washer and lever;
Pay attention to the following before repairing; b. Remove the retainer, locating board and
a) It is not suggested to repair the valve before locating screw;
pressure relief or when power on. T-Lever:
--------------------------------------------------------------- a. Screw off bolt, take out the steel pipe;
Caution: before repairing, reduce or release b. Remove screw, washer and lever;
pipeline pressure and release valve inner
c. Remove washer, locating board and
cavity pressure, prevent human body from
locating screw;
injuring, cut off power supply of driver
device, prevent valve abnormal movements Gearbox:
cause harm to human body. a. Screw off nut, lift off the gearbox from the
--------------------------------------------------------------- valve, and locate at clean place;
b) Understand pipeline medium, consult with
b. Remove the key and pin from stem;
authoritative department if necessary.
5.4.4 Main Body
---------------------------------------------------------------
Trunnion design:
Caution: it mustn’t maintenance when you
a. Remove screw 24, lift off top flange 8;
don’t know pipe medium clearly. To prevent
injuring, usually requires to wear exposure b. Remove O-ring 23 in top flange, remove
suit or uses protective equipments. fire safe seal 22 from cover 7;
--------------------------------------------------------------- c. Remove screw 21 from cover, and
c) No-smoking, don't use electric device with no
dismount the cover and stem 6 from the
explosive-proof type, fire without permission
body 1 together;
is forbidden.
d. Separate the cover, thrust washer 26 and
d) Removing after and before decomposed, put
bearing 27 from the stem. Take out the
the valve in a vertical position to empty
O-ring 20 and pin 25 from cover;
pipe remaining medium, taking care when open
e. Remove bolt 36 from trunnion 34, remove
and close the valve on several occasions.
the trunnion;
Page 8 of 16
f. Remove nut 12, take out the bonnet 2 and b. Fix spring 16 on bonnet 2, put the seat
seat retainer 4, gasket 9, seat follower 13, assembly into the bonnet, press the seat
o-ring 10, spring 16 slightly, locate them assembly to contact the spring;
on soft cloth or chipboard. Adown the c. Fix on pin 36 (if available). Fix the valve
flange end, be careful not to damage the body 1 on one bonnet, pay attention to
facing ring of the flange; the position of oil way, and bolt the nut 12
g. Take out the seat retainer, gasket 15, refer to table 1;
washer 14, seat follower, O-ring 17 and Table 1 Fastening suggest torque (Nm)
spring from the bonnet; Size Torque Size Torque
h. Lift out the ball 13 vertically, locate it on
1/2 50~60 1-5/8 1800~2200
soft cloth or chipboard;
9/16 70~80 1-3/4 2200~2600
i. Repeat f & g, separate bonnet and other
5/8 100~130 1-7/8 2800~3300
accessories on the other side;
Trunnion support design: 3/4 160~210 2 3500~4200
a. Follow the step a, b, c, d, f, g of trunnion 7/8 280~330 2-1/4 4200~4800

design, remove top flange 8, cover 7, 1 420~500 2-1/2 6100~7000
stem 6, one side bonnet 2, seat retainer 4, 1-1/8 500~600 2-3/4 8200~9400
seat follower 13, spring 16, etc; 1-1/4 850~1000 3 10300~11800
b. Lift out the ball 3 and trunnion support 34
1-3/8 1100~1300 3-1/4 14000~16000
together vertically from the valve body,
1-1/2 1400~1800 3-1/2 17000~19600
locate them on soft cloth or chipboard.
d. Fix bearing 33 into the bottom bore of the
Take off the trunnion support, bearing 33
ball, fix the ball 3 into valve body, pay
and thrush washer from the ball;
attention to keep the bore on bottom of
c. Follow the steps f & g of trunnion design,
the ball in line with bore on the bottom of
remove the bonnet, seat retainer, seat
the body;
follower, spring, etc on the other side;
e. Fix O-ring 35 on trunnion 34, lubricate
with oil. Fix on gasket 37, tread the
5.5 Valve Assembly
trunnion through body to the bottom bore
Before assembling, clean all parts, check
of the ball, pay attention to the bleeder
whether the parts are damaged. Restoration
hole on the trunnion. Bolt the bolt 36 refer
or change new ones if damaged.
to Table 1;
Trunnion design:
f. Fix the other bonnet with seat retainer on
a. Fix gasket 15, washer 14, seat follower 13
the body, bolt the nut refer to Table 1;
and O-ring 17 on seat retainer 4.
Lubricate the O-ring with oil;
Page 9 of 16
g. Fix O-ring 19/20, injection 40 (if available) attention that the flat trend on ball should
and gasket 18 into cover 7; Fix bearing 27 aim at the hole which for stem;
and thrust washer on stem 6; d. Follow the steps of f, g, h, I of trunnion
h. Tread the stem through valve body to the design, fix the bonnet on the other side,
flat trend of the ball, pay attention to the stem 6, cover 7 and top flange 8, etc;
direction of key trend; Put the fix pin 25 5.6 Former disassemble steps please refer to
into pinhole on the top of valve body, put valve disassemble figures. If have any
on the cover tread through stem and fix questions, please feel free to contact the
pin, bolt the screw 21 refer to Table 1; manufacture;
i. Fix top flange 8, bolt the screw 24; 5.7 To ensure the quality of the valve, suggest to
Trunnion support design: change the soft sealing when re-assemble,
a. Follow the step a, b, c of trunnion design, such as: gasket, thrust washer, valve seat
fix bonnet 2 on the other side; and packing;
b. Put bearing 33 into the bore of trunnion 6 Problem solving
support 34. Fix trunnion support and Some usual troubles are listed below for your
thrust washer 35 together on the ball 3; convenient to seek the solution:
c. Lift up the ball and trunnion support
together through the ball passage with
soft rope, fix them in the body, pay
Page 10 of 16
Failure Causes Troubleshooting
1. Perform gearing maintenance outlined on
section 5.2
1. The operator is malfunctioning;
The valve is 2. Lubricate valve seat with sealant, lubricate
2. Lack of lubricate oil;
difficult to actuator with proper industrial oil;
3. Ice exist in operate system or
operate 3. Heat or inject anti-icing fluid;
in the valve;
4. loosen bolt on top flange and cover; Check
4. Stem is locking
the valve; Check the damage situation;
Repair or replace stem;
1. Contaminant on sealing
1. Clean the contaminant;
surface
The seats 2. Re-facing the sealing surface or change the
2. Damage on sealing surface
are leaking sealing packing;
3. Leakage between valve seat
3. Change O-ring;
and bonnet, check whether
O-ring is out of work;
1. O-ring is out of work;

The stem is 1. Change O-ring;
2. Damage on sealing surface of
leaking 2. Repair or replace damage stem;
stem;
Leaking of
body and 1. O-ring is out of work; 1. Change O-ring
closure
1. Re-fix limit bottom or fix it at correct

Can’t close 1. Gear-drive equipment or limit
position;
in fully button is not fix correctly, or
position Gear-drive equipment failure;
section 5.2
Page 11 of 16
Washing Procedure
Procedure Process
Check Valve Check valve seat injection point/valve body drain
Check equipment Ensure Injection equipment is under work condition
Inject wash liquid Inject adequate wash liquid into each injection through valve
seat
Operate Valve Open and close valve three times
seat
Wet the valve Wait for 1-6 hours, let wash liquid wet the block and dirty
seat
Injection procedure
Procedure Process
1.Preparation Before injection, clean the valve follow para.4.5.1 procedure
2.Check valve
Endure valve is in fully close position
position
3.Inject standard Inject adequate wash liquid into each injection through valve
sealing lubricant seat
4.Operate valve Operate valve to fully open position
Open and close valve 3-4 times, then turn valve to fully closed
6.Operate valve
position, proportion the sealing lubricant.
Page 12 of 16
Washing Liquid/ Sealing lubricant using quantity
Valve Injection for each Injection Injection for Injection for each
3
size valve seat (oz) for each valve each valve seat
3 valve（cm ）
(oz)
（cm ）
2” 1 2 25 50
3” 1 2 35 65
4” 2 3 50 100
6” 2 4 65 130
8” 3 6 80 160
10” 3 6 90 180
12” 5 10 135 270
14” 5 10 155 310
16” 6 12 170 335
18” 9 18 265 525
20” 10 20 295 585
22” 11 22 330 655
24” 12 24 350 695
26” 13 26 395 785
28” 13 26 400 800
30” 15 30 445 890
34” 17 34 495 990
36” 21 42 620 1240
40” 32 64 960 1920
42” 34 68 995 1990
7. Quality Guarantee and services

7.1 Valve quality guarantee period is 18 the right to recall the products and carries
months (Within 18 months from the date of on the investigation and analysis.
shipment or 12 months after installation, 7.3 Manufacturer’s guarantee business only
whichever occurs first). The manufacture limits to the following conditions:
shall be responsible for the quality 1） Material repair costs.
problem caused by material defect and 2） Replacement of parts and material
occured in the case of correct operation, costs.
while is irresponsible for the improper 3） Purchase costs due to compensating
installation improper repair and alternation users’ problem products.
in private. 7.4 Manufacture is irresponsible for the
7.2 Users shall inform the manufacturer about damage beyond the valve self defects
the product problem. The manufacture has caused by unexpected disaster (Such as
Page 13 of 16
earthquake, typhoon etc).
7.5 The other assurances beyond the scope 7.7 NEWAY will track the valve quality and
of this document shall be agreed by user offer various services per user’s
and manufacture. requirements.
7.6 NEWAY can provide on-site installation 7.8 If user disassembles the valve to repair
and commissioning (If it is included in without manufacture’s permission, the
the contract). user will be regarded to giving up the
quality assurance above
.
Page 14 of 16
Disassemble fig 1 Trunnion design
Bolt
Washer
Steel Pipe Lever
Retainer Normal Lever

Screw
T-Lever
Fix board
24
8
Gearbox
22
23
Stud 20
Gearbox 27
Nut
26 31
30
6
28 29
21
7
18 25
19
3
5
4
14
13
17
1
33
15
16
37 35
11
34
12
10
9 36
2
32
Page 15 of 16
Disassemble fig 2 Trunnion support design
Bolt
Washer
Steel pipe Lever

普通手柄
T 形手柄
Retainer
Screw
Fix board
24
Gearbox
25
8
Stud
23
Gearbox
Nut 22
21
41
7
20
40
18
26 19
27
31
6
30 28
32
34 29
3
5
4
14
15
16
9
38
1
37
17 10 13 36 33 35 39
12 11
2
Page 16 of 16
No. PO PO15298
REV. DATE 2023-06-06

METERING SKID
5. VALVE WITH ACTUATOR – 8” 600#

DOC NO:NWS 0004.7
REV NO: 2014
BS/BSP/BSE series
Forged Steel Trunnion Ball Valve
Installation，Operation and Maintenance
Instruction
Translated Copy
Prepared by Lie Cai Date 2014-11-05

Reviewed by Wendong Fan Date 2014-11-05
Approved by Ian Cheng Date 2014-11-05
Translated by Ran Jing Date 2014-11-19
地址：苏州新区泰山路 666 号电话: 86-512-666-51365 传真: 86-512-666-18930-2020 邮编：215129

Add：No.666 Taishan Road, Suzhou New District, P.R. China Post Code: 215129 Tel: 86-512-666-51365
Fax: 86-512-666-18930-2020 E-Mail: neway@neway.com.cn http: //www.newayvalve.com
Document change records
Rev. No. Rev. identification Change Description Effective date Appro. No

2010 All First issue 2010/10/14 10230
2012 All Structure Upgrated to V5, 2012/06/01 12133
QA Was Added
Double-Piston Warning
Board Added, Draining And
2014 Red Script+Underline 2014/11/12 14138
Bleeding Valve Arranged
Separately
Page 2 of 16
BS/BSP/BSE series Forged Steel Trunnion Ball Valve

Installation，Operation and Maintenance Instruction
b) Obturate the valve passage and groove with

1. Overview connection covers to avoid sundries entering
This instruction applies to Neway 2 "~ 60" 150LB or bruise groove.
~ 2500LB BS/BSP/BSE series full port (FP) and c) If the valve need to be stored outside, please
reduced port (RP) trunnion ball valve. In order to be covered to avoid water buildup.
ensure the product be installed and operated d) If long-term storage is required, the valve
correctly, trouble obviated , please read this should use corrosion inhibitor and end
instructions carefully and keep in the archives for connection covers. Before using again , clean
future reference. care should be taken, if necessary, valve shall
Valve Instruction: be pressure tested once more.
BS: 3-pc design forged steel trunnion mounted
ball valve(double bleed seat); 3. Installing
BSP: 3-pc, double-piston design forged steel 3.1 The valve should be inspected before
trunnion mounted ball valve(both sides are installation:
double-piston seat); a) Check whether sundries in valve passage.
BSE: 3-pc bleeding, double-piston design forged b) Check whether connected surface is damaged.
steel trunnion mounted ball valve(one side bleed c) Check whether valve movement is normal.
seat, the other side is double-piston). d) Be sure the valve is in full-open position.
e) For BSE series, the accurate installation
2. Storage position is: When the valve is closed as Fig.1
The following care should be taken when storing shows, the high pressure end is seat①（bleed
valves: seat）, low pressure end is seat②(double
a) Make sure the valve is in full-opening position. piston seat).
Page 3 of 16
from the lifting devices. In difficult working

environment, sundries such as sand should
be avoid entering into valve passage.
---------------------------------------------------------------
3.3 For flange connection valve, in order to get a

Fig.1Installation Direction Indicate good sealing effect, pre-tighten the bolts in
diagonal sequence to ensure force uniformity.
---------------------------------------------------------------
Show as Fig.3:
Caution: The ball should be in full-opening
position during instalation. Failure to keep
the ball fully open during installation may
cause damage to the valve. \
---------------------------------------------------------------
Fig.3
3.2 Handling of Valves
3.4 Ensure enough space to valve operation.
1) The valve should be lifted in correct way so
that the body supports the load. ---------------------------------------------------------------
Caution: ball valve is 90 degrees rotation
-------------------------------------------------------------
operating valves, clockwise close;
2)Caution: Never use handwheel or other
counterclockwise drive open. For lever
protruding parts of the gearbox or actuator operated valves, keep enough space to
not designated for this purpose. If lifting lug operate.
is visible, please use lifting lug, if not, please ---------------------------------------------------------------
follow Fig2.
--------------------------------------------------------------- 3.5 The following care should be taken for
butt-welding valve when welding:
1) If the valve must be installed in full-close
position, please lay oil on the exposure part of
the ball to protect ball from splash welding slag.
---------------------------------------------------------------
Caution: For butt-welding valve with no
nipple pipe , never install valve when the
ball is in close position
Fig.2 lifting with end neck
---------------------------------------------------------------
3) The end protector covers should be kept in
2) During the welding of ball valve, temperature of
place on the end connections during all
handling. Remove only before installation of any point which is 3 inch(75mm) off brazing
the valve. Movement should be careful. seam should not exceed 302℉(150℃).Please
--------------------------------------------------------------- measure temperature with thermopile stick.
Caution: During handling, protect the end
connection faces and fittings against damage
Page 4 of 16
3) Before finally welding to pipe vessel, please with isolating valves, the bleed valve should be
obturate valve half bottom sealing changed to plug screw.
area(sealing between ball and valve seat and 4) Now the valve is ready to be pressure tested.
sealing between valve seat and bonnet) with 5) After pressure test, turn the valve to fully open
20mm wide bracer. In order to avoid the position before releasing the test fluid. The
sundries enter into this area. Before using or isolate valve should be in fully-opened position
pressure test, contaminant should be cleaned if it is installed on bleed hole and draining hole.
with cleaning ball in piping system. Screw off the screw plug or safety relief valve,
3.6 Hydrostatic Testing releasing the test fluid from body cavity.
When ball valves are installed in a piping 6) Screw on the screw plug or safety relief valve,
system that requires hydrostatic testing of the return the valve to fully open position or other
adjoining pipe, follow these procedures to position need to operate.
minimize any damage that could occur to the 7) For the structure of double piston on both sides,
sealing surfaces and seat seals inside the and no isolating valve on bleed hole, after pressure
valve, and reduce unnecessary leakage. testing, the plug screw should be taken down, and
1) Valve should be in the fully open position when rechange to bleed valve. For valves with bleed
the injection of test fluid begins. This will allow valve, the plug screw should also rechange to bleed
any pipeline debris to be flushed through the valve.
valve bore and out of the piping. Isolating valve 8) If medium is water, the pipe and valve cavity must
should be fully-opened if installed on bleed be dried and exhausted in time, and filling the pipe
hole or draining hole. with nitrogen, injecting grease when necessary,
2) Once the piping system has been purged of material of carbon steel should be painted
debris and the system has been filled anticorrosive oil to avoid corrosion resulting from
completely with the test fluid, the ball valve testing medium, which would affect the valve
should be placed in the partially open performance.
position(approximately 10o from the fully open
position).This allows test fluid into the body 4. Using
cavity of the valve. The isolating valve should 4.1 Products shall worked in specified conditions
be turned to middle position if it is installed on in purchase order.
bleed hole or draining hole. ---------------------------------------------------------------
3) For the structure of double piston on both sides, Caution: anything beyond the purchase
order specified working conditions (media,
and no isolating valve on bleed hole, warning
pressure, temperature, and the external
board should be installed under bleed valve,
environment etc.) are not allowed, otherwise
according to the board, bleed valve above the will produce risk.
diagonal should be taken down before ---------------------------------------------------------------
pressure test, then using the plug screw. Valve 4.2 Valve in normal working condition, should
Page 5 of 16
keep in fully open or fully closed state. Valve c) Isolating valve: handle paralleling with the
with isolating valve should be installed on channel is full-open position, vertical is full-
bleed hole or draining hole, the isolating hole closed position.
should be in full-open position, others in full-
closed position. We do not recommend that in
order to adjust the pipeline flux and make the
valve in partial open state.
4.3 Valve position observation

Whether valve be in open or not, it can be
learned through stem head to judge. Fig.6 full-open position
a) Flat trend----- Direction parallel flat trend is
the direction of ball passage. (As figure 4)
Fig.7 full-closed position
4.4 Double-block-and bleed

4.4.1 Whether valve is in fully open position or
fully close position, pressure from upstream and
downstream and be both isolated from valve
cavity by valve seat ring. Cavity release can
through valve body drain. (BSP valve usually vent
b) Unflat trend——Direction of valve location
and drain through relief valve)
direction on the top of valve stem is the
4.4.2 For 6 inches and above, both sides with
direction of ball passage.( As figure 5)
double piston structure, no isolating valve on the
relief valve, 3 by-pass valves should be installed
on the body, as shown in fig.8.
Page 6 of 16
a) Pressure relief: use appropriate hexagon ring

spanner into safety relief valve, turning
counter-clockwise direction, screw off the
gland and pressure will be released.
b) Drain: Screw off the safety relief valve directly.
Fig.8
① Relief valve. Used for pressure bleeding. 4.5 Lubricant and emergency injection
② Relief valve warning board. Used for Valve with lubricator can inject lubricant or
reminding users to change the relief valve sealing gum into valve seat or stem when
of plug screw. needed.
③ Relief valve. Bleeding pressure in cavity NEWAY RECOMMANDING：
manually. Sealing grease: DOW CORNING DC-111.
④ Plug screw. Used for draining.
Lubrication grease: DESCO 111(HS）, used
---------------------------------------------------------------
in acid or crude oil environment.
Caution: Valve cavity release in half open
position is prohibited; Valve cavity release 4.5.1 Valve Cleaning
under pressure is not suggested; Please Valve seat cavity is easy polluted for piping
ensure to wear appropriate cloth when system valve. In order to ensure the movement of
releasing valve cavity, and follow the safe valve seat, timely cleaning with approved washing
rules. Otherwise injury may occur.
liquid is suggested. Procedure refer to page 10.
---------------------------------------------------------------
4.5.2 Injection procedure please follow process on
4.4.3 Use of safety relief valve. Purpose for using page 10.
safety relief valve shall be: pressure relief and 4.5.3 Washing liquid/sealing gum using quantity
drain: refer to page 11.
Gland
5. Maintenance
5.1 Daily maintenance is the necessary for valves
in good condition. Mainly includes:
a) Check bolts, nuts fastening.
Normal draining
b) Check the sealing situation of stem, body
and bonnet all day long.
Page 7 of 16
c) Check valve corrosion situation. 5.4 Valve disassemble (refer to valve disassemble
fig 1 & fig 2)
5.2 Gearbox maintenance 5.4.1 After demounting from the piping, release
a) Inspect housing for damage and wear. the possible residual stress in the housing of
b) Check the sealing situation of gearbox and valve.
prevent from water which cause corrosion. 5.4.2 Fix valve vertically on mounting rack. Be
c) Lubricate gear box with approved lubricant careful not to damage the facing ring of
if necessary. flange, close the valve clockwise rotation.
5.4.3 Actuator
5.3 Maintenance Normal Lever:
For your safety, suggest valve repair by NEWAY. a. Remove the bolt, washer and lever;
Pay attention to the following before repairing; b. Remove the retainer, locating board and
a) It is not suggested to repair the valve before locating screw;
pressure relief or when power on. T-Lever:
--------------------------------------------------------------- a. Screw off bolt, take out the steel pipe;
Caution: before repairing, reduce or release b. Remove screw, washer and lever;
pipeline pressure and release valve inner
c. Remove washer, locating board and
cavity pressure, prevent human body from
locating screw;
injuring, cut off power supply of driver
device, prevent valve abnormal movements Gearbox:
cause harm to human body. a. Screw off nut, lift off the gearbox from the
--------------------------------------------------------------- valve, and locate at clean place;
b) Understand pipeline medium, consult with
b. Remove the key and pin from stem;
authoritative department if necessary.
5.4.4 Main Body
---------------------------------------------------------------
Trunnion design:
Caution: it mustn’t maintenance when you
a. Remove screw 24, lift off top flange 8;
don’t know pipe medium clearly. To prevent
injuring, usually requires to wear exposure b. Remove O-ring 23 in top flange, remove
suit or uses protective equipments. fire safe seal 22 from cover 7;
--------------------------------------------------------------- c. Remove screw 21 from cover, and
c) No-smoking, don't use electric device with no
dismount the cover and stem 6 from the
explosive-proof type, fire without permission
body 1 together;
is forbidden.
d. Separate the cover, thrust washer 26 and
d) Removing after and before decomposed, put
bearing 27 from the stem. Take out the
the valve in a vertical position to empty
O-ring 20 and pin 25 from cover;
pipe remaining medium, taking care when open
e. Remove bolt 36 from trunnion 34, remove
and close the valve on several occasions.
the trunnion;
Page 8 of 16
f. Remove nut 12, take out the bonnet 2 and b. Fix spring 16 on bonnet 2, put the seat
seat retainer 4, gasket 9, seat follower 13, assembly into the bonnet, press the seat
o-ring 10, spring 16 slightly, locate them assembly to contact the spring;
on soft cloth or chipboard. Adown the c. Fix on pin 36 (if available). Fix the valve
flange end, be careful not to damage the body 1 on one bonnet, pay attention to
facing ring of the flange; the position of oil way, and bolt the nut 12
g. Take out the seat retainer, gasket 15, refer to table 1;
washer 14, seat follower, O-ring 17 and Table 1 Fastening suggest torque (Nm)
spring from the bonnet; Size Torque Size Torque
h. Lift out the ball 13 vertically, locate it on
1/2 50~60 1-5/8 1800~2200
soft cloth or chipboard;
9/16 70~80 1-3/4 2200~2600
i. Repeat f & g, separate bonnet and other
5/8 100~130 1-7/8 2800~3300
accessories on the other side;
Trunnion support design: 3/4 160~210 2 3500~4200
a. Follow the step a, b, c, d, f, g of trunnion 7/8 280~330 2-1/4 4200~4800

design, remove top flange 8, cover 7, 1 420~500 2-1/2 6100~7000
stem 6, one side bonnet 2, seat retainer 4, 1-1/8 500~600 2-3/4 8200~9400
seat follower 13, spring 16, etc; 1-1/4 850~1000 3 10300~11800
b. Lift out the ball 3 and trunnion support 34
1-3/8 1100~1300 3-1/4 14000~16000
together vertically from the valve body,
1-1/2 1400~1800 3-1/2 17000~19600
locate them on soft cloth or chipboard.
d. Fix bearing 33 into the bottom bore of the
Take off the trunnion support, bearing 33
ball, fix the ball 3 into valve body, pay
and thrush washer from the ball;
attention to keep the bore on bottom of
c. Follow the steps f & g of trunnion design,
the ball in line with bore on the bottom of
remove the bonnet, seat retainer, seat
the body;
follower, spring, etc on the other side;
e. Fix O-ring 35 on trunnion 34, lubricate
with oil. Fix on gasket 37, tread the
5.5 Valve Assembly
trunnion through body to the bottom bore
Before assembling, clean all parts, check
of the ball, pay attention to the bleeder
whether the parts are damaged. Restoration
hole on the trunnion. Bolt the bolt 36 refer
or change new ones if damaged.
to Table 1;
Trunnion design:
f. Fix the other bonnet with seat retainer on
a. Fix gasket 15, washer 14, seat follower 13
the body, bolt the nut refer to Table 1;
and O-ring 17 on seat retainer 4.
Lubricate the O-ring with oil;
Page 9 of 16
g. Fix O-ring 19/20, injection 40 (if available) attention that the flat trend on ball should
and gasket 18 into cover 7; Fix bearing 27 aim at the hole which for stem;
and thrust washer on stem 6; d. Follow the steps of f, g, h, I of trunnion
h. Tread the stem through valve body to the design, fix the bonnet on the other side,
flat trend of the ball, pay attention to the stem 6, cover 7 and top flange 8, etc;
direction of key trend; Put the fix pin 25 5.6 Former disassemble steps please refer to
into pinhole on the top of valve body, put valve disassemble figures. If have any
on the cover tread through stem and fix questions, please feel free to contact the
pin, bolt the screw 21 refer to Table 1; manufacture;
i. Fix top flange 8, bolt the screw 24; 5.7 To ensure the quality of the valve, suggest to
Trunnion support design: change the soft sealing when re-assemble,
a. Follow the step a, b, c of trunnion design, such as: gasket, thrust washer, valve seat
fix bonnet 2 on the other side; and packing;
b. Put bearing 33 into the bore of trunnion 6 Problem solving
support 34. Fix trunnion support and Some usual troubles are listed below for your
thrust washer 35 together on the ball 3; convenient to seek the solution:
c. Lift up the ball and trunnion support
together through the ball passage with
soft rope, fix them in the body, pay
Page 10 of 16
Failure Causes Troubleshooting
section 5.2
1. The operator is malfunctioning;
The valve is 2. Lubricate valve seat with sealant, lubricate
2. Lack of lubricate oil;
difficult to actuator with proper industrial oil;
3. Ice exist in operate system or
operate 3. Heat or inject anti-icing fluid;
in the valve;
4. loosen bolt on top flange and cover; Check
4. Stem is locking
the valve; Check the damage situation;
Repair or replace stem;
1. Contaminant on sealing
1. Clean the contaminant;
surface
The seats 2. Re-facing the sealing surface or change the
2. Damage on sealing surface
are leaking sealing packing;
3. Leakage between valve seat
3. Change O-ring;
and bonnet, check whether
O-ring is out of work;
1. O-ring is out of work;

The stem is 1. Change O-ring;
2. Damage on sealing surface of
leaking 2. Repair or replace damage stem;
stem;
Leaking of
body and 1. O-ring is out of work; 1. Change O-ring
closure
1. Re-fix limit bottom or fix it at correct

Can’t close 1. Gear-drive equipment or limit
position;
in fully button is not fix correctly, or
position Gear-drive equipment failure;
section 5.2
Page 11 of 16
Washing Procedure
Procedure Process
Check Valve Check valve seat injection point/valve body drain
Check equipment Ensure Injection equipment is under work condition
seat
seat
Wet the valve Wait for 1-6 hours, let wash liquid wet the block and dirty
seat
Injection procedure
Procedure Process
1.Preparation Before injection, clean the valve follow para.4.5.1 procedure
2.Check valve
Endure valve is in fully close position
position
4.Operate valve Operate valve to fully open position
Open and close valve 3-4 times, then turn valve to fully closed
6.Operate valve
position, proportion the sealing lubricant.
Page 12 of 16
Washing Liquid/ Sealing lubricant using quantity
Valve Injection for each Injection Injection for Injection for each
3
size valve seat (oz) for each valve each valve seat
3 valve（cm ）
(oz)
（cm ）
2” 1 2 25 50
3” 1 2 35 65
4” 2 3 50 100
6” 2 4 65 130
8” 3 6 80 160
10” 3 6 90 180
12” 5 10 135 270
14” 5 10 155 310
16” 6 12 170 335
18” 9 18 265 525
20” 10 20 295 585
22” 11 22 330 655
24” 12 24 350 695
26” 13 26 395 785
28” 13 26 400 800
30” 15 30 445 890
34” 17 34 495 990
36” 21 42 620 1240
40” 32 64 960 1920
42” 34 68 995 1990
7. Quality Guarantee and services

7.1 Valve quality guarantee period is 18 the right to recall the products and carries
months (Within 18 months from the date of on the investigation and analysis.
shipment or 12 months after installation, 7.3 Manufacturer’s guarantee business only
whichever occurs first). The manufacture limits to the following conditions:
shall be responsible for the quality 1） Material repair costs.
problem caused by material defect and 2） Replacement of parts and material
occured in the case of correct operation, costs.
while is irresponsible for the improper 3） Purchase costs due to compensating
installation improper repair and alternation users’ problem products.
in private. 7.4 Manufacture is irresponsible for the
7.2 Users shall inform the manufacturer about damage beyond the valve self defects
the product problem. The manufacture has caused by unexpected disaster (Such as
Page 13 of 16
earthquake, typhoon etc).
7.5 The other assurances beyond the scope 7.7 NEWAY will track the valve quality and
of this document shall be agreed by user offer various services per user’s
and manufacture. requirements.
7.6 NEWAY can provide on-site installation 7.8 If user disassembles the valve to repair
and commissioning (If it is included in without manufacture’s permission, the
the contract). user will be regarded to giving up the
quality assurance above
.
Page 14 of 16
Disassemble fig 1 Trunnion design
Bolt
Washer
Steel Pipe Lever
Retainer Normal Lever

Screw
T-Lever
Fix board
24
8
Gearbox
22
23
Stud 20
Gearbox 27
Nut
26 31
30
6
28 29
21
7
18 25
19
3
5
4
14
13
17
1
33
15
16
37 35
11
34
12
10
9 36
2
32
Page 15 of 16
Disassemble fig 2 Trunnion support design
Bolt
Washer
Steel pipe Lever

普通手柄
T 形手柄
Retainer
Screw
Fix board
24
Gearbox
25
8
Stud
23
Gearbox
Nut 22
21
41
7
20
40
18
26 19
27
31
6
30 28
32
34 29
3
5
4
14
15
16
9
38
1
37
17 10 13 36 33 35 39
12 11
2
Page 16 of 16
Material List
ML.GP.01.01 Rev. 0
October 2017
Bettis G-Series Spring-Return

Pneumatic Valve Actuator
Component Material List
Material List Table of Contents
ML.GP.01.01 Rev. 0 October 2017
Table of Contents
Section 1: Major Component Material List
1.1 Typical G-Series Major Component Material List�� 5
Section 2: Seal Material List

2.1 Typical G-Series Seal Material List�� 7
Section 3: Typical Coatings

3.1 Nitriding�� 8
3.2 Teflon lined cylinder bores�� 8
Table of Contents 3
Section 1: Major Component Material List Material List
October 2017 ML.GP.01.01 Rev. 0
Section 1: Major Component Material List

1.1 Typical G-Series Major Component Material List
Figure 1 G-Series Spring-Return Pneumatic (also available in double-acting type)
Table 1. Material List

Item Description Material
1 Housing Cast Ductile Iron ASTM A536
2 Housing cover Cast Ductile Iron ASTM A536
3 Yoke & Yoke Cover Cast Ductile Iron ASTM A536
4 Yoke pin Alloy steel AISI 8620 HT
5 Guide block Cast Ductile Iron ASTM A536
Spherical washer Alloy steel, Nitrided AISI 4140 HT
6 Guide bar Alloy steel, Nitrided AISI 4140 HT
Guide bar bearing Steel/Bronze/TFE Garlock DU style
7 Extension rod Alloy steel AISI 4340 HT
8 Tension rod Alloy steel AISI 4140 HT
9 Spring cartridge weldment Steel
10 Tension Lok Alloy steel
11 O-Ring Seal Nitrile
12 Hydraulic Override Assembly Carbon steel
13 Cover Plate for Spring Can Carbon steel
14 Spring Alloy steel ASTM A304/A401
15 Extension rod retainer nut Alloy steel AISI 4140 HT
16 Travel stop screw Alloy steel, Zinc plated ASTM A193
Travel stop screw nut Alloy steel, Zinc plated ASTM A194
17 Yoke pin bearing Steel/Bronze/TFE Garlock DU style
Yoke pin thrust bearing UHMWPE plastic
Yoke/Guide block bearing UHMWPE plastic
Yoke bearing Steel/Bronze/TFE Garlock DU style
4 Major Component Material List

Material List Section 1: Major Component Material List
18 Position indicator thrust bearing Acetal plastic

Position indicator bearing Acetal plastic
19 Position indicator assembly Stainless steel AISI 304
20 Inner endcap Cast Ductile Iron ASTM A395
21 Piston Seal Nitrile
22 Piston Cast Ductile Iron ASTM A395
24 Split ring Alloy steel AISI 6150 HT
25 Piston rod Alloy steel, Nitrided AISI 4140 HT
27 Pipe plug Steel ASTM A105
28 Tiebar nut Alloy steel ASTM A194 2H
29 Outer endcap Cast Ductile Iron ASTM A395
30 Tiebar Alloy steel, Nitrided ASTM A193 B7
31 Cylinder Steel, TFE lined ASTM A53
32 Polypak Seal Urethane Impregnated
33 Rod bushing Acetal plastic
Spring guide Cast Ductile Iron ASTM A536
Tension rod bushing Acetal plastic
34 Rod Wiper Urethane Impregnated
Major Component Material List 5

Section 2: Seal Material List Material List
October 2017 ML.GP.01.01 Rev. 0
Section 2: Seal Material List

2.1 Typical G-Series Seal Material List
Table 2.
Description Type Application
Piston OD / Cylinder ID D-ring Dynamic
Piston / Tiebar T-seal Dynamic
Piston rod Polypak Dynamic
Yoke O-ring Rotary
All remaining seals O-ring Static
6 Seal Material List

Material List Section 3: Typical Coatings
Section 3: Typical Coatings

3.1 Nitriding
Bettis utilizes a Nitride surface finish on many component parts instead of Chrome or
Nickel plating.
The nitrided surface is not a coating, it is an integral part of the component base material.
Because of this, it will not pitt, crack, chip or flake off and any possibility of hydrogen
embrittlement (a common problem in any plating process) is eliminated.
The Nitride surface layer is extremely hard and displays improved wear resistance when
compared with plated coatings. Dent resistance is also improved.
The Nitride surface layer has also been shown to display superior corrosion resistance to
plated coatings.
Nitride surface finishing has become very popular in the fluid power industry in the past
decade replacing chrome and nickel plating in many applications.
Typical components - piston rods, tiebars, CBA centerbars, cylinder bores, pistons.
Typical process results in a thin surface layer of iron oxide over a second layer of porous Iron
Nitride over a third layer of non-porous Iron Nitride all fused on top of the base substrate
steel material.
3.2 Teflon lined cylinder bores

The standard coating on all Bettis pneumatic cylinder bores is Xylan, a proprietary Teflon
coating.
The use of this Teflon lining results in superior corrosion resistance while improving seal life
and overall actuator performance.
Typical Coatings 7
World Area Configuration Centers (WACC) offer sales support, service,
inventory and commissioning to our global customers.
Choose the WACC or sales office nearest you:
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T +55 15 3413 8888
24 Angus Crescent
ASIA PACIFIC Longmeadow Business Estate East
P.O. Box 6908 Greenstone
No. 9 Gul Road 1616 Modderfontein Extension 5
#01-02 Singapore 629361 South Africa
T +65 6777 8211 T +27 11 451 3700
No. 1 Lai Yuan Road EUROPE www.emerson.com/bettis

Wuqing Development Area
Tianjin 301700 Holland Fasor 6 ©2019 Emerson. All rights reserved.
P. R. China Székesfehérvár 8000
T +86 22 8212 3300 Hungary The Emerson logo is a trademark and service mark of Emerson Electric Co.
T +36 22 53 09 50 BettisTM is a mark of one of the Emerson family of companies.
All other marks are property of their respective owners.
Strada Biffi 165
29017 Fiorenzuola d’Arda (PC) The contents of this publication are presented for information purposes
Italy only, and while every effort has been made to ensure their accuracy, they
T +39 0523 944 411 are not to be construed as warranties or guarantees, express or implied,
regarding the products or services described herein or their use or
For complete list of sales and manufacturing sites, please visit applicability. All sales are governed by our terms and conditions, which are
www.emerson.com/actuationtechnologieslocations or contact us at available on request. We reserve the right to modify or improve the designs
info.actuationtechnologies@emerson.com or specifications of our products at any time without notice.
Type
350/360/370SS Stainless Steel Regulators
Series Installation, Operation and
Maintenance Instructions
Type 350SS 1/2" NPT Type 360SS 1/4" NPT

Adjustment Screw Adjustment Screw
Assembly Assembly
Bonnet Bonnet
Spring Guide Spring Guide
Range Spring Range Spring
*Diaphragm * Diaphragm
Assembly Assembly
* Pintle Assembly * Pintle Assembly
Body Assembly
* Housing Seal O-Ring Body Assembly * Housing Seal O-Ring
Collar
* Filter O-Ring (2)
Pintle Spring
Drip Well Housing Filter, 25 Micron, SS Base

Assembly
Filter Retainer Pintle Spring
Filter Retaining Screw
Type 370SS 1/2" NPT

Cover
Contents
Sealing Diaphragm Section Description Page
1.0 Specifications 2
Body Assembly
2.0 Installation 2
3.0 Operation 3
Collar
4.0 Maintenance & Repair 3
* Housing Seal O-
Ring 5.0 Warranty 4
Filter, 25 Micron, SS * Filter Seal
O-Ring (2)
Drip Well Housing

Assembly
Filter Retainer 8 Columbia Drive

Filter Retaining Screw Amherst, NH 03031 USA
603-886-9400
Fax: 603-889-1844
www.controlair.com
sales@controlair.com
*Included with repair kit
441-622-075 350/60/70 SS Page 1

DANGER, WARNING, CAUTION and NOTE statements
DANGER Refers to conditions or hazards which could result in serious personal injury or death.
WARNING Refers to conditions or hazards which could result in personal injury.
CAUTION Refers to conditions or hazards which could result in equipment or property damage.
NOTE Alerts you to facts or special instructions.
ALL DANGER, WARNING, AND CAUTION NOTICES MUST BE COMPLIED WITH IN FULL
Personal injury, property damage, equipment damage, or leakage due to escaping gas or bursting of
DANGER pressure containing parts may result if this regulator is over pressurized or installed where service
conditions could exceed the limits given in the specifications. To avoid such injury or damage, provide
pressure-relieving or limiting devices (as required by the appropriate code, regulation or standard) to
prevent service conditions from exceeding those limits.
1. SPECIFICATIONS
TYPE 350SS TYPE 360SS TYPE 370SS
Output Ranges: 0-30 psig (0-2.0 BAR), 0-60 psig (0-4.0 BAR), 0-100 psig (0-7.0 BAR), Not applicable
0-150 psig (0-10.0 BAR)
Exhaust Capacity: 1.0 SCFM (1.7 m3/hr) at downstream pressure of Not applicable
10 psig (0.7 BAR) above set point
Maximum Supply
Pressure: 290 psig (20.0 BAR) 150 psig (10.0 BAR)
Maximum Flow 1/4” = 1.2
Coefficients (Cv): 1/2” = 3.3
Air Consumption: 4 SCFH (0.1 m3/hr) Not applicable

Operating -20° to +185° F (-29° to +85° C)
Temperatures: Autodrain Option: (Type-350 and Type-370 only) 320 to 1850F (00 to 850C)
Low Temperature Option: -58° to +194° F (-50° to +90° C)
Filter: 25 micron Not applicable 25 micron
optional 5 micron filter optional 5 micron filter
Porting: Inlet/Outlet: 1/4" NPT or 1/2" NPT 1/4" NPT 1/4" NPT or 1/2" NPT
Gauge (2): 1/4" NPT 1/4" NPT 1/4" NPT
Exhaust: 1/8" NPT 1/8" NPT
Materials: 316 stainless steel: body, bonnet, filter, range spring, pintle spring
Fluorocarbon: diaphragm, seals
Silicone: diaphragm, seals (low temperature option)
Weight: 1/4" NPT: 2.2 lbs. (1.0 kg) 1/4" NPT: 2.0 lbs. (0.9 kg) 1/4" NPT: 2.1 lbs (0.95 kg)
1/2" NPT: 2.8 lbs. (1.3 kg) Not applicable 1/2" NPT: 2.5 lbs (1.14 kg)
Operating Media: Air, inert gas, sweet (natural) and sour gases
2. INSTALLATION
2.1 Install the regulator/filter as close as possible to the instrument or tool it is to service.
2.2 Clean all pipelines to remove dirt and scale prior to installation.
NOTE Failures attributable to air supply contamination are not covered by the warranty.
WARNING This instrument vents to atmosphere. The use of gas other than air may create a
hazardous environment.
2.3 Install the regulator/filter so that the direction of flow is from the "IN" to "OUT" connection as
marked on the body of the regulator/filter.
441-622-075 350/60/70 SS Page 2

2.4 For best drainage, orient the drain valve so that it is at the lowest point on the drip well
housing. Positioning of the drain valve may be improved by rotating the drip well with respect
to the body.
2.5 The exhaust port should be kept free and unplugged. Position the regulator so that the vent is
at the lowest point possible, or provide additional protection to prevent contaminants from
entering the regulator. Rotating the bonnet relative to the body may change the vent hole
orientation.
WARNING The Type 350/360SS has a low capacity internal relief that provides limited down-stream protection
against over pressurization .
WARNING Non-relieving version does not provide internal relief of excess pressure. To avoid exceeding outlet
pressure limits, a pressure-limiting device should be used.
2.6 Exhaust may be remotely vented by installing tubing to the 1/8" NPT port.
2.7 Apply pipe compound or sealing tape to the male pipe threads prior to installing regulator/filter.
Use caution to prevent the sealant from getting inside the regulator/filter.
3. OPERATION
3.1 Prior to turning on supply air, back off adjusting screw until there is no compression of the
range spring.
3.2 After applying the air supply, output pressure will be increased by rotating the adjustment
screw clockwise. Pressure can be decreased by turning counter clockwise.
3.3 Tighten locknut to maintain desired pressure setting.
4. MAINTENANCE & REPAIR
4.1 To remove condensate from the Type 350 and Type 370, slowly open drain valve by turning
clockwise and bleed accumulated liquid.
To avoid personal injury, property damage, or equipment damage caused by sudden release of pres-
DANGER sure or explosion of accumulated gas, do not attempt any maintenance or disassembly without first
isolating the regulator from system pressure and relieving all internal pressure from the regulator.
4.2 To clean filter element (Type 350 and Type 370)

4.2.1 Shut off supply pressure and relieve all internal pressure.
4.2.2 Drain condensate from drip well.
4.2.3 Remove four corner bolts from bottom of unit and remove drip well housing.
4.2.4 Remove filter retaining screw.
4.2.5 Remove filter retainer, filter o-ring seals and filter.
4.2.6 Clean parts and reassemble in reverse order.
4.3 To clean/replace pintle assembly

4.3.1 Follow steps 4.2.1 through 4.2.4.
4.3.2 Unscrew collar and remove.
4.3.3 Remove pintle spring and pintle. 1/4" NPT version may require needle nose pliers or push pintle stem
from above by removing bonnet and diaphragm assembly.
4.3.4 Clean/replace parts and reassemble in reverse order.
441-622-075 350/60/70 SS Page 3

4.4 To clean/replace diaphragm assembly
4.4.1 Back out the adjusting screw until the spring is no longer compressed.
4.4.2 Remove the four bonnet screws and separate the bonnet from the body of the regulator. Remove the
spring guide and spring.
4.4.3 Remove the diaphragm assembly, clean or replace it as necessary and reassemble in reverse order.
After placing the diaphragm assembly on the body, push down the assembly to make sure that the
pintle is seated properly and strokes smoothly.
4.5 Repair kits/replacement parts
4.5.1 Repair kits include all parts marked with an asterisk (*). See diagrams on page 1.
4.5.2 When ordering repair kits or replacement filters, order as:
REPAIR KITS
Type 350 Includes: Pintle Assembly, Housing Seal O-Ring, Diaphragm Assembly, Filter Seal O-Ring (2)
Model Porting Description Part Number
Type 350 1/4” NPT Relieving 449-871-068
Type 350 1/4” NPT Non-relieving 449-871-069
Type 360 Includes: Pintle Assembly, Housing Seal O-Ring, Diaphragm Assembly
Type 360 1/2" NPT Relieving 449-871-094
Type 360 1/2" NPT Non-relieving 449-871-095
REPLACEMENT FILTERS
Type 350/370 1/4” NPT 25 micron filter 446-777-011
4.5.3 Other replacement parts are available. Please consult the factory for part numbers and availability.
5.WARRANTY & DISCLAIMER

ControlAir LLC products are warranted to be free from defects in materials and workmanship for a period of
eighteen months from the date of sale, provided said products are used according to ControlAir LLC
recommended usages. ControlAir LLC’s liability is limited to the repair, purchase price refund, or replacement in
kind, at ControlAir LLC’s sole option, of any products proved defective. ControlAir LLC reserves the right to
discontinue manufacture of any products or change products materials, designs or specifications without notice.
WARNING These products are intended for use in industrial compressed-air systems only.
Do not use these products where pressures and temperatures can exceed those
listed under Specifications.
Before using these products with fluids other than air, for non-industrial application, life-support systems, or other
applications not within published specifications, consult ControlAir LLC
8 Columbia Drive
Amherst, NH 03031 USA
603-886-9400
Fax: 603-889-1844
www.controlair.com
sales@controlair.com
441-622-075 REV 05/25/2022 350/60/70 SS Page 4

TopWorx™ D-Series Valve Controllers
Master Installation, Operation & Maintenance Manual
1
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2
Table of Contents
Page 3 Table of Contents
Page 4 Installation on Actuator
Page 5 GO™ Switch: Options L2/L4/Z2/Z4
Page 8 Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2
Page 10 Inductive Sensors: Options E2/E4/E6/ V2/V4
Page 12 4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
Page 16 HART Device Options: LH/MH/KH/EH/TH/ZH/0H
Page 34 D2-FF Discrete Valve Controller Description
Page 35 AS-I Sensor Communication Module (SCM) : Option AS
Page 36 Bus Options
Page 46 ESD Theory of Operation
Page 47 Proof Testing for TopWorx™ D-Series
Page 49 Pneumatic Hookup Procedures
Page 48 Spool Valve and Pilots-Assembly
Page 51 Installation & Maintenance Instructions
Page 54 Proof Testing for TopWorx™ D-Series
Page 56 Dimensions and Materials: TopWorx™ DXP
Page 57 Dimensions and Materials: TopWorx™ DXP - Flameproof
Page 58 Ex d IIC Dimensions and Materials: TopWorx™ DXS
Page 59 Dimensions and Materials: TopWorx™ DXR
Page 60 Indicator Assembly
Page 61 TopWorx™ Certification
Page 62 Safe Use
Page 64 TopWorx™ D-Series Replacement Part Number List
Page 66 Recommended Operating Temperatures
3
Installation on Actuator
Orientations, Normal and Reverse Acting
Normal acting is full clockwise when the process valve is closed and counterclockwise when the process valve is open. Reverse acting
is full clockwise when the process valve is open and counterclockwise when the process valve is closed.
90° indicator dome assemblies are designed to accommodate any mounting arrangement and can be adjusted up to 9° off axis if
needed. 45° indicator dome assemblies can only accommodate normal acting applications that are mounted parallel ±9°. Consult your
local distributor or factory representative for 45° reverse acting or mounted perpendicular applications.
The image to the left shows a TopWorx™ unit mounted

parallel to the process valve in the closed position. The
green arrow at the top shows the “normal acting” direction
of travel to open the valve. This is the standard orientation
and unless other-wise specified, your unit will be factory set
to operate in this fashion.
The image to the right shows a TopWorx™ mounted

perpendicular to the process valve in the closed position.
The green arrow at the top shows the “normal acting”
direction of travel to open the valve.
Mounting
TopWorx™ has numerous mounting bracket kits, both rotary and linear, available to meet your specific application. Consult your local
distributor or factory representative for ordering information. The illustration below shows a direct NAMUR mount on a quarter turn
valve. Refer to your mounting kit documentation for specific mounting instructions
Storage
Until conduit, conduit covers, and any applicable spool valve port connections are properly installed, the TopWorx™ unit will not support
its IP/NEMA rating as the unit ships with temporary covers. Ensure that it is stored in a dry environment with a relative humidity range
between 10%-95% and a temperature ranging from -40ºF (-40ºC) to 160ºF (71ºC). Once properly installed, the temperature range
listedon the name-plate will supersede this storage temperature range.
Mounting Assembly
Installation Notes
1. Use caution not to allow undue axial (thrust) load on the shaft.
2. Cycle the valve a couple of times prior to final tightening of the mounting kit hardware.
This allows the shaft to self-center in the pinion slot, or coupler. Refer to the dimensions
and materials section of this document for appropriate tightening torque. Please refer to
the Proof Testing section for proper safety function set-up.
3. Always use sound mechanical practices when applying torque to any hardware or making
pneumatic connections. Refer to the Integrated Pneumatic Control Valves section for
detailed information.
4. This product comes shipped with conduit covers in an effort to protect the internal
components from debris during shipment and handling. It is the responsibility of the
receiving and/or installing personnel to provide appropriate permanent sealing
devices to prevent the intrusion of debris or moisture when stored or installed
outdoors.
5. It is the responsibility of the installer, or end user, to install this product in

accordance with the National Electrical Code (NFPA 70) or any other national or
regional code defining proper practices
4
GO™ Switch: Options L2/L4/Z2/Z4
Calibration Procedure
Never perform switch calibration while an area is known to be hazardous.
For intrinsically safe models with L2/L4, the unit must be wired in accordance with the control drawing S-K127 and S-K127A.
For intrinsically safe models with Z2/Z4, the unit must be wired in accordance with the control drawing ES-01743-1 and ES-01744-1.
GO™ Switch calibration may be performed using a Volt-Ohm meter with the Ohm setting across COM and NO. When the switch
is active, the meter will read ≤0.5 Ohms, or the Diode setting may be used simply to indicate continuity. If a 120VAC source is used,
an appropriately sized resistor must be used in series to limit current to a maximum of 1.5 Amperes when circuit rating is unknown or
permanent damage may occur.
For models mounted in perpendicular orientation, the target disk will have to be rotated to realign the target disk to match the
desired orientation.
Step 1: Grasp the target disk and gently lift until the target disk disengages the orientation pin in the shaft.
Step 2: Rotate the disk as needed to realign the targets. Use the images provided on the previous page as a reference.
Step 3: Follow steps 1 through 3 for models mounted in Parallel orientation above.
For reverse acting applications (Counterclockwise to close), the switch functions will be transposed. Sw 1 (and Sw 3 if in an L4/Z4
model) be-come open. Sw 2 (and Sw 4 if in an L4/Z4 model) become closed.
The target disk has been designed to accommodate various applications and rotations. If your application is different from
those outlined here, please consult the factory for further information.
L2/L4 Specifications 3-1 Z2/Z4 Specifications 3-1
Repeatability .002" (.05 mm) Repeatability .002" (.05 mm)
Response Time 8 milliseconds Response 8 milliseconds

Time
Differentia 0.020 - .150” (0.5 - 3.8mm) Differentia 0.020 - .150” (0.5 - 3.8mm)
Operating Operating
-60° to 221°F (-40° to 105°C) -60° to 221°F (-40° to 105°C)
Temperature Temperature
Contact Material Silver cadmium oxide, gold flashe Contact Palladium silver w/sawtooth surface
Material configuratio
Forms SPDT, Form C Forms DPDT, Form CC
Ratings 4A@120VAC / 2A@240VAC / 3A@24VDC 4A@120VAC / 2A@240VAC / 3A@24VDC /

Ratings
0.5A@125VDC
Target Material Magnet Target Material Magnet
Sensing Range Approx. 1/10" (2.5 mm) Sensing Range Approx. .050 - .080" (1.3 - 2.0 mm)
5
Continued
Electrical Connections & Wiring 3-1C

Option L2
Terminal Strip Assembly
Switch 1
Green to GND Ground
Bracket
Bracket
COM (Black) Terminal 2
NO (Blue) Terminal 3 Terminal
Terminal StripStrip
LabelLabel
NC (Red) Terminal 1
Switch 3 12pt Terminal
12pt Terminal StripStrip
(x2) (x2)
Green to GND Ground

COM (Black) Terminal 5
NO (Blue) Terminal 6
NC (Red) Terminal 4
Option L4
Switch 1 Switch 2
Green to GND Ground Green to GND Ground
COM (Black) Terminal 2 COM (Black) Terminal 5
NO (Blue) Terminal 3 NO (Blue) Terminal 6
4-40x0.5
4-40x0.5self
selftap
tapscrew (x6)
screw (x6)
NC (Red) Terminal 1 NC (Red) Terminal 4 Torque
Torque40
40IN-OZ
IN-OZ
Switch 3 Switch 4
Green to GND Ground Green to GND Ground
4-40x0.25 SE
4-40x0.25 selfMSEM
screwscrew
(x2) (x2)
Torque 100
Torque 100IN-OZ
IN-OZ
COM (Black) Terminal 8 COM (Black) Terminal 11
NO (Blue) Terminal 9 NO (Blue) Terminal 12
NC (Red) Terminal 7 NC (Red) Terminal 10 NOTE: Refer to the wiring
diagram on the inside lid of
your product to determine
Option Z2 actual pin out location.
Switch 1
Green to GND Ground
COM (Black) Terminal 2 COM (Black/White) Terminal 5
NO (Blue) Terminal 3 NO (Blue/White) Terminal 6
NC (Red) Terminal 1 NC (Red/White) Terminal 4
Switch 3
Green to GND Ground
COM (Black) Terminal 8 COM (Black/White) COM (Black/White)
NO (Blue) Terminal 9 NO (Blue/White) NO (Blue/White)
NC (Red) Terminal 7 NC (Red/White) NC (Red/White)
Option Z4
Switch 1 Switch 3
Green to GND Ground Green to GND Ground Green to GND Ground Green to GND Ground
COM (Black) Terminal 2 COM (Black/White) Terminal 5 COM (Black) Terminal 14 COM (Black/White) Terminal 17
NO (Blue) Terminal 3 NO (Blue/White) Terminal 6 NO (Blue) Terminal 15 NO (Blue/White) Terminal 18
NC (Red) Terminal 1 NC (Red/White) Terminal 4 NC (Red) Terminal 13 NC (Red/White) Terminal 16
Switch 2 Switch 4
Green to GND Ground Green to GND Ground Green to GND Ground Green to GND Ground
COM (Black) Terminal 8 COM (Black/White) Terminal 11 COM (Black) Terminal 20 COM (Black/White) Terminal 23
NO (Blue) NC
NO (Blue) Terminal 9 NO (Blue/White) Terminal 12 Terminal 21 NO (Blue/White) Terminal 24
(Red)
NC (Red) Terminal 7 NC (Red/White) Terminal 10 NC (Red) Terminal 19 NC (Red/White) Terminal 22
*The above terminations are typical and may vary depending on your configuration. Refer to the wiring diagram located on the inside top housing for a wiring diagram specific to your configurati
6
Continued
Target Arrangement
All TopWorx™ products are factory set for 90° rotation normal acting on parallel orientation with switch 1 (full clockwise) for the process
valve closed position. When changing orientation the target disk will have to be relocated for your application. All target disks are supplied
with 4 slots on 90° increments allowing the TopWorx™ unit to be rotated 90°, 180°, or 270° from standard. Loosen target by rotating CCW
and slide target to desired position. Once target is properly positioned, tighten target by rotating CW and tighten to 20 in-oz.
TYPICAL L2/Z2 TARGET ARRANGEMENT

MINIMAL USUABLE ROTATION 45°
MAXIMUM USUABLE ROTATION 125°
90° PROCESS VALVE OPEN (OPEN FULL CCW) 90° PROCESS VALVE OPEN (CLOSED FULL CW)
NORMAL ACTING NORMAL ACTING
PARALLEL ORIENTATION PARALLEL ORIENTATION
SW1 FOR PROCESS VALVE CLOSED (NOT MADE) SW1 FOR PROCESS VALVE CLOSED (MADE)
SW3 FOR PROCESS VALVE OPEN (MADE) SW3 FOR PROCESS VALVE OPEN (NOT MADE)
TYPICAL L4/Z4 TARGET ARRANGEMENT
90° PROCESS VALVE OPEN FULL CCW 90° PROCESS VALVE OPEN FULL CW
NORMAL ACTING NORMAL ACTING
PARALLEL ORIENTATION PARALLEL ORIENTATION
SW1 FOR PROCESS VALVE CLOSED (NOT MADE) SW1 FOR PROCESS VALVE CLOSED MADE)
SW3 FOR PROCESS VALVE CLOSED (NOT MADE) SW3 FOR PROCESS VALVE CLOSED (MADE)
7
Mechanical Switches: Options M2/M4/M6/K2/
K4/K6/T2 Calibration Procedure
Never perform switch calibration while an area is
known to be hazardous. Calibration procedures PRODUCT SPECIFICATIONS
for DPDT switches are the same as those for
OPTION M
SPDT switches.
Switch Type Mechanical
Calibration may be performed using a Volt-Ohm meter Sealed No
by using the Ohm setting across COM and NO. When
Circuitry SPDT
the switch is active, the meter will read <0.5 Ohms, or the
Diode setting may be used to indicate continuity. Termination Quick Connect
Rating 15A@125VAC or 250VAC
If a 120Vac source is used, an appropriately sized
resistor must be used in series to limit current to a Conforming to standards UL: 1054
maximum of 15 Amperes when circuit rating is unknown, or Contact Resistance 15MΩmax. (initial)
permanent damage may occur.
Insulation Resistance 100MΩmin. (at 500V DC)
Step 1: With valve in the CLOSED position, disengage the OPTION K
BOTTOM cam from the splined Hub and rotate Clockwise
until SW1 activates. Switch Type Mechanical
Release cam to re-engage splined Hub. Sealed No
Step 2: Rotate valve to the OPEN position. Disengage Circuitry SPDT

the TOP cam from the splined Hub and rotate Counter- Termination Quick Connect
clockwise until SW2 activates.
Release cam to re-engage the splined Hub. Rating 0.1A@125VAC MAX
Conforming to standards UL: 1054
Step 3: Cycle valve CLOSED and OPEN several times to
insure switches will maintain calibration.
OPTION T
For Reverse Acting actuators:
Step 1: With valve in the CLOSED position, disengage Switch Type Mechanical
the TOP cam from the splined Hub and rotate Counter-
Sealed No
clockwise until SW2 activates.
Release cam to re-engage the splined Hub. Circuitry DPDT
Step 2: Rotate valve to the OPEN position. Disengage the Termination Quick Connect
BOTTOM cam from the splined Hub and rotate Clockwise Rating 15A 125V AC or 250V AC
until SW1 activates.
Release cam to re-engage the splined Hub. Conforming to UL recognized and CSA
standards certified, meets MIL-S-880
Repeat Step 3 above. Contact Gold or silver
*When using the (4) and (6) switch options, use the same Terminals End or side
calibration steps as above for the switches you determine to
indicate OPEN and which indicate CLOSED.
**Switches may also be set at midpoint, or any point, of

travel for Dribble
Control, or any other logic necessary for the application.
Mechanical Switch Assembly

Switch Option M2/K2/T2 Switch Option M4/K4 Switch Option M6/K6
8
Continued
Mechanical Switches: Options M2/M4/M6/K2/K4/K6/T2
Wiring Diagrams and Charts

Option M/K Option T2
Switch# Connection Color Code Terminal# Switch# Connection Color Code Terminal#
NC Red 1 NC1 Red 1
1 COM Black 2 COM1 Black 2
NO Blue 3 NO1 Blue 3
1
NC Red/White 4 NC2 Red/White 4
2 COM Black/White 5 COM2 Black/White 5
NO Blue/White 6 NO2 Blue/White 6
NC Yellow 7 NC1 Yellow 7
3 COM Brown 8 COM1 Brown 8
NO Orange 9 NO1 Orange 9
2
NC White/Yellow 10 NC2 White/Yellow 10
4 COM White/Brown 11 COM2 White/Brown 11
NO White/Orange 12 NO2 White/Orange 12
NC White 13
5 COM Gray 14
NO Violet 15 NOTE: Refer to the wiring diagram on
the inside lid of your product to determine
NC Pink 16 actual pin out location
6 COM White/Gray 17
NO White/Violet 18
9
Inductive Sensors: Options E2/E4/E6
Calibration Procedure
Never perform switch calibration while an area is known to be hazardous.
When installing a TopWorx™ product with P&F NAMUR sensors, use of a commercially available switch tester like P&F part#
ST0-03 is suggested.
Calibration may be performed using a 24Vdc power supply.

Step 1: With valve in the CLOSED position, disengage the BOTTOM cam from the splined hub and rotate clockwise until SW1 activates.
Release cam to re-engage splined hub.
Step 2: Rotate valve to the OPEN position. Disengage the TOP cam from the splined hub and rotate counter-clockwise until SW2
activates. Release cam to re-engage the splined hub.
Step 3: Cycle valve CLOSED and OPEN several times to insure switches will maintain calibration.
For Reverse Acting actuators:

Step 1: With valve in the CLOSED position, disengage the TOP cam from the splined hub and rotate counter-clockwise until SW2
activates. Release cam to re-engage the splined hub.
Step 2: Rotate valve to the OPEN position. Disengage the BOTTOM cam from the splined hub and rotate clockwise until SW1 activates.
Release cam to re-engage the splined hub.
Repeat Step 3 above.
*When using the (4) and (6) switch options, determine which switches are to indicate OPEN and which indicate CLOSED and
then use the same calibration steps as above.
**Switches may also be set at midpoint, or any point, of travel for Dribble Control, or any other logic necessary for the
application.
P & F NJ2-V3-N Switch Assembly
SwitchOption
Switch OptionE2
E2 Switch Option
Switch Option E4
E4 SwitchOption
Switch OptionE6E6
10
Continued
Inductive Sensors: Options E2/E4/ Wiring Chart
E6 Product Specifications
LEAD WIRE TERMINATIONS CHART
SWITCH # LEAD COLOR TERMINAL#
PRODUCT SPECIFICATIONS 1 BROWN + 1
General specification
BLUE - 2
Switching element function NAMUR NC
2 BROWN + 3
Rated operating distance Sn 2 mm
BLUE - 4 4
Installation embeddable
3 BROWN + 5
Output polarity NAMUR BLUE - 6
Assured operating distance Sa 0 ... 1.62 mm 4 BROWN + 7
Reduction factor rAl 0.25 BLUE - 8
Reduction factor rCu 0.2 5 BROWN + 9
Reduction factor rV2A 0.7 BLUE - 10
Nominal ratings
6 BROWN + 11
Nominal voltage Uo 8V BLUE - 12
Switching frequency f 0 ... 1000 Hz
Hysteresis H typ. % NOTE: Refer to the wiring diagram on
Current consumption actual pin out location
Measuring plate not detected ≥3 mA
Measuring plate detected ≤1 mA
Standard conformity
EMC in accordance with IEC / EN 60947-5-2:2004

Standards DIN DIN EN 60947-5-6
(NAMUR)
Ambient conditions
Ambient temperature -25 ... 100 °C (248 ... 373 K)

Mechanical specification
Connection type 0.1m, PVC cable

Core cross-section 0.14 mm2
Housing material PBT
Sensing face PBT
Protection degree IP67
General information
Use in the hazardous area see instruction manuals

Category 1G; 2G; 1D
11
4-20mA Transmitter: Options LX/MX/KX/EX/TX/ZX/0X
The 2-wire 4-20mA transmitter will generate a nominal 4 – 20mA output for full-range actuation of the valve. The transmitter is capable of
generating signals below 4mA and above 20mA if the position sensor indicates an out of range value.
Features:
1) Single push button easy calibration eliminates zero/span calibration interaction in both clockwise and counterclockwise actuator/
valve rotation directions.
2) Non-volatile memory of set points (set points remain after loss of power)
3) 4-20mA power connection is not polarity sensitive
4) No internal backlash – direct shaft position feedback
5) No gear wear or mechanical binding
6) Small package size for easier access to limit switch cams. The small packaging allows for additional options that can be mounted
in the valve monitoring enclosure
7) Position measurement range from 20º to 320º. Factory set for 20º to 180º operation in counter clockwise rotation to open and 20º
to 90º operation in clockwise rotation to open applications.
8) Advanced diagnostics includes detection of dead band, out of range indication and detection of internal memory errors
9) Transmitter PCB is potted and sealed
10) Included with all valve monitoring switching options, incl. DPDT mechanical
11) +/- 1% position linearity for the complete device
12) Selectable +/- 3% over and under travel capability or full linear options set during calibration
13) Hysteresis: 0.5% of full-scale
14) Repeatability: 0.3% of full scale
15) Temperature Range: -40º to 85ºC
Potentiometer Features Electrical Data

-Hollow shaft mounting requires no gears and has no backlash -Voltage Input Range: 8.5 - 34 Volts DC
-Direct shaft position feedback -Standard Output Signal: Two wire 4-20mA with out
-Capable of 4,000,000 lifetime operations of range indication
-Better than 0.3° resolution -Input Polarity: Bi-Directional
-Conductive plastic Potentiometric sensor
-for environmental protection
-Temperature Range: -40º to +85ºC
Potentiometer Electrical Data

-Voltage Input Range: 0-35 Volts
-Actual Electrical Travel 340° (dead band of 20°)
-Current Maximum: 3mA Blue
Blue
-Recommended operating wiper current is less than or equal to
1 micro amp (recommend using the wiper voltage to drive an
operational amplifier working as a voltage follower in which a
very small load is applied to the wiper)
-Independent Linearity ±2% Green
-Resistance Tolerance ±20%
Red
NOTE: Refer to the wiring diagram on

actual pin out location
12
Continued
Calibration Flow Chart
Apply power to
device, LED on
Is button pressed
and held for at least NO
0.5 seconds?
YES
Is button released Is button released Is button released Is button

before 3 seconds? NO before 5.5 seconds? before 8 seconds? released? NO
NO NO
YES YES YES YES
Calibrate counterclockwise, Calibrate clockwise, device Calibrate counterclockwise, Calibrate clockwise, device
device waits for 4ma set point, waits for 4ma set point, LED device waits for 4ma set point, waits for 4ma set point, LED
LED flashes code 3-1, rotary flashes code 3-2, rotary LED flashes code 5-1, linear flashes code 5-2, linear
User moves valve to 4ma position
Is button pressed
and released? NO
YES
Is the set point within

required range? NO
YES
Device waits for 20ma set point,

LED flashes code 3-3
User moves valve to 20ma position Is the actual reading Start position is too
greater than maximum low or in dead band,
NO LED flashes code 4-3
4ma value?
Is button pressed
YES
and released? NO
Start position is too high,
YES LED flashes code 4-4
Is the set point within Has greater than Has less than Wrong direction of
required range and has at maximum allowed minimum allowed rotation occurred, LED
least 20 degree of rotation rotation occurred? NO rotation occurred? NO flashes code 4-7
been detected?
YES YES Less than allowed
YES
rotation has occurred,
Device stores set points, LED on
Greater than allowed
rotation has occurred,
Is malfunction detected
in stored set points? NO
YES
Internal error, LED
flashes code 4-1
13
Continued
Troubleshooting
Error Code and Problem Table
Problem Probable Cause/Solution

Transmitter Module has no current output If the LED on the Transmitter Module is not lit
- Loose or shorted signal connection (fix connection
- Controller Board not responding (Replace Transmitter Module)
If the LED on the Circuit Board is lit
- Potentiometer is disengaged from shaft (must be returned for repair)
- Defective controller board (Replace Transmitter Module)
Transmitter does not output 4 or 20mA (+/-1%) at desired end of travel Unit not calibrated (calibrate)
Unit is calibrated (recalibrate - if still fails, replace board)
Output is not linear or does not track valve position or rotation Input signal is not linear
- Linkage or drive mechanism is introducing non-linearity
- Unit is not calibrated (calibrate)
Error Code 4-3 Start position is too low or in the dead-band position.
Error Code 4-4 Start Position is too high

Error Code 4-5 Start and stop positions are less than 20º, increase valve rotation between start and stop
positions to greater than 20º.
Error Code 4-6 Rotation has exceeded the 320º limit. Decrease valve rotation between start and stop positions
to less than 320º.
Error Code 4-7 Calibration rotation was in the wrong direction or the potentiometer passed through the dead-
band position.
Error Code 4-1 Internal Error has occurred. Recalibrate, if error continues, replace module.
LED Flash Code Diagram
Flash Codes
( first count – second count Interpretations
0-0 Calibrated
3-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
3-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Rotary Mode
3-3 Waiting for 20mA Full Open Setting Button Press
4-1 Calibration Required
4-3 Calibration Start Value is Too Low
4-4 Calibration Start Value is Too High
4-5 End Value is Too Close to Start Value
4-6 Maximum Rotation Exceeded
4-7 Wrong Direction of Rotation
5-1 Counter-Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
5-2 Clockwise Calibration, Waiting to calibrate the 4mA position, Linear Mode
Operation of the 4-20mA Current Position Transmitter

During run mode, the 4-20mA position transmitter will output 4-20mA for valve positions between and including the set points. The
module has an optional over or under travel correction if the valve position exceeds the high or low set point by +/-3%. In other words,
the output will be 4mA for +/-3% over and under travel on the low end and 20mA for +/-3% over and under travel on the high end. If
the valve position exceeds 3% of over travel then values below 4mA or above 20mA will be output. The user selectable other option
is to calibrate the device with-out the over and under travel capability. See the calibration procedure in this document for additional
information.
Operation of the Stand Alone Potentiometer

The potentiometer only version will generate a ratio metric voltage output based on the excitation voltage and the position of the valve.
Standard potentiometer options include 0-1k ohm and 0-10k ohm.
14
Continued
D-Series Replacement Procedure: 4-20mA Position Transmitter
(Use the following installation procedure to replace an existing D-Series in the field
Typically the 4-20mA Position Transmitter module and potentiometer options are already installed in TopWorx™ valve controller products.
Use the following installation directions only if you are replacing an existing unit
1) First remove the valve monitor enclosure from the valve/actuator

2) Install the 4-20mA position transmitter using the supplied or existing mounting bolts (See illustration below)
3) Remove the existing shaft and replace with the new shaft and position sensor kit assembly (See illustration below)
a) Remove circlip and washer from shaft on bottom of enclosure (outside)
b) Pull shaft out gently from top side of enclosure
c) Install lube (from packet) on new shaft just below potentiometer and spread around O-ring seals on shaft
4) The alignment boss on the bracket (indicated in the Illustration below) should hold one of the mounting ears of the sensor in place.
Once mounted, verify that no rotary movement of the potentiometer housing is possible
5) If applicable, plug the position sensor cable into the 4-20mA position transmitter keyed header connector
6) Connect the three output wires to the indicated terminal block positions if you are using the potentiometer only option.
7) The module is now ready for calibration/operation
8) Before mounting the DXP to an actuator, make sure the potentiometer alignment marks are aligned as shown in the illustration
below with the valve in the closed position.
9) The potentiometer has been factory set for typical valve rotation ranges from 2º to 180º in counter-clockwise rotation applications
from the 4mA position to the 20mA position and from valve rotation ranges from 2º to 90º in clockwise rotation applications from
the 4mA position to the 20mA position. Please contact TopWorx™ for proper potentiometer set up for ranges greater than specifie
above.
The potentiometer has been factory set for typical valve rotation ranges from 2º to 180º in counter-clockwise rotation applications from
the 4mA position to the 20mA position and from valve rotation ranges from 2º to 90º in clockwise rotation applications from the
4mA position to the 20mA position. Please contact TopWorx™ for proper potentiometer set up for ranges greater than specified
above.
Module and Bracket Potentiometer Shaft Assembly
TRANSMITTER MODULE
BRACKET
ALIGNMENT BOSS
15
4-20mA Transmitter with HART: Options LH/MH/KH/EH/ZH/0H
Features and Specification
Description
The TopWorx HART 4-20 mA Position Transmitter is a 2-wire high impedance slave transmitter. It is capable of both analog and digital
signaling. The transmitter and DD (Device Descriptions) are registered with FieldComm Group™ and supports HART 7.
Valve position is sensed directly through a position sensor with hard endpoint detection capability via limit switches.
Features and Specification
Features:
-Local user interface via Graphic LCD
-Selectable endpoint hysteresis ±3 %
-Internal device temperature
monitoring
-Point to Point and Multi-drop mode
-Burst mode and Event Notificatio
-Supports NE-107 and NE-43
-Five-point valve position calibration
-Polarity and overvoltage protection
-Alarms and counters
16
Specifications
Physical Specificatio Min. Typ. Max.

Device Terminal Voltage 10.0 VDC 24 VDC 39 VDC
Linearity (1/4 Turn) - 1 % of span -
Hysteresis - 0.5 % -
Repeatability - 0.5 % -
Shaft Rotation 20° - 180° 1800 (Consult Factory for Additional Shaft
Rotation Sensing)
Internal Temperature Sensor Accuracy - ±2.5 °C -
Operating Temperature Limits -40°C - 80 °C
Device Resistance and Capacitance - Rx: 27.12k ohms, -
Cx: 6.11nF @ 950
Hz
High (H) Alarm NE-43 Current - 22.3mA -
Low (L) Alarm NE-43 Current - < 3.5mA -
Multi-Drop Current Draw 4.0mA
Lift-Off oltage 10.0V
For additional device specifications that include commands, please refer to ES-06 16-1 HART Instruction Manual Supplement.
Device Information
Wiring Diagram
Figure 1: Wiring Diagram
Note: Optional cable shield to be connected on one cable end only. If connected on device side, make sure switchbox housing and
grounding strap are properly earth grounded.
High/Low Alarm Jumper:

The TopWorx HART product supports NE-43 which requires the loop current to be driven to a level greater than 21 mA or below
3.5 mA in the event of a device failure. This loop current alarm value is user selectable via a jumper located on the device.
17
Figure 2: Loop Current Alarm High/Low Selection
Overview:
Manufacturer TopWorx
Device Type Transmitter
HART Protocol Revision Revision 7
Device Description Revision 1
Burst Mode Yes
Event Notificatio Yes
Dynamic Variables Yes, 4, SV, TV, QV can be mapped. PV cannot.
Device Variables Yes, 14
Device Variables:
Table 1: Device Variables
Index Device Variable Units Dynamic Variable Mapping Description Range

0 Position % Primary Variable Travel % of Calibrated Span
1 = Tripped, 0 = Not
1 Limit Switch 1 None Tertiary Variable End of Travel 1 Tripped
1 = Tripped, 0 = Not
2 Limit Switch 2 None Quaternary Variable End of Travel 2 Tripped
Auxiliary Limit 1 = Tripped, 0 = Not
3 None User selectable to SV,TV, or QV Optional Aux. limit switch
Switch Tripped
Internal Device
4 Celsius Secondary Variable Ambient device conditions -55 to 130
Temperature
Last Close Stroke
5 Milliseconds User selectable to SV,TV, or QV Travel time to close the valve 0 to 4294967295
Time
Last Open Stroke
6 Milliseconds User selectable to SV,TV, or QV Travel time to open the valve 0 to 4294967295
Time
Time last spent in the opened
7 Opened Dwell Time Seconds User selectable to SV,TV, or QV 0 to 4294967295
position
Time last spent in the closed
8 Closed Dwell Time Seconds User selectable to SV,TV, or QV 0 to 4294967295
position
18
9 Cycle Count None User selectable to SV,TV, or QV Counted valve strokes 0 to 9999999
0 = Opened,1 =
Closed,2 = Opening,
10 Valve State None User selectable to SV,TV, or QV Indicates current valve position 3 = Closing,4
= Stopped,5 =
Un-known
Highest Device Highest ambient temperature seen
11 degC, degF User selectable to SV,TV, or QV -55 to 130
Temperature by the device.
Lowest Device Lowest ambient temperature seen

12 degC, degF User selectable to SV,TV, or QV -55 to 130
Temperature by the device.
Accumulated time the valve last

Transition
13 Milliseconds User selectable to SV,TV, or QV spent between the open and closed 0 to 4294967295
Dwell Time positions.
Field Device Status:

Table 2: Field Device Status
Bit Status NE-107 Trigger UI Code
0 Primary Variable Out of Limits S PV has exceeded the sensor limits. 19 – 01
Non-Primary Variable Out of

1 S Non-PV has exceeded the sensor limits. 19 – 02
Limits
2 Loop Current Saturated S Set when the loop current output has reached the physical limit. 19 – 04
3 Loop Current Fixed N Active during loop test and multi-drop mode. 19 – 08
4 More Status Available N Active when any bit in the Additional Field Device Status is set. 19 – 10
Set at initial device power up or after a device RESET.

5 Cold Start N 19 – 20
Cleared after receiving first HA T command.
Set when the configuration has been changed by a primary or secondary maste .
6 Configuration Change N 19 – 40
Reset by HART Command 38.
7 Device Malfunction F Set or cleared by results of a self-test. 19 – 80
Additional Field Device Status:

Table 3:Additional Field Device Status
Byte Bit Status NE-107 Trigger UI Code
0 Communication Fault F Communication with host was unexpectedly lost. 00-01
1 Low Frequency Oscillator Fault F Oscillator in the analog module failed to start. 00-02
2 Local Calibration in Progress S Complete the calibration method. 00-04
3 Temperature Sensor Failure S Reset the device. Contact factory if the alert persists. 00-08
0
4 Calibration Span Failed S Valve travel calibration end set-point failed. 00-10
5 Cycle Count Limit Alert M Cycle count exceeded user set alert value. 00-20
6 DAC Trim Required S Analog loop current needs to be trimmed. 00-40
7 Valve Calibration Required S Valve travel needs to be calibrated into the device. 00-80
19
0 Last Close Stroke Time Alert M Valve stroke time is greater than the user defined value 01 – 01
1 Last Open Stroke Time Alert M Valve stroke time is greater than the user defined value 01 – 02
2 Closed Dwell Time Alert M Valve dwell time is greater than the user defined value 01 – 04
3 Open Dwell Time Alert M Valve dwell time is greater than the user defined valu 01 – 08
1
4 Electrical Hardware Failure F Reset the device. Ensure loop power is properly sup-plied. 01 – 10
5 DAC Output Voltage Out of Range F Loop current driver voltage out of range. 01 – 20
6 Position Sensor Fault F Sensor is in the dead band, shorted, or disconnected. 01 – 40
7 Limit Switch Fault F End of travel limit switch is latched. 01 – 80
2 0 Transition Dwell Time Alert M Transition dwell time of the valve is greater than the user defined value
Maintenance Required [Condensed
0 M 06 – 01
Status]
1 Device Variable Alert S 06 – 02
2 Critical Power Failure F 06 – 04
3 Failure [Condensed Status] F 06 – 08

6
4 Out of Specification [Condensed Status S 06 – 10
5 Function Check [Condensed Status] C 06 – 20
6 Unused - Returns 0 - - 06 – 40
7 Unused - Returns 0 - - 06 – 80
0 Device Variable Simulation Active C Device has been placed in simulation mode. 08 – 01
1 Non-Volatile Memory Defect F Memory check failed 08 – 02
2 Volatile Memory Defect F Memory check failed 08 – 04
3 Watchdog Reset Executed F Processor was reset due to failure to kick the watchdog timer. 08 – 08
8
4 Power Supply Conditions Out of Range M Low board level supply voltage. 08 – 10
5 Environmental Conditions Out of Range M Device temperature exceeded limits of -50 °C to 85 °C. 08 – 20
6 Electronic Defect F 08 – 40
7 Device Configuration Locke C Device locked bit is set. 08 – 80
0 Status Simulation Active C 09 – 01
1 Discrete Variable Simulation Active C 09 – 02
2 Event Notification Overfl C 09 – 04
3 Unused - Returns 0 - - -
9
Operation
White left Button: From the main screen, press one Green Select Button: used to select an option and
time to show status screen. On any other screen, this move to its secondary menu.
button is used to return to the previous level of screens
Red LED Shows when Switch 2
is Activated
Green LED Shows when

Switch 1 is Activated
Orange LED Indicates alert

Status Available
Red Right Button: This

button cycles through all the
screens on the current level
20
Position Sensor Deadband
Red Dot should not be

within the Deadband Red
Area
Local (at Device) Calibration

Hysteresis Setting: (See Figure 5)
Hysteresis/Valve Mode of the valve endpoint readings can be adjusted to 0% (Linear Mode) or 3% (Rotary Mode). At 3% hysteresis, an
over or under travel correction of the valve end points are set within 3%. In other words, the output will be 4mA for 3% range travel from
the low-end calibration set point and 20mA for 3% range travel on the high-end calibration set point. If the valve position exceeds 3% of
over travel, then values below 4mA or above 20mA will be output. At 0% hysteresis, the position readings at both valve open and closed
end points will be exact with no over and under travel correction.
To change the end-point hysteresis (default 3%), press the three times until “HYSTERESIS” is shown. Press the Green Select
button.
The 0% option is displayed. Press the Green Select button to set the hysteresis to 0%. or press the button to move to the 3%
hysteresis screen. Press the Green Select button to set the hysteresis to 3%. A success screen will show the hysteresis (Deadband)
setting.
Example: 2-Point Clockwise Local Calibration
To execute 2-point Clockwise valve calibration: From the main screen (Figure 6-1) press the three times on the HART device until
“SET VALVE CAL” is shown (Figure 6-2). Press the Green Select button and the device will ask, “ARE YOU SURE?” (if you want to
continue with valve calibration) as shown in Figure 6-3. Press the Green Select button to get to the calibration menu. Cycle through the
different calibration options by pressing the button. Press the Green Select button to select “2 POINT CW” calibration (Figure 6-4).
The device asks “PLACE VALVE AT 0%” (Figure 6-5). Rotate shaft to the desired 0% position and press the Green Select button. Select
“STORE 0% AS OPEN?” (Figure 6-6). The screen should now show “PLACE VALVE AT 100%” (Figure 6-7). Rotate the shaft clockwise
until shaft is in the 100% or “CLOSED” position. Press the Green Select button again to see “STORE 100% POINT?” (Figure 6-8). After
pressing the Green select button, the screen will show “SUCCESS” (Figure 6-9) and then return to the home screen. The output current
reading should be 20mA when the target is at 100% (CLOSE). The current reading should be 4ma when the target is at the 0% (OPEN)
position. If these are both true, the device is calibrated correctly.
21
22
Figure 5: Local User Interface Flow Chart
23
24
1 2
3 4
5 6
7
5 9
68
Figure 6.1-6.9: HART CW Calibration Procedure
Example: 5-Point Clockwise Calibration
For additional accuracy, utilize the 5-point calibration. This feature is typically used in conjunction with valve positioners to more
accurately align both system’s valve position measurement.
To execute 5-point Clockwise valve calibration: From the main screen on the HART Device, press the button four times until “SET
VALVE CAL” is shown. Press the Green Select button and the device will ask, “ARE YOU SURE?” (if you want to continue with valve
calibration). Press Green Select to get to the calibration menu. Cycle through the different calibration options by pressing the
button.
Press Green Select to select “5 POINT CW TO CLOSE” calibration. The device asks “PLACE VALVE AT 0%” (Figure 6-5). Rotate shaft
to the desired 0% position and press the Green Select. Select “STORE 0% AS OPEN?”. The other option is “STORE 0% AS CLOSE”.
The device will then cycle through the same procedure at 25%, 50%, 75% and then 100% valve rotation. At the 100% location, the
screen should now show “PLACE VALVE AT 100%”. Rotate the shaft clockwise until shaft is in the 100% or “CLOSED” position. Press
the Green Select again to see “STORE 100% POINT?”. After pressing the Green select the screen will show “SUCCESS” and then
return to the home screen. The output current reading should be 20ma when the target is at 100% (CLOSE), 16ma at 75%, 12ma at
50%, 8ma at 25% and 4ma at 0% (OPEN).
If these are measurements are true, the device is calibrated correctly.
25
Remote (Not at Device) Calibration/Set-up
Remote calibration/setup can be performed at a maintenance/control system or handheld device. The user has the option of configuring
the device either through a guided or manual setup. For example; by executing the calibration method through AMS as shown in Figure
7.
Figure 7: AMS Guided Setup Screen
Another example is setting up threshold configuration of the device as shown in Figure 8: Manual Setup Device Configurati
Example . Many features are available utilizing a control system, maintenance system or handheld. For example:
n Device Information n Burst Mode Configuration

n Device Variable Reading/Setting n Event Notificatio
n Device Overview n Variable Mapping
n Alerts n Polling Addressing/Multidrop setup
n Device/Alert Simulation n Security – Software Lock
n Position Calibration n Trends
n Threshold Configuration for Alerts n Loop Test
n Communication Statistics n DAC Trim
n Communication Settings n Factory/Processor Reset
n Device Location n PV Range
n Clock/Date Set
Remote calibration/setup can be performed with a HART handheld device.
The handheld device menu is shown in Table 4: Handheld Device Menu
26
Figure 8: Manual Setup Device Configuration Exampl
27
Table 4: Manual Setup Device Configuration Example
28
29
Alerts
If the status indicator LED(Orange) is flashing, then the device has an alert. From the home screen on the HA T device, press the
White Left button once to get to the status screen. The status of the device will be indicated. Each status code is accompanied with brief
description. For additional information on the status code and recommended action, refer to Table 5: Status Codes
Figure 9: Status Screen
Alerts are also available remotely at the control system or handheld device. An example is shown Figure 10:
Figure 10: AMS Active Alert Example Screen
30
Table 5: Status Codes
Displayed Status at Device
Status Text - Text - Status Description Alert Description Recommended Action

Code Line 2 Line3
Primary Variable Out of The Primary Variable is beyond its Check the valve for over travel.
260 PRI VAR OUT LIM
Limits operating limit. Recalibrate the device.
A Device Variable not mapped to the

Non-Primary Variable Check the device variable limit
261 NP VAR OUT LIM Primary Variable is beyond its operating
Out of Limits settings.
limits.
The loop current has reached its Check the valve for over travel.
Loop Current
262 LOOP I SATUR8D maximum or minimum value and cannot Verify the position sensor is
Saturated
increase or decrease any further. connected and not in the deadband.
The device is in multi-drop mode or the

If analog loop current signaling is
263 LOOP I FIXED Loop Current Fixed loop current is set to a fixed level and is
desired disable multi-drop mode.
not responding to process inputs.
Automatically reset once the Host

More status is available via Command
264 MORE STATUS More Status Available issues HART Command 48 - Read
48 - Read Additional Status
Additional Device Status.
Automatically reset once the host

Power has been cycled or a
265 COLD START Cold Start issues the first command to the
Device Reset has occurred.
device.
Automatically reset for the specific

CHANGE Configuratio An operation changed the devices
266 CONFIG host which issued Command 38 -
D Changed configuration
Reset Configuration Changed Bit
Reset the device. Request the

The device detected a serious error
device to run a self-test if possible.
267 DEVICE MALFUNC Device Malfunction or failure that compromises device
Contact the factory if the condition
operation.
persists.
A device peripheral bus communication Reset the device. Contact factory if

10 COMM FAULT Communication Fault
fault has occurred. the alert persist.
Low Frequency The low frequency clock source failed Reset the device. Contact factory if
11 LFO FAULT
Oscillator Fault to start. the alert persist.
Local Calibration in Valve position may not reflect actual

12 CAL IN PROGRES Complete the calibration method.
Progress value during calibration.
Temperature Sensor The device temperature sensor has Reset the device. Contact factory if
13 TMP SNS FAULT
Failure failed. the alert persist.
Stroke must be greater than 20

Calibration Span Valve stroke is too small or calibration
14 CALSPAN FAILED Degrees.
Failed is bad.
Recalibrate the valve span.
Valve maintenance is recommended.

Cycle Count Limit
15 CYC CNT LIMIT Cycle Count Limit has been exceeded. Readjust or reset the upper cycle
Alert
count limit parameter.
Execute the DAC trim method to trim

DAC trim is required to ensure accurate
16 DA TRIM REQD DAC Trim Required the loop current to the proper value
loop current output.
against a calibrated current meter.
Calibrate the valve stroke into the

Valve Calibration Calibrate the valve travel into the
17 VLV CAL REQD device by running the calibration
Required device.
method.
31
Status Text - Text - Status Description Alert Description Recommended Action

Code Line 2 Line 3
Last Close Set when the stroke time is outside Valve maintenance is recommend-
20 CLS STR TIME Stroke Time the range set by the upper and ed. Adjust the limits according to
Alert lower limit ranges. the valves stroke time.
Last Open Set when the stroke time is outside Valve maintenance is recommended.
21 OPN STR TIME Stroke Time the range set by the upper and lower Adjust the limits according to the
Alert limit ranges. valves stroke time.
Set when the stroke time is outside Stroke/Partially stroke the valve to
Closed Dwell Time
22 CL DWEL TIME the range set by the upper and lower reset the timer, clear the counter
Alert
limit ranges. manually, increase the limit.
Set when the stroke time is outside Stroke/Partially stroke the valve to
Open Dwell Time
23 OP DWEL TIME the range set by the upper and lower reset the timer, clear the counter
Alert
limit ranges. manually, increase the limit.
Electrical Hardware Set when an electrical component on Reset the device. Ensure loop power
24 ELECTRIC HDWARE
Failure the device failed. is properly supplied.
DAC Output Voltage The loop transistor drive voltage is Reset the device. Ensure loop power
25 DAC OUT RANGE
Out of Range higher than expected. is properly supplied.
The device detected an issue with Check the wiring connections for the
26 POSITN SENSOR Position Sensor Fault
the position sensor. positions sensor / potentiometer.
The device detected an issue with Check the wiring connections for
27 LIM SW FAULT Limit Switch Fault
the limit switch. each limit switch.
Valve maintenance is recommended.

TRANST Transition Dwell Time Set when the transition dwell time
30 DWEL TM Adjust the limits according to the
N Alert exceeds the upper limit parameter.
transition dwell time.
Maintenance Required This bit is set to indicate that the

Check the additional device status
70 MAINT REQD [Condensed field device or valve requires
bits for details
Status] maintenance.
This bit is set if any of the device Check that the process inputs have
71 DEVICE VARIABL Device Variable Alert
variables are in an alert state. not exceed the device senor limits.
This bit is reserved for devices that

72 CRITICL PWR FLT Critical Power Failure operate from stored power and is not This bit will not ever be set
implemented in this device.
Failure [Condensed Signal invalid due to malfunction in Check the additional device status
73 FAILURE STATUS
Status] the device or sensor. bits for details.
Permissible ambient or process

Out of Specificatio conditions exceeded or the Check the additional device status
74 OUT OF SPEC
[Condensed Status] measuring uncertainty of sensors is bits for details.
probably greater than expected.
32
Status Text - Text - Line Status Description Alert Description Recommended Action
Code Line 2 3
Function Check Signal temporarily invalid due to on- Check the additional device status
75 FUNCT CHECK
[Condensed Status] going work on the device. bits for details.
Device Variable Disable Device Variable Simulation

90 VAR SIM ACTIVE Device variables are being simulated.
Simulation Active mode.
Non-Volatile Memory Reset the device. Contact the factory
91 NV MEM DEFECT FRAM Uncorrectable bit Error.
Defect if the problem persists.
VOL "RAM/Code overwrite Error. Reset the device. Contact the factory
92 DEFECT Volatile Memory Defect
MEM Micro-processor Stack Overflo ." if the problem persists.
WDT Watchdog Reset Code execution has exceeded the
93 EXECD Reset the device.
RST Executed WDT timer limit.
PWR Power Supply Conditions Regulated power supply voltage is out
94 RANGE Verify the bus voltage is in range.
SUP Out of Range of range.
ENVI- Environmental "Internal Temperature outside Ensure the environmental conditions
95 RANGE
RON Conditions Out of Range -40 to 80 C" are appropriate for the
96 ELECTR DEFECT Electronics Defect Internal electronics failure. Contact the factory.
Device Configuration
97 CONFIG LOCKED The device is locked by the host. Unlock the device.
Locked
100 SIMUL ACTIVE Status Simulation Active Status alerts are being simulated. Disable Status Simulation mode.
Discrete Variable Disable Discrete Variable Simulation

101 VAR SIM ACTIVE Discrete variables are being simulated.
Simulation Active mode.
The device buffers 3 unacknowledged
Event Notification Over- Event notification buffers hav events. Ensure the host
102 EVENT OVER- FLO
flo overflowed acknowledges the events in a timely
manner.
Certifications
HART DEVICE ONLY:
Ex ia IIC Ga
Tamb = -40ºC to +80ºC Input Simple apparatus Inputs
Device Entity Parameters:
Ui 28 V Ui 0
Ii 100 mA
Pi 0.7 W
Ci 11 nF Ci 22.993 μF
Li 14 μH Li 14 μH
Uo 7.71 V
Io 100 mA
Po 0.7 W
Co 0.993 μF
Lo 3541 μH
33
D2-FF Discrete Valve Controller Description & Speci- Intrinsically Safe Input Parameters:
ficatio Bus Connector pins 1 to 3
I.S. Parameters FISCO Parameters
The TopWorx™ D2-FF Discrete Valve Controller combines position sensing
and monitoring with FOUNDATION Fieldbus communications and pilot valve Ui 30V Ui 17.5V
output drivers. It in-corporates the following features:
Ii 380mA Ii 380mA
Pi 1.5W Pi 5.32W
FOUNDATION Fieldbus digital communication:
• Link active scheduler capability/Link Master (LAS) Ci 5nF Ci 5nF
• Pre-instantiated** blocks include Resource Block (RB), Transducer Li 10μH Li 10μH
Block (TB), Analog Input (AI) Function Block, Discrete Output (DO)
Function Block, 2 Discrete Input (DI) Function Block, Proportional,
Integral, and Derivative (PID) Function Block Electrical Specification
• GO Switch option for open/close status or two external Limit/Auxiliary
switch inputs Current Consumption 17.65mA nominal
• Function block instantiation, live download, auto commission/
replacement Max. Applied Voltage 35VDC
• Fast function block execution time: DI: 15ms, AI: 15ms, DO: 20ms,
PID: 20ms Operating Voltage 9-32VDC
• Easy integration into AMS and DeltaV systems
• Device Dashboards powered by enhanced Electronic Device Fieldbus Specification
Description Language (EDDL)
• Comaptible with Honeywell Experion, Yokogawa PRM & Fieldmate, Topology Point to Point
ABB 800xA and GE Mark Vie Host systems Bus with Spurs
Daisy Chain
Tree
Position sensing/monitoring
Cable Twisted Pair
• GO switch option for open/close status
• Potentiometer option for position percentage
Bus Length 1900m (max)
indication, can be used for any rotation
range between 20 and 320 degrees. End
Transmission Speed 31.25 kbit/s
position offsets are adjustable
Control and monitor inputs and outputs Intrinsically Safe Yes
• Supports single/double and normal reverse
Function Block DI 15ms
acting actuators Execution Times AI 15ms
• Local LEDs for visual indication DO 20ms
• Local push buttons for calibration PID 20ms
• Remote configuration from control system
or field communicato
• Stroke valve method
• Cycle count monitoring
• Open/close time monitoring
• Temperature monitoring
• Open/short circuit protection
• Integrated field diagnostics and alert system
• Embedded NAMUR NE 107 diagnostics
• External Limit/Auxiliary switch monitoring
**Pre-instantiated blocks are the pre-installed factory default function blocks. Instantiation is the capability to add blocks to and delete
blocks from FF devices on the link. Up to 15 additional copies of each function block can be added to a device (except the transducer
and resource blocks). Not an available feature in some DSC systems.
D2-FF Assembly: “Inside the Box”
For more information concerning

the
TopWorx™ D2-FF Discrete Valve
Controller visit us online at
http://www.topworx.com
and go to the download
documents
section or call 502-969-8000 and
reference # ES-02512-1.
34
Bus Option AS: ASi with GO Switches and optional pilot(s)
Wiring Diagram:
Bus Option AS: ASi with GO Switches and optional pilots
Wiring Diagram:
GREEN ASI +
N/O GRN CLOSE
SW2 ASI -
N/C BRN YELLOW + OUTPUT 0
GREEN: - SOLENOID
INPUT 0- CL SW YELLOW +
INPUT 0+ OUTPUT 1
-
0V YELLOW +
INPUT 1- OUTPUT 2
-
INPUT 1+ GREEN: GREEN
OP SW +
INPUT 2
-
COM WHT GREEN +
N/O GRN OPEN INPUT 3
SW1
-
N/C BRN ES-02927-1
35
Bus Options AS/A0: ASi — continued —
Openness 800+ products, 150 Vendors
Type of Network Sensor Bus
Physical Media 2-wire cable (flat or round
Network Topology Bus, Ring, Tree, Star
Maximum Devices
v3.0 62 nodes (or 496 I/O pionts)
Maximum Devices
Maximum Distance 100 meters

Maximum Distance with repeaters
300 meters
(max. of 2 repeaters can be used)
Communication Methods
Transmission Properties 5 mSec latency max. on fully loaded segment
Primary Usage
• Master/Slave with cyclic polling
• Manchester Bit Encoding implemented via Alternating Pulse Modulation (APM)
Power & Communications on same pair

• Limited to 200 mA per device power consumption (29.5V DC to 31.6V DC)
• Requires AS-i specific power supply on communications bus for decodin
• Devices can be supplied from bus (<200 mA)
Device Power Supply
• Additional power can be supplied by AS-i power bus cable having multiple power supplies
(required for higher power outputs)
• Supply shall be powered by a limited-voltage power supply
Wiring Types
Round: Normal 2 wire cable. #16AWG (1.5mm
Flat: 2 wire flat AS-i cable (1.5mm conductors) Yellow for communications / Black for additional power
Grounding aspects Ungrounded communications bus
Shielding Unshielded wire
Terminators No terminators required
Device Addressing Automatic when connected one at a time to the segment or with Handheld Addressing Unit
Governing Body ATO (AS-i Trade Organization)
Website www.as-interface.com
EN 61326-1:2006, EN 61000-4-2:1995 inc. A2:2001, EN 61000-4-3:2002, EN 61000-4-4:2004 inc.
Electromagnetic Compatibility
A1:2010, EN 61000-4-6:2009, EN 61000-4-8:1993 inc. A1:2001, EN 55011:2009 inc. A1:2010
Data bit Bit Function Input Output

DO Output O1 NA Solenoid coil 1
D1 Output O2 NA Solenoid coil2
D2 Input 12 Open Limit Green NA
D3 Input 13 Closed Limit Red NA
AS-i Bit Settings Bit Function Input Output

Parameter bit
P0 Not used Extended ID code 1 0
P1 Not used IO Code B
P2 Not used Extended ID code 2 E
P3 Not used ID code A
Two Inputs/Two
Watchdog On Profile: S-B.A.
Outputs
36
Bus Options DN: DeviceNet with GO Switches and Optional Pilot Valve(s)
Bus Options D0: DeviceNet without switches
37
Bus Options DN/D0: DeviceNet — continued —
Remote multiplexer, compatible with ODVA’s DeviceNet protocol for discrete I/O. This is a product family which
Description:
supports three (3) discrete inputs, two (2) discrete outputs, and 1 analog 10-bit input.
DeviceNet Device Profile General Purpose Discrete I/O, Class 7 with objects:
Identity (Class 1)
- Message Router (Class 2)
- DeviceNet (Class 3)
- Assembly (Class 4) -------- 5 instances
- Connection (Class 5)
- Parameter (Class Fhex) ---10 instances
- Valve (Class 6Ehex)
- Alarm (Class 6Fhex) --5 instances
- Alarm Group (Class 70hex) --2 instances
DeviceNet Conformance: Designed to conform to the ODVA DeviceNet Specification olume I, Version 2.0 and Volume II, Version
Communications: 2.0. Predefined Master/Slave Connection Set, Group 2 Only Serve
Polled I/O
DeviceNet I/O Protocols:
Change-of-state (COS), Cyclic
Module Status(MS): green/red bi-color LED
Status Indicators:
Network Status(NS): green/red bi-color LED
I/O Electrical specification

Ratings Min Typical Max Units Comments
Input Power
Device Power 11 24 25 Vdc per DeviceNet spec.
Discrete Inputs
Inputs 11 24 25 Vdc
Open, Close Outputs
Max voltage 25 Vdc
Output current 0 0.02 0.5 A Each output simultaneously
Surge current 4 A peak
Turn-on time 10* 40** ms *Resistive load
Turn-off tim 10* 40** ms **Function of solenoid
Standard Conformity
EN 61326-1:2006, EN 61000-4-2:2009, EN 61000-4-3:2006 inc. A2:2010, EN 61000-4-4:2004 inc.
Electromagnetic Compatibility A1:2010, EN 61000-4-5:2006, EN 61000-4-6:2009, EN 61000-4-8:2010, EN 55011:2009 inc.
A1:2010, EN 55014-1:2006
Module Status (MS)

LED State Module Status Meaning
OFF No power There is no power though DeviceNet.
Green Device operational Operating normally
Flashing Green Device in standby Needs commissioning.
Flashing Red Minor fault Recoverable fault.
Red Unrecoverable fault May need replacement
Flashing Red/Green Device self-testing In self-test mode.
Network Status (NS)

LED State Module Status Meaning
OFF No power/Not on-line Has no power or has not completed the Dup_MAC_ID test.
Flashing Green On-line, not connected On-line but is not allotted to a Master.
Green On-line Operating normally.
Flashing Red Connection time-out One or more I/O connections are timed out.
Detected an error which makes it incapable of communicating
Red Critical link failure on the link. (Bus off or Duplicate MAC ID.
38
How to Install and Establish DeviceNet Communications
1. Make sure that the DeviceNet network is terminated properly.

2. Set the baud rate and address of the device if different from default (see next section on how to address and set baud
rate).
3. Make sure that there is power on the DeviceNet network and that it is plugged into a Master device.
4. Connect the DeviceNet wires into the device.
5. In autobaud mode (default), the device Module Status LED (labeled MS) will continue to blink until the device recognizes
valid traffic on the DeviceNet link and syncs to a specific baud ra
6. In fixed baud rate mode, the device will undergo its initialization sequence, flashing both LEDs After approximately 4
seconds, the Module Status LED (labeled “MS”) will go on solid green and the Network LED will flash green
7. The green Network Status LED (labeled “NS”) will go on solid once the Master recognizes the unit on the link and
allocates the connection (commissions it).
8. The device is now operating on the network.
How to Configure the DeviceNet Node Address and Baud Rate
1. The address and baud rate are pre-set to 63 and 125k baud at the factory.
2. The user may change these values via dip switch reconfiguration at any time (see the following tables
3. A change to the baud rate will NOT take effect until the device is reset with either a RESE command or a power cycle.
4. A change to the address will be saved internally and will cause the unit to immediately undergo a soft reset. Upon restart
the new address will be active, along with the new baud rate, if previously changed.
Address Selection
ADDRESS Switch Position DeviceNet DIP Switch Position

Baud Rate
Node SW 1 SW 2 SW 3 SW 4 SW 5 SW 6 SW 7 SW 8
Address
Switch Position Values 125k OFF OFF
32 16 8 2 2 1 250k OFF ON
0 OFF OFF OFF OFF OFF OFF 500k ON OFF
1 OFF OFF OFF OFF OFF ON Autobaud ON ON
2 OFF OFF OFF OFF ON OFF
3 OFF OFF OFF OFF ON ON
4 OFF OFF OFF ON OFF OFF
5 OFF OFF OFF ON OFF ON
...
62 ON ON ON ON ON OFF
63 ON ON ON ON ON ON
How to Read Discrete Input Data – DeviceNet

1. Plug the DeviceNet connector into the device. This powers the unit electronics.
2. Allocate a Poll Connection to the device from the client.
3. Perform a poll command to the device from the client. The device returns 2 bytes of data using Assembly Instance 1
(default).
4. The discrete input channel values will be available in the first 2 bits of data in the 1st byte returned. The bits are defined as
Table 1 Poll Response (Input Data) Assembly Instance 1
Bit Positions
Byte 7 6 5 4 3 2 1 0
Calibrate Calibrate Close Open

Reset Auxiliary Close Limit Open Limit
1 Close Open Output Output
Switch State Input State Switch State Switch State
Switch State Switch State State State
Close Open
Cycle Count
2 0 0 0 0 0 Timeout Timeout
Alarm Alarm Alarm
39
Bus Options DN/D0: DeviceNet — continued
— Table 2 Poll Response (Input Data) Assembly Instance 2
Bit Positions
Byte 7 6 5 4 3 2 1 0
Calibrate Calibrate Close Close

Reset Auxiliary Close Limit Open Limit
1 Close Open Output Output
Switch State Input State Switch State Switch State
Switch State Switch State State State
Analog Analog Analog Close Open
Cycle Count
2 Input Input 0 0 Input Timeout Timeout
Alarm
Overcurrent Undercurrent Alarm Alarm Alarm
3 Analog Input LSB (bits 0-7)
Analog Input MSB

4 0 0 0 0 0 0 (bits 8 and 9)
Using Assembly instance 3 (Parameter 10), the cycle open and close times are added on to the poll bytes as shown below:
Table 3 Poll Response Assembly Instance 3
Byte Description
1 Input Status Bits
2 Alarm Bits
3 AI LSB
4 AI MSB
5 LS Byte of Last Open Time
6 MS Byte of Last Open Time
7 LS Byte of Last Close Time
8 MS Byte of Last Close Time
Using Assembly instance 4, the cycle count is added on to the poll bytes as shown below:

Byte Description
1 Input Status Bits
2 Alarm Bits
3 AI LSB
4 AI MSB
5 LS Byte of Last CycleTime
6 MLS Byte of Last Cycle Count
7 MMS Byte of Last Cycle Count
8 MS Byte of Last Cycle Count
Assembly instance 5 incorporates all data, as shown:

Byte Description
1 Input Status Bits
2 Alarm Bits
3 AI LSB
4 AI MSB
5 LS Byte of Last Open Time
6 MS Byte of Last Open Time
7 LS Byte of Last Close Time
8 MS Byte of Last Close Time
9 LS Byte of Last Cycle Count
10 MLS Byte of Last Cycle Count
11 MMS Byte of Last Cycle Count
12 MS Byte of Last Cycle Count
40
How to Energize and De-energize Valve Solenoids
1. Reconnect the device and allocate a Poll Connection to the device from the client.
2. Issue a Poll command from the client with a data value of 00, 01, or 02. Each of the two possible outputs will be turned ON
or OFF, as defined by a corresponding bit value of 1 or 0. Note that having both open and close bit set is an illegal state
and will be ignored by the controller.
Table 6 Poll Request (Output Data)

Bit Positions
Byte 7 6 5 4 3 2 1 0
1 0 0 0 Reset Cycle Enable Cal Reset Output 2 Output 1
Count Mode Alarms
Setting the Reset Alarms bit to 1 clears the Open and Close Time counters and resets all active alarm notification bits. As long as this bit
is set, the alarms will be inactive.
The Enable Cal Mode bit is set to 1 to allow calibration of the limit switches sense positions. When the device is commanded into
Cal Mode, normal operation of the outputs is disabled. The Closed and Open limit switches can then set active, which will cause the
associated input LEDs to be activated, along with activating the corresponding Input 1 or Input 2 status bits.
The Reset Cycle Count bit is set to 1 to clear the cycle counter.
Parameters
The TopWorx device is software-configured for several parameters. Table 7 defines the legal values and the default values for the I/O
configuration selections available
Table 7 Configuration Parameters (Class 15

Instance Parameter Name Values Default Setting Default Value Description
1 Max Open Time 0 to 65535 Disabled 0 Maximum allowed time for valve to open before
(0-655.35 triggering alarm (in 10's of milliseconds)
sec.)
2 Max Close Time 0 to 65535 Disabled 0 Maximum allowed time for valve to close before
(0-655.35 triggering alarm (in 10's of milliseconds)
sec.)
3 Cycle Count Limit 0 to Disabled 0 Maximum number of valve cycles before triggering
4294967295 alarm
4 Analog High Limit 0 to 1024 Disabled 1024 Highest analog value before triggering alarm
5 Analog Low Limit 0 to 1024 Disabled 0 Lowest analog value before triggering alarm
6 DeviceNet Fault Action 0 or 1 Use Fault Value 0 0 = Use Fault Value
1 = Hold last State
7 DeviceNet Fault Value 0 or 1 OFF 0 0 = OFF
1 = OPEN
2 = CLOSE
3 = No Change
8 DeviceNet Idle Action 0 or 1 Use Fault Value 0 0 = Use Fault Value
1 = Hold Last State
9 DeviceNet Idle Value 0 or 1 OFF 0 0 = OFF
1 = OPEN
2 = CLOSE
3 = No Change
10 Assembly configuratio 0 or 4 Standard Assembly 1 See Table 1 through Table 5
41
Definitions of these parameters are as follows
1. Max Open Time: Maximum allowed time in 10’s of milliseconds for valve to open before triggering alarm.
2. Max Close Time: Maximum allowed time in 10’s of milliseconds for valve to close before triggering alarm.
3. Cycle Count Limit: Maximum number of valve cycles before triggering alarm.
4. *Analog High Limit: Highest analog value before triggering alarm.
5. *Analog Low Limit: Lowest analog value before triggering alarm.
6. Output Fault Action: Selection to determine whether each output will hold its last state or assume the value identified in
the next parameter upon a device fault.
7. Output Fault Value: The value each output will assume after a Fault if Fault Value is selected above (hold last state is not
selected).
8. Output Idle Action: Selection to determine whether each output will hold its last state or assume the value identified in the
next parameter if an Idle Command is issued by the Master.
9. Output Idle Value: The value each output will assume upon an Idle Command if Idle Value is selected above (hold last
state is not selected).
10. Assembly Configuratio : This determines what data is returned in the poll response.
42
Bus Options PB: Profibus with GO Switches and Optional Pilot alve(s)
Utilize the jumper across the two RESET pins

shown above ONLY when a reset is required.
Bus Options P0: Profibus ithout Switches
Utilize the jumper across the two RESET pins

shown above ONLY when a reset is required.
43
Bus Options PM/PB: Profibus protocol — continued
Type of Network Device Bus
Physical Media Twisted pair, fibe
Network Topology Bus, Ring, Star
Maximum Devices max. 126 stations on one bus (maximum of 244 bytes input and output data possible for each slave)
Maximum Distance "93.75Kbps and less - 1200 meters 500Kbps - 400 meters
1.5Mbps - 200 meters 12Mbps - 100 meters"
DP 93.75Kbps and less - 1200 meters
500Kbps - 400 meters
1.5Mbps - 200 meters
12Mbps - 100 meters
Maximum Distance with repeaters 9,500 meters with repeaters
(max. of 9 repeaters can be used)
Communication Methods Peer-to-peer, multicast or cyclic master-slave (uses token passing sequence)
Primary Usage Used for Discrete and Analog for PLC, Variable Speed Drives, Remote I/O communications
Power & Communications Power is supplied separately from communications bus (can be supplied on a parallel power bus)
Device Power Supply Devices are powered separately from communications bus. A 5A fuse must be placed in series with the input power terminals.
Wiring Types Shielded twisted pair #22 AWG

Device Addressing Handheld/Software only
Governing Body PROFIBUS International (PI)
Website www.profibus.co
Electromagnetic Compatibility EN 61326-1:2006, EN 61000-4-2:1995 inc. A2:2001, EN 61000-4-3:2002, EN 61000-4-4:2004 inc. A1:2010, EN 61000-4-6:2009, EN 61000-4-8:1993
inc. A1:2001, EN 55011:2009 inc. A1:2010
NOTE: In order to meet EMC requirements the Profibus communication cabling must be encased by conduit and properly grounded to the device
housing."
Technical Data Line Parameters Line Type A Line Type B

Power requirements Impedence 135 to 165 100 to 130
Capacitance per unit length (pF/m) <30 <60
"24 VDC +-10% Loop resistance (V/km) 110 ---

PROFIDP 4I20 Max I = 350 mA maximum
(solenoids/activated)" Core diameter (mm) 0.64 >0.53
Core cross section (mm²) >0.34 >0.22
Profibus inf Recommended Line Lengths
ID 09ED HEX Transmission rate (kBaud) 9.6 19.2 93.75 187.5 500 1200 1500
GSD fil TWIS09ED.GSD

Line Type A 1200 1200 1200 1000 400 200 100
Transmission Speed 12Mbaud (max) Line Type B 1200 1200 1200 600 200 - -
Software Parameters
Output Fail Closed Fail Open Dual Coil Intput Diagnostic
Byte 1 Byte 1 Byte 1
Bits Bits Bits
7 n/a n/a n/a n/a 7 n/a n/a 7 n/a
6 n/a n/a n/a n/a 6 n/a n/a 6 n/a
5 n/a n/a n/a n/a 5 n/a n/a
5 n/a
4 n/a n/a n/a n/a 4 n/a n/a
4 n/a
3 n/a n/a n/a n/a 3 SPARE Input 4
3 n/a
2 n/a n/a n/a n/a 2 SPARE Input 3
2 Hard Wired
1 Output 2 n/a n/a High Closed 1 High Closed Input 2 high
1 Hard Wired
0 Output 1 High Open High Closed High Open 0 High Open Input 1 high
0 Hard Wired
Low Closed Low Open high
44
Reed Switch Sensor Communication Module (SCM) Calibration: Options R2/R4
Options R2: SCM Calibration
Never perform limit switch calibration while an area

is known to be hazardous.
First, be sure you have an air supply connected, and the

appropriate spool valve to actuator connections. Set the air
supply between 30 and 80psi.
Step 1
For standard explosion-proof units: Using a 24VDC
Secondary or
Dual Pilot Spool
regulated power supply, connect (+) to COM and (-) to NO
To I/O
Valve Terminals terminals. Limit current to the internal limit switches below
Logic
maximum current ratings.
Signal IN
Caution: Many power supplies do not have
To I/O current limiting; therefore, ALWAYS use a load
Voltage IN for resistor with a value of 200 to 2500 Ohms in
Pilot Valve
To I/O
Control
series with the COM or NO legs of the circuit or
Logic
damage may occur.
Signal IN
To Pilot Valve Step 2
To I/O With the valve in the CLOSED position, disengage the
lower cam from the splined Hub and rotate clockwise until
the Red LED lights. Release the cam to re-engage the
splined Hub, making sure it is seated on the splines. This
Option
OptionR4:
R4SCM
: SCM sets the CLOSED limit switch.
Step 3
Cycle the valve to the OPEN position using the attached
control equipment.
Step 4
Secondary or While the valve is in the OPEN position, disengage the
To I/O Dual Pilot Spool upper cam from the splined Hub and rotate the upper cam
Valve Terminals
counterclockwise until the Green LED lights. Release the
Logic
Signal IN
cam to re-engage the splined Hub, making sure to seat the
cam on the splines. This sets the OPEN limit switch.
To I/O
Voltage IN for Step 5
Pilot Valve
To I/O Control Cycle valve several times to insure limit switches maintain
Logic calibration.
Signal IN Check that the target assembly is secure to the actuator
To Pilot Valve pinion, and all air connections are tight.
To I/O
NOTE: Continuity may be verified using a continuity

light or by using an Ohmmeter in series with the NO
Electrical Ratings connection.
SCM R2/R4 200mA@120VAC (25W MAX)
NOTE: Refer to the wiring diagram on the inside lid of your product
to determine wiring configuration and actual pin out location
**Install per control drawing #ES-01743-1
45
ESD Theory of Operation
The purpose of the TopWorx™ Emergency Shut-Down (ESD) model is to partially stroke a valve that maintains a full open or full closed
position for an extended period of time while offering an ESD function. A partial stroke test (PST) verifies functionality of critical valves
that must be in their fail position during an emergency. Increasing the frequency of partial stroke testing (i.e. reducing the proof test
interval) improves the SIL (Safety Integrity Level) that the system can achieve through a reduction in the PFD avg (Average Probability
of Failure On Demand). These partial stroke tests can be performed without shutting down or disrupting the process. In an emergency,
the ESD function overrides partial stroke testing and the valve moves to its fail position.
This ESD unit incorporates a sensor communication module (SCM-ESD) to perform the partial stroke test, verify its status, and output
that status back to the user. In combination with the SCM, the ESD unit uses either the optional TopWorx™ pilot and spool valve or
a customer supplied solenoid valve to drive the actuator during both normal operation and partial stroke testing. A TopWorx™ GO™
Switch is included for partial stroke confirmation and two (2) limit switches built into the SCM confirm open and close positio
Once the unit is installed, the SCM-ESD must be calibrated for that specific valve, actuato , and solenoid exhaust settings. During
calibration, the unit records the time to partially stroke the valve. All future PST times are compared to this original value for determining
the test status. To pass a PST, the time must be within +/-20%, 30%, or 40% of the stored calibration value. This PST time tolerance
can be changed prior to calibration.
The partial stroke test is initiated via an optional partial stroke test button with a lockable cover, the calibration button on the top of the
SCM, or a pulsed DO from the PLC. Upon issuing a PST command, the SMC-ESD begins a timer while switching a relay to de-energize
the pilot/ solenoid. The valve moves from its normal position toward its fail position until the GO™ Switch is made. Once made, the
SCM energizes the pilot/solenoid and the valve moves to its normal position while outputting the PST status.
Option ES: SCM Electrical Ratings

Current/Voltage
"0.25A@24VDC w/5V drop
Open/Closed Indication 0.25A@120VAC w/5V drop"
Module Voltage 18-28VDC
Module Current 50mA (MAX)
Pilot Current (Standard) 20mA
"800mA@24VDC MAX
PST Feedback Relays
CALIBRATION
SWITCH
250mA@125VAC MAX"
"800mA@24VDC MAX
Pilot MAX Valve Rating
ALARM COM
250mA@125VAC MAX"
PSI
PASS/FAIL
DIAGNOS-
RELAY
Suggested Calibration Set-Up:

COM
{
PARTIAL
STROKE TEST
FEEDBACK
24VDC(+) COM
LOAD
24VDC(-) WW NO
200(4W) to
2500(1/2W)Ohms
For More Information

To download more information concerning the TopWorx™ D-Series ESD Valve Controller,
including a copy of the Sira Functional Safety Assessment Report visit us online at
http://www.topworx.com
or call 502-969-8000 and reference # ES-00936-1.
46
™
47
48
Pneumatic Hookup Procedures
Prior to connecting the supply air to the spool valve, flush the ™
system to remove any debris or contaminates. Galvanized pipe

can easily flake and contaminate the system and therefore
is not recommended. A 40 micron point of use filter at every
device is recommended.
4-Way Spool Valves

The TopWorx™ spool valve is a 5 port, 4-way valve driven by
an internally mounted pilot. The spool valve supply port and
work ports are marked as follows:
Highly Recommended
TopWorx™ highly recommends Locktite 567 brand thread sealant.
Do not use a hard setting pipe compound. If Teflon thread seal tape is
used, start the wrap on the second thread from the leading thread of the
fitting. This will prevent tape shreds from contaminating the spool valve
seals.
Breathers (AL-M31) should be installed in the exhaust ports to keep

debris from falling into the spool valve and damaging the seals.
This must be addressed prior to installation, or storage.
VALVE SPECIFICATION
ITEM PERFORMANCE
MEDIA AIR
MIN: -25C (-13F)
MEDIA TEMPERATURE MAX: +65C (149F)
OPERATIONAL AMBIENT MIN: -25C (-13F)
TEMPERATURE MAX: +65C (149F)
MIN: 30 PSI (2 BAR)
INLET/SYSTEM PRESSURE MAX: 145 PSI (10 BAR)
OPERATIONAL PRESSURE MIN: 30 PSI (2 BAR)
DIFFERENTIAL MAX: 145 PSI (10 BAR)
SAFE WORKING PRESSURE 150 PSI (10.3 BAR)
FLOW/Cv(Kv) CV=1.06 (KV=.92)
BODY PORT CONNECTIONS 1/4" npt (1.06Cv), 1/2" npt (3.7Cv)
ALLOWABLE LEAKAGE Ext: 3.9 cc/min, int: 25 cc/min
OPTIMAL DESIGN LIFE 1 MILLION CYCLES
BODY: ALUMINIUM (BLACK ANODIZED)
AND STAINLESS STEEL 316L;
MATERIAL IN CONTACT W/ FLUID INTERNAL: STAINLESS STEEL, LT
NITRILE, PTFE, ACETAL
Spool Valve Assembly
49
Spool Valves and Pilots
SINGLE PILOT ASSEMBLY
DOUBLE PILOT ASSEMBLY
50
Installation & Maintenance Instructions 1.06Cv and 3.7Cv
MOUNTED, AIR OPERATED, SPRING RETURN AND DUAL PILOT, OFFERED IN ALUMINIUM AND STAINLESS STEEL
CONSTRUCTIONS, WITH AND WITHOUT MANUAL OVERRIDE (MO),
DESIGNED FOR 30 PSI TO 145 PSI (2 BAR TO 10 BAR) FOR TOPWORX CONTROLLER
WARNING: To prevent the possibility of death, serious If not connected, all exhaust ports must be protected with
injury or property damage, the Spool Valve and Pilot Valve Stainless Steel Exhaust Protectors. Connect these
must be installed and serviced only by a qualified service Exhaust Protectors to ports 3 and 5 of the valves. When used
technician avoiding the following hazards: outside, or stored for longer periods of time, and/or where
exposed to harsh environments (dusts, liquids etc.).
• Pressure hazard. Depressurize valve and vent Exhaust Protectors must be used. The reliability of the valve
cannot be guaranteed if an exhaust protection other than that
hazardous or combustible fluid to a safe area before supplied is used. Refer “Exhaust Restriction” section.
inspection or removal of the valve from service.
• Electrical hazard. Turn off all electrical power to Pilot • Storage conditions: protected from exposure to weather;
storage temperature: -40°C to +70°C, Relative humidity:
Valve. 95%.
• Risk of electric shock – More than one disconnect • The Valve must be kept in its original packaging as long as
switch may be required to de-energized the device for it is left unused. The protective covers must not be removed
from the connection ports and solenoid operators.
servicing. • Ambient temperature: -25°C to +65°C. The maximum
• Explosion, fire or toxic gas hazards. Extinguish all temperature of the fluid does not exceed the ambient
open flames and avoid any type of sparking or ignition temperature.
• After storage at low temperature, the spool valves
during leakage testing. must gradually be brought to operating temperature
prior to pressurization.
DESCRIPTION • The Valves are intended to be operated within the technical
1.06Cv and 3.7Cv feature options for spring return, dual pilot, with characteristics specified on the nameplate
and without manual operator valves. • Changes to the products may only be made after consulting
the manufacturer or his representative.
Stainless Steel version: Body and End Cap are offered in SS 316L • These solenoid spool valves are designed to operate
material. Aluminum version: Body and End Cap are Black Anodized. with filtered ai .
Pipe connection for 1.06Cv: 1/4’” NPT • Spool Valve Rating: 30 psi to 150 psi (2 Bar to 10 Bar).
Pipe connection for 3.7Cv: 1/2’” NPT • -40C version of Pilot Valve Pressure Rating: 30 psi to 116
All valves are configured for internal pilot pressure supply. Pilot psi (2 Bar to 8 Bar).
pressure supply is from Pilot Valve mounted inside the TopWorx • Ensure that Pressure supply to the Pilot valve shall be
Indicator Box as shown in Figure 1. 30 psi to 116 psi (2 Bar to 8 Bar) as minimum 30 psi (2
Bar) pressure is required for Spool valve to operate and
Versions isolated from atmosphere: The internal parts of the maximum limit of Pilot Valve is 116 psi (8 Bar).
valve are isolated from the outside atmosphere in order to provide
protection in aggressive environments. All the exhaust ports of the
spool valve are pipable, providing better environmental protection,
particularly recommended for sensitive areas such as clean Caution:
rooms and applications in the pharmaceutical or food processing Installation of a Valve
industries. It is necessary to connect pipes or fittings to the exhaust Check Nameplate for correct catalog number, pressure and service.
ports to protect the internal parts of the spool valve if used outside Never apply incompatible fluids or exceed pressure rating of the
or in harsh environments (dusts, liquids etc.). valve. Installation and maintenance to be performed by qualified
personnel only.
SPECIAL CONDITIONS FOR SAFE USE
• Do not connect the pressure supply to the exhaust port
3. The "environmentally protected” construction is not
adapted for NO function. Contact us for functions available
in specific versions. Connect pipes for the required
functions in accordance with this documentation and the
port markings on the product.
• Make sure no foreign matter enters the circuit to prevent

blocking the valve function. Restrict the use of sealing tape
or sealing matter to a minimum. These valves are intended
for use with clean and dry air. Recommended minimum
filtration: 50 micron
• The dew point of the fluid used must be at least –10°C

(18°F) below the minimum temperature to which the fluid
may be exposed.
• When using lubricated air, the lubricant must be compatible

with the elastomers used. Instrument air in compliance with
ANSI/ ISA standard S7.3 (1975) exceeds the necessary
requirements and is, therefore, an acceptable fluid for
these valves
51
Future Service Considerations ASSEMBLY OF 3.7Cv VERSIONS:
• Provision should be made for performing seat leakage, Steps to assemble 3.7Cv series valve:
external leakage and operational tests on the valve with a 1. Interface Plate Assembly will be mounted on Indicator Box
nonhazardous, non-combustible fluid with the help of 4 screws for Spring Return versions and 4
• When assembling this product to a pilot to ATEX 2014/34/ Screws for Dual Pilot versions.
EU, take the least favorable category, maximum working 2. Spool Valve is mounted on the Interface Plate Assembly.
pressure and temperature into account. Compliance with screws are used to mount the Spring Re-turn versions and 4
the Essential Health and Safety Requirements has been Screws to mount the Dual Pilot versions as shown in figures
assured by compliance with the European Standards EN 3 & 4.
13463-1. The mounting position for he pilots as shown in 3. Interface Plate Assembly: TopWorx to manufacture Interface
figure 1 (a) Plate, and Sub-assembly of Plate, O Ring, and Ball plug
Valve Operation (1.06Cv and 3.7Cv

Without Manual With Manual
Operator Operator Fig.3
3.7Cv Spring Return -
Spring Aluminum & Stainless
Return Air Steel, With & Without MO
Operated
Dual Pilot
Air Operated
TopWorx™
ASSEMBLY Indicator Box
• ASSEMBLY OF 1.06Cv VERSIONS: 1.06Cv series valves
are directly mounted on Indicator Box. Spring return Interface Plate
and dual pilot both mount with 4 screws. See figure 1 & Assembly
2.TopWorx Indicator Box shown in the pictures are only for
illustration purpose. Fig.4
3.7Cv Dual Pilot -
Aluminum & Stainless
Steel, With & Without MO
TopWorx™
Indicator Box
TopWorx™
TopWorx™
Indicator Box
Indicator Box
Fig.1
1.06Cv Spring Return - Interface Plate
Aluminum & Stainless Interface Plate
Steel, With & Without MO Assembly
Assembly
Manual Override
TopWorx™
The MO is indicated with symbol in ( ) Figure 5. MO provides
Indicator Box manual operation when desired or during an electrical power
outage. Refer to figure 4 for MO Operation. To engage valve
manually, insert a screwdriver into arrow slot, push the MO forward
till it stops and then rotate it as far as possible to “2”. Valve will
now be in the same position as when the solenoid is energized. To
disengage MO, rotate arrow slot as far as possible to “0”.
Please note that MO is mechanical type. For Spring Return Valves,

MO will return to it’s original position due to Valve Spring force. For
Dual Pilot Valves, MO returns to it’s original position when other
side of the valve is energized.
Fig.2
1.06Cv Dual Pilot -
Aluminum & Stainless
Steel, With & Without MO
52
Prior to putting into operation, make sure the manual MAINTENANCE
override is returned to its Disengaged position “0” Prior to maintenance work or putting into operation, power off,
to prevent the risk of personal injury or damage to depressurize and vent the valve to prevent the risk of personal
equipment. injury or damage to equipment.
Cleaning
Fig. 5 Manual Overide
Maintenance of the valves depends on the operating conditions.
They must be cleaned at regular intervals. During servicing,
the components must be checked for excessive wear. The
components must be cleaned when a slowing down of the cycle is
noticed even though the pilot pressure is correct or if any unusual
noise or a leak is detected.
Sound emission
The exact determination of the sound level can only be carried out
by the user having the valve installed in his system. The emission
of sound depends on the application, fluid and type of equipment
used.
Preventive maintenance
• Prepare and follow routine inspection schedule based on the
media, environment and frequency of use.
• Keep the medium flowing through the valve as free from dirt and
foreign material as possible. Depending on medium and service
conditions, clean valve strainer or filter as required to keep the
valve free of contamination. In the extreme case, contamination
will cause faulty valve operation and the valve may fail to shift.
• Operate the valve at least once a month to check its function.
General recommendations for pneumatic connection: • If problems arise during maintenance or in case of doubt, please
contact us or one of our authorized representatives.
Connect piping or tubing to valve according to markings on valve
body. Refer to flow diagrams in OPERATION section. Apply pipe Troubleshooting
compound sparingly to male pipe threads only. If applied to valve Incorrect outlet pressure: Check the pressure on the supply
threads the compound may enter the valve and cause operational side of the valve; it must correspond to the values indicated on the
difficul . Avoid pipe strain by properly supporting and aligning nameplate.
piping. When tightening the pipe, do not use valve or solenoid as
a lever. Locate wrenches applied to valve body or piping as close Caution: Observe the minimum pilot pressure value 3 Bar.
as possible to connection point. To avoid personal injury or damage to equipment, check that
the valve operates correctly before putting it back into
Caution: To avoid damage to the valve body, DO NOT operation.
OVERTIGHTEN PIPE CONNECTIONS. If PTFE tape, paste,
spray or similar lubricant is used, use extra care when Troubleshooting
tightening due to reduced friction.
Replace the entire valve.
• Threaded ¼ and ½ port versions:
Connection of the Spool Valve: Connect pipes as indicated on
the label: pressure inlet at port 1. Pressure outlet at ports 2 and
4. The exhausts are channeled through the valve to ports 3 and
5.
EXHAUST RESTRICTION
Valve function: The Exhausts are channeled through the
valve to ports 3 and 5. The Exhaust Speed can be controlled
by using adjustable Exhaust Reducers. Caution: Do not seal off
the Exhaust as this will prevent the Valve from shifting. For best
results, do not restrict flow through the Exhaust below Cv 0.10
(ø2 mm). If Exhaust is fully restricted, then the Valve will not
shift.
EXHAUST PROTECTOR
Depending on the versions (1.06 or 3.7 Cv),
Stainless steel exhaust protectors can be used.
1/4” NPT Part# PS-01236-1
1/2” NPT Part# PS-01237-1
53
Continued-Proof Testing for D-Series TopWorx™
Sira Test & Certification Ltd has conducted a Failure Mode, Effect and Diagnostic Analysis (FMEDA) of the D-Series Discrete Valve
Controller against the requirements of IEC61508-2.
For More Information
To download more information concerning the TopWorx™ D-Series Valve Controller, including a copy of the Sira
Functional Safety Assessment Report visit us online at http://www.topworx.com Or call 502-969-8000
54
54
Continued-Proof Testing for D-Series TopWorx™
55
Dimensions and Materials: TopWorx™ DXP
Casted aluminum bracket is recommended for installation with SS 8553 valve in vibrating environment.
MATERIALS OF CONSTRUCTION
Cast A360 aluminum with

dichromate conversion coating
Enclosure inside & out, epoxy coated
exterior rated for 250 hrs. salt
spray per ASTM B117"
Fasteners 316 Stainless Steel optional
Shaft 316 Stainless Steel optional
Shaft Bushing Oilite Bronze
Indicator Dome Polycarbonate, UV F1 rated
O-ring seals available in: Buna,

Seals & Silicone
Fastener Torque Specification
Enclosure 8 ft.-lbs [10.8 N·m] +/-10%

Housing Bolts
Indicator 320 in-oz. [2.3 N·m] +/-10%

Dome Screws
Bottom 10 ft.-lbs [13.6 N·m] +/-10%

Mounting Holes
NOTE: REPLACE ENCLOSURE BOLTS WITH

ONLY THOSE PROVIDED FROM THE
MANUFACTURER !
56
Dimensions and Materials: TopWorx™ DXP - Flameproof Ex d IIC
Cast A360 aluminum with

dichromate conversion coating
Enclosure inside & out, epoxy coated
exterior rated for 250 hrs. salt
spray per ASTM B117
Shaft Bushing Oilite Bronze
O-ring seals available in: Buna,

Seals & Silicone

Housing Bolts
Indicator 320 in-oz [2.3 N·m] +/-10%

Dome Screws
Bottom 10 ft-lbs [13.6 N·m] +/-10%

Mounting Holes

MANUFACTURER !
57
Dimensions and Materials: TopWorx™ DXS
Enclosure Cast 316 Stainless Steel
Shaft Bushing N/A
O-ring seals available in: Buna

Seals & Silicone,

Housing Bolts
Indicator 320 in-oz. [2.3 N·m] +/-10%

Dome Screws
Bottom 10 ft.-lbs [13.6 N·m] +/-10%

Mounting Holes

MANUFACTURER !
58
Dimensions and Materials: TopWorx™ DXR
Enclosure Valox™ 364
304 Stainless Steel

Fasteners standard 316 Stainless
Steel optional
316 Stainless Steel

Shaft optional
Shaft Bushing Delrin™ 500P white
Polycarbonate, UV F1
Indicator Dome rated
Seals Silicone
Enclosure 20 in-lbs [2.3 N·m]

Housing Bolts +/-10%
Indicator 20 in-oz. [2.3 N·m]

Dome Screws +/-10%
Bottom 8 ft.-lbs [10.8 N·m]

Mounting Holes +/-10%

MANUFACTURER !
59
Indicator Assembly
IndicatorDome,
Indicator Dome,
+±5°
5Oadjustable
adjustable
Polycarbonate
Polycarbonate 10-32
10 - 32Captive
Captivescrews,
screws,
withkeyed
with keyedmask.
mask. Stainless
stainless (x4)
steel (x4)
Several rotation
Several rotationand
and
form
form options.
options
O-Ring
O-ring
Available
AvailableininBuna-N,
Buna-N,
Silicone, EPDM, Viton
Silicone Color-coded Indicator
Color-coded indicator is
is
available in several
available several
coordinating rotations and
and
forms for various valve
types, such as 9090°,, 180
0 0
180°,
and Thru-divert
and applications.
thru-divert applications
Cam/Shaft Assemblies
60
TopWorx™ D-Series Certification
PESO
Ex ia IIC T* Gb; Ex tb IIIC T* Db
Ex ib IIC T* GB; Ex tb IIIC T* Db
IECEx SIR 14.0078X / Sira 14ATEX2241X
IECEx BAS 11.0022X / Baseefa 11ATEX0035X (FF)
USL/CNL Class I, Div 1, GrABCD
UL File E125326
EAC RU C-US.ГБ08.В.02500
NEPSI GYJ13.1297X
InMetro NCC12.1260X, NCC12.0767X
PESO P347552
Ex d IIC T* Gb or Ex d IIB+H2 T* Gb; Ex tb IIC T* Db

IECEx SIR 07.0093X / Sira 07ATEX1273X
USL/CNL Class I, Div 1, GrCD; Class II, Div 1, GrEFG
UL File E125326
EAC RU C-US.ГБ08.В.02500
KOSHA 13-AV4BO-0003X & 14-AV4BO-0073X
NEPSI GYJ13.1295X
InMetro NCC 12.1138X
PESO P353049
Ex e MB IIC T* Gb; Ex tb IIIC T* Db

IECEx SIR 09.0088X / Sira 09ATEX3209X (DXR)
Ex nA nC IIC T* Gc; Ex tb IIIC T* Dc

IECEx BAS 11.0023X / Baseefa 11ATEX0036X (FF)
USL/CNL Class I, Div 2, GrABCD; Class II, Div 2, GrFG
UL File E125326
USL/CNL General Purpose

UL File E359150
Environmental Ratings: Type 4, 4X; IP 66/67
Conformance to Directives: ATEX 2014/34/EU, EMC 2004/108/EC, LVD 2006/95/EC
*Operating and Ambient temperature ratings vary depending on bus/sensor option(s), reference certificate for specific markings available.
Consult factory for certification questions or to request a custom product
61
Safe Use
User instructions (in compliance with ATEX 2014/34/EU Directive, Annex II, 1.0.6)
Instructions for safe selection, installation, use, maintenance and repair
1) The equipment may be used in zones 0, 1 or 2.
2) The equipment may be used in the presence of flammable gases and vapors with apparatus groups IIC or IIB or II and with
temperature classes T1 or T2 or T3 or T4 or T5 or T6.
3) The equipment is certified for use in ambient temperatures in the range of -50°C to +60°C and should not be used outside this
range. (NOTE: Ambient temperature range may change according to protection method)
4) The equipment is to be installed by suitably trained personnel in accordance with the applicable code of practice (typically IEC
60079-14)
5) Under certain extreme circumstances, the plastic cover over the valve position indicator may generate an ignition-capable level
of electrostatic charge. Therefore, particularly in the event of an installation in zone 0, the equipment shall not be installed in a
location where the external conditions are conducive to the build-up of electrostatic charge, e.g. wind-blown dust, etc. Additionally
the equipment shall only be cleaned with a damp cloth.
6) Periodic inspection of the equipment and system should be performed by suitably trained personnel in accordance with the
applicable ode of practice (typically IEC 60079-17) to ensure it is maintained in a satisfactory condition.
7) The equipment does not require assembly or dismantling.
8) The equipment is not intended to be repaired by the user. Repair of the equipment is to be carried out by the manufacturer, or their
approved agents, in accordance with the applicable code of practice.
Special Conditions of Safe Use (All installations)

Clean only with a damp cloth to prevent possibility of electrostatic discharge.
For Explosion Proof installations, the internal ground connection shall be used and the external ground connection, if supplied in addition,
is supplemental bonding allowed where local authorities permit, or is required.
When installing with a third party listed nipple-mount solenoid, it is the responsibility of the installer to provide fittings, and apparatus,
suitable for the area classification in accordance with the National Electrical Code
All cable entry devices or conduit stopping boxes shall be certified according to protection type and suitable for the conditions of use and
correctly installed.
The IIC enclosures are excluded from use in carbon disulphide atmospheres.
The air pressure to the valve block, when fitted, shall not exceed 150 PSI
Special Conditions or Safe Use (Flameproof Installations)
1. The IIC enclosures are excluded from use in carbon disulphide atmospheres.
2. The air pressure to the valve block, when fitted, shall not exceed 150 PSI
3. For ambient temperatures above 110ºC, the degrees of ingress protection IP66 and IP67 are not endorsed.
4. The slotted hexagonal head cover screws are not of standard form; they shall only be replaced with identical screws sourced from
the equipment manufacturer.
5. The hexagonal head cover screws are to be replaced only with stainless steel 304, grade A2-70 or A4-80 screws to ISO 35061.
6. Cover fasteners are to be tightened to a torque valve of 10.85Nm (8 ft./lbs) minimum.
Continued
62
Special Conditions or Safe Use Continued (Intrinsically Safe Installations)
The D-Series Intrinsically Safe TopWorx™ may contain one or more devices covered by the following certificates
The installer shall confirm which certified sub-assemblies are contained within the equipment and ensure compliance with the appropriate
certificate (with particular reference to input parameters
Number Description
PTB 99ATEX2219X plus supplement 1 Pepperl & Fuchs slot-type initiators, types SJ… & SC...
PTB 00ATEX2032X plus Supplements 1 & 2 Pepperl & Fuchs cuboidal inductive sensors, type NJ...
PTB 00ATEX2048X plus Supplements 1, 2 & 3 Pepperl & Fuchs cylindrical inductive sensors, types NC… & NJ...
PTB 00ATEX2049X plus Supplement 1 Pepperl & Fuchs SN sensors, type NJ...
KEMA 02ATEX1090X plus Amendment 1 Turk two-wire proximity sensors type …-….-.Y1. /….
IFM inductive proximity switch type NE****, NF****, NG****, NI****,
PTB 01ATEX2191 NN****, NT****, NS****
LCIE 02ATEX6122X Crouzet electro-valve type 81519xxx
Sira 12ATEX2192U 4-20 mA Transmitter Module
1. The 4-20 mA loop circuit and the various additional sub-assemblies (switches, sensors and valves) shall be treated as separate
intrinsically safe circuits.
2. The DXR (resin) enclosure shall only be installed where there is a low risk of mechanical damage.
3. The switchbox may contain simple switches, which shall have a maximum input power (Pi) of 1.3 W for T4 or 0.7 W for T6 from an
intrinsically safe supply.
4. For a T4 temperature class, the switchbox may contain simple switch and resistor arrangements, which shall have a maximum
input power (Pi) of 0.7 W from an intrinsically safe supply. These are not permitted for a T6 temperature class.
5. For a T6 temperature class, the input parameters to sensors covered by PTB 99ATEX2219X, PTB 00ATEX2032X, PTB
00ATEX2048X or PTB 00ATEX2049X shall be limited to Ui = 16V, Ii = 25mA, Pi = 64mW.
6. For a T6 temperature class, the Turck proximity sensors listed in certificates KEM 02ATEX1090X shall have the maximum input
parameters as follows:
7. Type AX & GX: Ui = 15V, Ii = 20mA, Pi = 200mW
8. All other sensors: Ui = 15V, Ii = 60mA, Pi = 130W
9. When the equipment incorporates a 4-20 mA Transmitter Module (Sira 12ATEX2192U), the manufacturer may apply the marking
“II 1G’ or ‘II 2 D’ or ‘II 2 GD’. A T6 temperature class is not permitted with this Module fitted. The ambient temperature is limited
to a maximum range of -40ºC to +53ºC, but this range may be reduced, depending on the enclosure and gasket type, as well
as the internal sub-assemblies fitted. Additionally, the output from the 4-20mA Transmitter Module shall only be connected to a
Novotechnic WAL30 potentiometer
Preventative Maintenance
The TopWorx™ DXP/DXS Switchbox is designed to operate for one million cycles without servicing. Call the factory when you are
approaching this milestone for a preventative maintenance kit and instructions.
63
TopWorx™ D-Series Replacement Part Number List
35 Series GO™ Switches
35-13319M Option L2/L4 - SPDT
7Z-23528M Option Z2/Z4 - DPDT Stainless Steel
Switch / Module Replacement Kits
AV-FFD2-1 Foundation Fieldbus module replacement ( with piezo pilots)
AV-FFD2-2 Foundation Fieldbus module replacement ( without piezo pilots)
AV-AS1-1 AS-Interface module
AV-DN1-1 DeviceNet module
AV-MSW1 (M) SPDT mechanical switch replacement
AV-E1 (E) P+F NJ2-V3-N sensor replacement
AV-TSW1 (T) DPDT mechanical switch replacement
AV-420TBD 4-20mA transmitter replacement assembly w/ potentiometer
Indicator / Dome Replacement Kits
AV-GB002 90º, Green/Open, Red/Closed, Buna O-Ring
AV-YB002 90º, Yellow/Open, Black/Closed, Buna O-Ring
AV-BB002 90º, Black/Open, Yellow/Closed, Buna O-Ring
AV-4B002 45º, Green/Open, Red/Closed, Buna O-Ring
Shaft Replacement Kits Mechanical Switches (M2 or T2)
"Standard shaft
AV-SSB201 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
"NAMUR Shaft
AV-NSB201 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
"Shaft Replacement Kits
GO™ Switches (L2 - Manufactured after July 1, 2007)"
"Standard shaft
AV-SSB205 Buna-N O-Rings & (2) Target Assembly w/ Hardware"
"NAMUR shaft
AV-SNB205 Buna-N O-Rings & (2) Target Assembly w/ Hardware"
"Shaft Replacement Kits
SCMs with Reed Switches (R2)"
"NAMUR Shaft
AV-NSB203 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
"Standard Shaft
AV-SSB203 Buna-N O-Rings & (2) cam Assembly w/ Hardware"
Consult Factory
To order replacement parts or for information concerning parts or spool valve options not listed call
TopWorx™ at 502-969-8000
64
TopWorx™ D-Series Replacement Part Number List Continued
Pilot Replacement Kits
AV-A24PRK 24vdc pilot
AV-A110PRK 110vac pilot
AV-A220PRK 220 VAC pilot
AV-S15MPMRK Piezo pilot
Spool Valve Replacement Assemblies
RKD-SV-B1A20 ASCO 1.06Cv Spool Valve, Fail Open/Closed, Aluminum
RKD-SV-B1620 ASCO 1.06Cv Spool Valve, Fail Open/Closed, SST
RKD-SV-B2A20 ASCO 1.06Cv Spool Valve, Fail Last, Aluminum
RKD-SV-B2620 ASCO 1.06Cv Spool Valve, Fail Last, SST
AV-AB1A30 ASCO 8553 Spool Valve, Fail Open/Closed, Aluminum
AV-AB1630 ASCO 8553 Spool Valve, Fail Open/Closed, SST
AV-AB2A30 ASCO 8553 Spool Valve, Fail Last, Aluminum
AV-AB2630 ASCO 8533 Spool Valve, Fail Last, SST
* If you are needing a replacement for a TopWorx™ switchbox with a non-ASCO spool valve, please consult the factory for a kit number.
65
Recommended Operating Temperatures
No Approvals (D XP/DXS) *DXR Enclosure limited to -40°C to 80°C
Option Switch Description Switchbox (NO Integrated Solenoid) Switchbox (WITH Integrated Solenoid)
L 35 GO™ Switch SPDT -60°C to +105°C Consult Factory

Z 35 GO™ Switch DPDT -60°C to +105°C Consult Factory
M Mechanical switch - SPDT -40 to +85°C Consult Factory
K Mech. switch w/Au contact -40 to +85°C Consult Factory
T Mechanical switch DPDT -40 to +85°C Consult Factory
R Reed Switch SPDT -40 to +80°C Consult Factory
E PEPPERL+FUCHS NJ2-V3-N -25° to 100°C Consult Factory
_X 4-20mA Transmitter -40 to +80°C Consult Factory
_H 4-20 Xmitter with HART -40 to +80°C Consult Factory
AS Asi -40 to +80°C Consult Factory
DN DeviceNet -40 to +80°C Consult Factory
PB Profibu -40 to +80°C Consult Factory
FF Foundation Fieldbus -40 to +80°C Consult Factory
FL Foundation Fieldbus w/GO -40 to +80°C Consult Factory
FP FF w/GO and potentiometer -40 to +80°C Consult Factory
ES ESD/PST -40 to +80°C Consult Factory
66
™
GLOBAL SUPPORT OFFICES
North America Asia-Pacifi Europe, Middle East, Africa

3300 Fern Valley Road 1 Pandan Crescent Horsfield ay
Louisville, Kentucky 40213 USA Singapore 128461 Bredbury Industrial Estate
1 502 969 8000 65 6777 8211 Stockport
info.topworx@emerson.com info.topworx@emerson.com SK6 2SU UK
44 0161 406 5155
info.topworx@emerson.com
Visit www.topworx.com for comprehensive information on our company,

capabilities, and products – including model numbers, data sheets,
specifications, dimensions, and certification
info.topworx@emerson.com
www.topworx.com
The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2016
Emerson Electric Co. ©2016 TopWorx™, All rights reserved.TopWorx™, and GO™ Switch
are trademarks of TopWorx™. All other marks used in this document are the property of their
respective owners. Information contained herein - including product specifications is subject to
change without notice.
ES-01857-1 R26
67
SENSOR USING SENSOR USING SENSOR USING
1.25” PISTON .50” PISTON .25” PISTON
X X X
X X X
X X X
No. PO PO15298
REV. DATE 2023-06-06

METERING SKID
6. FLOW COMPUTER
Totalflow product line
User manual
XSeries G4 6200/6201EX Flow Computer

2104349 ver. AD
2104349 (AD)
Proprietary information
© Copyright 2018 ABB, All rights reserved.
Intellectual property & copyright notice
©2018 by ABB Inc., Totalflow (“Owner”), Bartlesville, Oklahoma 74006, U.S.A. All rights reserved.
Any and all derivatives of, including translations thereof, shall remain the sole property of the Owner, regardless
of any circumstances.
The original US English version of this manual shall be deemed the only valid version. Translated versions, in
any other language, shall be maintained as accurately as possible. Should any discrepancies exist, the US
English version will be considered final.
Notice: This publication is for information only. The contents are subject to change without notice and should not
be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by
Owner.
Inquiries regarding this manual should be addressed to ABB Inc., Totalflow Products, Technical
Communications, 7051 Industrial Blvd., Bartlesville, Oklahoma 74006, U.S.A.
Trademark Ownership
Windows® is a registered trademark of Microsoft
Teflon® is a registered trademark of Dupont
Table of contents
Introduction ........................................................................................................................................... x
Organization & style.................................................................................................................................. x
Getting help .............................................................................................................................................. x
Before you call ............................................................................................................................ x
Key symbols ............................................................................................................................................. x
Safety practices and precautions ............................................................................................................. xi
Safety guidelines ...................................................................................................................... xii
Safety first ................................................................................................................................ xii
Equipment markings ................................................................................................................. xiii
Grounding the product .............................................................................................................. xiii
Operating voltage ..................................................................................................................... xiii
Danger from loss of ground ......................................................................................................xiii
Safe equipment ....................................................................................................................... xiv
Fuse replacement .................................................................................................................... xiv
Compliance ............................................................................................................................................ xiv
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE) .................... xiv
1 System description ............................................................................................................. 1–1
1.1 Overview ................................................................................................................................ 1–1
1.1.1 Capabilities............................................................................................................... 1–2
1.1.2 Functionality ............................................................................................................. 1–2
1.1.3 Flow computer calculations ...................................................................................... 1–3
1.1.4 Log period records ................................................................................................... 1–4
Display function ........................................................................................................ 1–5
1.1.6 Display annunciators ................................................................................................ 1–5
1.2 Computer hardware ................................................................................................................ 1–7
1.2.1 Enclosure ................................................................................................................. 1–8
1.2.2 G4 EX main processor board ................................................................................. 1–10
1.2.3 G4 EX termination board ........................................................................................ 1–12
1.2.4 Explosion proof multivariable transducer (EXIMV) ................................................. 1–17
1.2.5 Display assembly ................................................................................................... 1–19
1.2.6 Resistive temperature detector (RTD) .................................................................... 1–19
1.2.7 6270 Optional Equipment Unit (OEU) .................................................................... 1–20
1.2.8 Solar panel ............................................................................................................. 1–21
1.2.9 Lithium battery........................................................................................................ 1–22
1.3 G4 EX application licensing .................................................................................................. 1–22
1.3.1 Credit Key (USB).................................................................................................... 1–24
1.4 Laptop computer running PCCU32 ...................................................................................... 1–24
1.5 Local G4 EX connectors ....................................................................................................... 1–25
1.5.1 RS-232 serial PCCU cable (round military cable) .................................................. 1–25
1.5.2 PCCU32 USB connection ...................................................................................... 1–25
1.5.3 Bluetooth connectivity ............................................................................................ 1–26
1.5.4 Network connectivity (dynamic IP with router)........................................................ 1–26
2 Installation ............................................................................................................................ 2–1
2.1 Unpacking and inspection ...................................................................................................... 2–1
2.1.1 Unpacking ................................................................................................................ 2–1
2.1.2 Inspection ................................................................................................................. 2–1
2.1.3 Damaged components ............................................................................................. 2–1
2.2 2” Pole mount installation ....................................................................................................... 2–1
2.2.1 Type A ...................................................................................................................... 2–2
2.2.2 Type B ...................................................................................................................... 2–3
2.2.3 Type C ..................................................................................................................... 2–4
2.2.4 Manifold input lines .................................................................................................. 2–6
2104349– rev. AD Page iii

2.2.5 Standard RTD probe installation .............................................................................. 2–7
2.2.6 Explosion proof RTD probe assembly ...................................................................... 2–8
2.2.7 6270 Optional Equipment Unit (OEU) installation .................................................. 2–10
2.2.8 Battery Pack Installation ......................................................................................... 2–12
2.2.9 Lithium battery installation ...................................................................................... 2–13
2.2.10 Solar panel installation ........................................................................................... 2–14
2.2.11 AC charging unit installation ................................................................................... 2–16
2.2.12 Uninterrupted power supply (UPS) to the G4 EX ................................................... 2–18
3 G4 EX start-up ......................................................................................................................3–1
3.1 PCCU32 installation and setup ............................................................................................... 3–1
3.1.1 Step-by-step instructions .......................................................................................... 3–1
3.2 Establishing local communication ........................................................................................... 3–1
3.2.1 Connecting to a local port via a RS-232 cable ......................................................... 3–2
3.2.2 Connecting to local USB port ................................................................................... 3–3
3.2.3 Setup of the G4 EX for Bluetooth connectivity ......................................................... 3–5
3.2.4 Setup of the G4 EX for Ethernet connectivity ........................................................... 3–7
3.3 Setting up the G4 EX ............................................................................................................ 3–13
3.3.1 Date/time ................................................................................................................ 3–13
3.3.2 Station ID ............................................................................................................... 3–14
3.3.3 Location.................................................................................................................. 3–14
3.4 Security system .................................................................................................................... 3–14
3.4.1 Device legacy bi-level security ............................................................................... 3–14
3.4.2 WinCCU32 software security ................................................................................. 3–16
3.4.3 Role Based Access Control (RBAC) ...................................................................... 3–17
3.5 Application licensing Credit Key ........................................................................................... 3–25
3.5.1 Credit Key driver installation ................................................................................... 3–25
3.5.2 Access/view the Credit Key with PCCU32 7.0 (or later) ......................................... 3–25
3.5.3 Adding credits to the Credit Key by telephone ....................................................... 3–27
3.5.4 Transferring credits to the G4 EX from the Credit Key ........................................... 3–28
3.5.5 Transferring Credits to the Credit Key from the G4 EX .......................................... 3–29
3.6 G4 EX configuration ............................................................................................................. 3–30
3.6.1 Contact hour ........................................................................................................... 3–30
3.6.2 Log period .............................................................................................................. 3–31
3.6.3 Volume calculation period ...................................................................................... 3–31
3.6.4 Calculated method ................................................................................................. 3–31
3.6.5 Supercompressibility calculation (Fpv) ................................................................... 3–32
3.6.6 Constants ............................................................................................................... 3–33
3.6.7 Alarm Limits ........................................................................................................... 3–34
3.6.8 Reset Volume ......................................................................................................... 3–34
3.7 Start Up the G4 EX ............................................................................................................... 3–35
3.7.1 Putting the G4 EX On Line ..................................................................................... 3–35
3.7.2 Setting G4 EX Temperature Calculation ................................................................ 3–35
3.8 G4 EX Standard Displays ..................................................................................................... 3–35
3.8.1 Program Display ..................................................................................................... 3–35
4 G4 ex Maintenance...............................................................................................................4–1
4.1 Overview ................................................................................................................................ 4–1
4.1.1 Maintenance Support ............................................................................................... 4–1
4.1.2 How to Use This Chapter ......................................................................................... 4–1
4.1.3 Cleanliness............................................................................................................... 4–1
4.1.4 Front Mounted LCD .................................................................................................. 4–1
4.1.5 Returning Parts for Repair........................................................................................ 4–1
4.2 Backing Up Configuration Files .............................................................................................. 4–1
Page iv 2104349– rev. AD

4.3 Restoring Configuration Files ................................................................................................. 4–2
4.3.1 Step-by-Step Instruction ........................................................................................... 4–2
4.4 Performing a Warm Boot ........................................................................................................ 4–2
4.4.1 Hardware Warm Boot ............................................................................................... 4–2
4.4.2 Software Warm Boot ................................................................................................ 4–3
4.5 Performing a Cold Boot .......................................................................................................... 4–4
4.5.1 Hardware Cold Boot ................................................................................................. 4–4
4.5.2 Software Cold Boot .................................................................................................. 4–5
4.6 Changing the G4 EX Clock ..................................................................................................... 4–6
4.6.1 Clock Change Not Crossing an Hour Boundary ....................................................... 4–6
4.6.2 Forward Clock Change Crossing an Hourly Boundary ............................................. 4–6
4.6.3 Backward Clock Change Crossing an Hourly Boundary .......................................... 4–6
4.7 Replacing the G4 EX battery Pack ........................................................................................ 4–6
4.8 Replacing the G4 EX board .................................................................................................... 4–8
4.9 Replacing the G4 EX termination board ............................................................................... 4–13
4.9.1 Step-by-step instructions ........................................................................................ 4–13
4.10 Replacing the Liquid Crystal Display (LCD) board ............................................................... 4–15
4.11 Replacing the lithium battery ................................................................................................ 4–16
4.12 Replacing the transducer (EXIMV) ....................................................................................... 4–17
4.13 Calibration ............................................................................................................................ 4–19
4.13.1 Required test equipment ........................................................................................ 4–19
4.13.2 Hold mode .............................................................................................................. 4–20
4.13.3 Static pressure (SP) calibration checks .................................................................. 4–20
4.13.4 Differential pressure (DP) calibration checks ......................................................... 4–22
4.13.5 Calibrating static pressure (SP).............................................................................. 4–23
4.13.6 Calibrating differential pressure (DP) ..................................................................... 4–25
4.14 Onboard I/O calibration overview ......................................................................................... 4–26
4.14.1 Hold mode .............................................................................................................. 4–26
4.14.2 Calibrating onboard analog inputs.......................................................................... 4–26
4.14.3 Onboard pulse and digital inputs ............................................................................ 4–27
4.15 Zero transducer .................................................................................................................... 4–28
4.15.1 Static pressure ....................................................................................................... 4–28
4.15.2 Differential pressure ............................................................................................... 4–28
4.16 RTD calibration and bias ...................................................................................................... 4–28
4.16.2 Calibrating RTD temperature bias .......................................................................... 4–30
4.17 Changing the orifice plate ..................................................................................................... 4–30
4.17.1 Taking meter run out of service (simplex fitting) ..................................................... 4–30
4.17.2 Leaving meter run in-service procedure (senior fitting) .......................................... 4–31
5 Troubleshooting .................................................................................................................. 5–1
5.1 Overview ................................................................................................................................ 5–1
5.1.1 Troubleshooting support .......................................................................................... 5–1
5.1.2 Visual alarm codes ................................................................................................... 5–1
5.1.3 Sleep mode .............................................................................................................. 5–1
5.1.4 Solar panel ............................................................................................................... 5–1
5.1.5 Communication ........................................................................................................ 5–1
5.2 Troubleshooting visual alarm codes ....................................................................................... 5–2
2104349– rev. AD Page v

5.2.1 Troubleshooting a blank LCD screen ....................................................................... 5–4
5.2.2 Troubleshooting a Low Lithium alarm (LL) ............................................................... 5–4
5.2.3 Troubleshooting an Analog to Digital Failure alarm (AD) ......................................... 5–4
5.2.4 Resistive Temperature Detector (RTD) Continuity test ............................................ 5–6
5.2.5 RTD Current Source (Resistive) test ........................................................................ 5–6
5.2.6 RTD Impedance test ................................................................................................ 5–7
5.3 Power troubleshooting ............................................................................................................ 5–8
5.3.1 Overview .................................................................................................................. 5–8
5.3.2 Power supply test ..................................................................................................... 5–8
5.3.3 Charger Circuit test .................................................................................................. 5–9
5.3.4 Solar panel charging system test ........................................................................... 5–10
5.3.5 AC charging system unit test.................................................................................. 5–11
5.3.6 Auxiliary equipment isolation test ........................................................................... 5–12
5.3.7 Sleep mode ............................................................................................................ 5–13
5.3.8 Reset procedures ................................................................................................... 5–13
5.4 Communications troubleshooting ......................................................................................... 5–14
5.4.1 Overview ................................................................................................................ 5–14
5.4.2 Setting up communication ...................................................................................... 5–15
5.4.3 Transceiver supply voltage test .............................................................................. 5–16
5.4.4 6270 OEU supply voltage test ................................................................................ 5–16
5.4.5 Transceiver check .................................................................................................. 5–17
5.4.6 Termination board supply voltage test.................................................................... 5–17
5.4.7 RS-232 communication .......................................................................................... 5–18
5.4.8 RS-232 termination board test ............................................................................... 5–18
5.4.9 RS-232 OEU termination strip test ......................................................................... 5–19
5.4.10 RS-485 communication test ................................................................................... 5–20
5.4.11 RS-485 termination board test ............................................................................... 5–20
5.4.12 RS-485 OEU termination strip test ......................................................................... 5–22
6 Reference material .................................................................................................................23
6.1 Reference materials on ABB/Totalflow website ........................................................................ 23
6.2 I/O daughter card...................................................................................................................... 24
6.2.1 Materials supplied in the upgrade kit .......................................................................... 24
6.2.2 I/O daughter card specifications ................................................................................. 24
6.2.3 Installation .................................................................................................................. 24
6.2.4 Upgrading the flash .................................................................................................... 25
6.2.5 Unit operating status shut down instructions .............................................................. 26
6.2.6 Internal PCCU connector disassembly (if installed).................................................... 26
6.2.7 I/O daughter card installation ..................................................................................... 26
6.2.8 Internal PCCU connector reassembly (if previously installed) .................................... 28
6.2.9 Implementation ........................................................................................................... 28
6.3 4–20 milliamp transmitters ........................................................................................................ 34
6.3.1 Powering 4–20 Milliamp Transmitters ........................................................................ 34
6.3.2 Example 1 .................................................................................................................. 36
6.3.3 Example 2 .................................................................................................................. 36
6.3.4 Conclusion ................................................................................................................. 36
Page vi 2104349– rev. AD

Table of figures
Figure 1–1 Typical G4 EX installation ................................................................................................ 1–2
Figure 1–2 Liquid Crystal Display (LCD) and indicators ..................................................................... 1–6
Figure 1–3 G4 EX enclosure .............................................................................................................. 1–9
Figure 1–4 G4 EX enclosure left side ................................................................................................. 1–9
Figure 1–5 G4 EX enclosure right side............................................................................................. 1–10
Figure 1–6 G4 EX main processor board ......................................................................................... 1–11
Figure 1–7 G4 EX termination board ................................................................................................ 1–13
Figure 1–8 Typical DI point schematic ............................................................................................. 1–14
Figure 1–9 DI connection example ................................................................................................... 1–14
Figure 1–10 DI connection example ................................................................................................. 1–15
Figure 1–11 Typical DO point schematics ........................................................................................ 1–16
Figure 1–12 DO connection example ............................................................................................... 1–16
Figure 1–13 Typical AI point schematic............................................................................................ 1–17
Figure 1–14 AI example connections ............................................................................................... 1–17
Figure 1–15 Explosion proof multivariable transducer (EXIMV) ...................................................... 1–18
Figure 1–16 Liquid Crystal Display (LCD) assembly ........................................................................ 1–19
Figure 1–17 Explosion proof RTD .................................................................................................... 1–20
Figure 1–18 Optional communication enclosure .............................................................................. 1–21
Figure 1–19 Solar panel – typical installation ................................................................................... 1–22
Figure 1–20 RS-232 local communication cable .............................................................................. 1–25
Figure 1–21 USB local communication cable ................................................................................... 1–26
Figure 1–22 Ethernet communication cable ..................................................................................... 1–27
Figure 1–23 Ethernet connectivity diagram ...................................................................................... 1–27
Figure 2–1 Type A Installation Configuration ..................................................................................... 2–3
Figure 2–2 Type B Installation Configuration ..................................................................................... 2–4
Figure 2–3 Type C installation configuration ...................................................................................... 2–5
Figure 2–4 G4 EX EXIMV ports .......................................................................................................... 2–6
Figure 2–5 Thermowell installation into the meter run ....................................................................... 2–7
Figure 2–6 RTD probe wiring ............................................................................................................. 2–8
Figure 2–7 Explosion proof RTD overview ......................................................................................... 2–8
Figure 2–8 Explosion proof RTD disassembled ................................................................................. 2–9
Figure 2–9 RTD probe wiring ........................................................................................................... 2–10
Figure 2–10 6270 OEU pipe mounting installation ........................................................................... 2–11
Figure 2–11 6270 OEU wall mount installation ................................................................................ 2–12
Figure 2–12 6270 OEU enclosure .................................................................................................... 2–13
Figure 2–13 Lithium battery .............................................................................................................. 2–14
Figure 2–14 Solar panel installation ................................................................................................. 2–15
Figure 2–15 AC charger installed ..................................................................................................... 2–17
Figure 2–16 AC charger outlet box installation ................................................................................ 2–17
Figure 2–17 AC charger inside the conduit enclosure ..................................................................... 2–18
Figure 2–18 G4 EX to UPS .............................................................................................................. 2–19
Figure 3–1 System Setup Screen ....................................................................................................... 3–2
Figure 3–2 Windows found new hardware wizard .............................................................................. 3–3
2104349– rev. AD Page vii

Figure 3–3 Specific location selection window....................................................................................3–4
Figure 3–4 Specify location for USB driver (Totalflow.inf) ..................................................................3–4
Figure 3–5 System setup - Bluetooth ..................................................................................................3–6
Figure 3–6 Select a Bluetooth device dialog box ................................................................................3–6
Figure 3–7 System Setup dialog box - Bluetooth ...............................................................................3–7
Figure 3–8 Network tab .......................................................................................................................3–8
Figure 3–9 Communication setup .......................................................................................................3–9
Figure 3–10 System Setup window ..................................................................................................3–10
Figure 3–11 Windows desktop Shortcut dialog box ..........................................................................3–11
Figure 3–12 Network tab ...................................................................................................................3–12
Figure 3–13 System setup ................................................................................................................3–13
Figure 3–14 Station Setup tab ..........................................................................................................3–15
Figure 3–15 Security Setup dialog box .............................................................................................3–16
Figure 3–16 WinCCU32 Edit a Device ID dialog box .......................................................................3–17
Figure 3–17 Role administration menu path .....................................................................................3–18
Figure 3–18 Security Editor dialog box .............................................................................................3–18
Figure 3–19 Roles dialog box ...........................................................................................................3–19
Figure 3–20 User Name and Password dialog box ..........................................................................3–20
Figure 3–21 System Setup dialog box ..............................................................................................3–20
Figure 3–22 Send Role Based Access Control File dialog box ........................................................3–21
Figure 3–23 Totalflow-TCP Setup tab ...............................................................................................3–21
Figure 3–24 Login dialog box ............................................................................................................3–22
Figure 3–25 System Setup dialog box ..............................................................................................3–23
Figure 3–26 Security Log tab ............................................................................................................3–24
Figure 3–27 Credit Key License Utility ..............................................................................................3–26
Figure 3–28 Credit Key License Utility – Status ...............................................................................3–26
Figure 3–29 Application Credit Key entry screen .............................................................................3–27
Figure 3–30 Application Credit verification codes .............................................................................3–28
Figure 3–31 App Licensing tab .........................................................................................................3–29
Figure 3–32 Transfer to Credit Key ...................................................................................................3–30
Figure 4–1 Reset Button Location ......................................................................................................4–3
Figure 4–2 Lithium battery Connector .................................................................................................4–5
Figure 4–3 6270 OEU Configuration ...................................................................................................4–7
Figure 4–4 G4 EX Front End Exploded View......................................................................................4–9
Figure 4–5 Termination board ...........................................................................................................4–10
Figure 4–6 G4 EX board ...................................................................................................................4–11
Figure 4–7 G4 EX board Secondary Component Side. ....................................................................4–12
Figure 4–8 G4 EX Back End Exploded View ....................................................................................4–13
Figure 4–9 Termination board secondary component side ..............................................................4–14
Figure 4–10 EXIMV installation overview .........................................................................................4–17
Figure 4–11 G4 EX with block manifold ............................................................................................4–18
Figure 4–12 Calibration diagram .......................................................................................................4–22
Figure 4–13 RTD calibration screen .................................................................................................4–29
Figure 5–1 Troubleshooting flowchart .................................................................................................5–2
Page viii 2104349– rev. AD

Figure 5–2 LCD and indicators ........................................................................................................... 5–3
Figure 5–3 Power supply – G4 EX termination board ........................................................................ 5–4
Figure 5–4 G4 EX termination board .................................................................................................. 5–9
Figure 5–5 6270 OEU charger regulator .......................................................................................... 5–11
Figure 5–6 Current measurement troubleshooting cable ................................................................. 5–12
Figure 5–7 Communication troubleshooting flow chart .................................................................... 5–15
Figure 5–8 OEU termination strip ..................................................................................................... 5–20
Figure 6–1 Termination panel with I/O daughter card installed ............................................................ 25
Figure 6–2 32-Bit Loader screen .......................................................................................................... 25
Figure 6–3 I/O Interface screen ............................................................................................................ 27
Figure 6–4 I/O daughter card ............................................................................................................... 28
Figure 6–5 Generic Wiring Diagram ..................................................................................................... 29
List of tables
Table 1–1 XFC family genealogy ....................................................................................................... 1–1
Table 1–2 Typical G4 EX display options ........................................................................................... 1–5
Table 1–3 Default annunciator locations ............................................................................................ 1–6
Table 1–4 G4 EX status and alarm description .................................................................................. 1–6
Table 1–5 G4 EX main processor board specifications ................................................................... 1–11
Table 1–6 Explosion proof EXIMV specifications ............................................................................. 1–18
Table 1–7 Standard RTD probes ...................................................................................................... 1–20
Table 1–8 Standard Thermowells ..................................................................................................... 1–20
Table 3–1 Configurable calculation factors ...................................................................................... 3–31
Table 3–2 Fpv analysis data ............................................................................................................. 3–32
Table 3–3 Gas Orifice Constants ..................................................................................................... 3–33
Table 3–4 Alarm Limits ..................................................................................................................... 3–34
Table 3–5 G4 EX Displayed Items ................................................................................................... 3–35
Table 4–1 Calibration configurable parameters ............................................................................... 4–19
Table 5–1 Visual alarm codes ............................................................................................................ 5–3
Table 5–2 Specifications for solar panels ......................................................................................... 5–10
Table 5–3 RS-232 field wiring on the G4 EX termination board ...................................................... 5–18
Table 5–4 RS-485 field wiring on the G4 EX termination board ...................................................... 5–21
2104349– rev. AD Page ix

Introduction
This manual is designed to provide an experienced flow meter technician with the
requirements necessary to install, set up and operate a Totalflow XFCG4
6200/6201EX.
Organization & style

Each of the chapters in this manual presents information in an organized and
concise manner. Readers are able to look at the headings and receive a broad
picture of the content without reading every word. Also, there are overviews at the
beginning of each chapter that provides the user with an idea of what is in the
chapter and how it fits into the overall manual.
Readers will also note that each heading level number is formatted to include the
chapter, section, and subsection numbers. E.g. 4.15.2 indicates that the reader is
reading subsection 2 of section 15 in chapter 4.
Getting help
At Totalflow, we take pride in the ongoing support we provide our customers.
When you purchase a product, you receive documentation which should answer
your questions; however, Totalflow Technical Support provides you an 800
number as an added source of information.
If you require assistance, call:
USA: (800) 442-3097 International: 001-918-338-4888
Before you call

- Know your Totalflow’s model and serial number. Serial numbers can be
found on a plate located on each unit.
- Be prepared to give the customer service representative a detailed
description of the problem.
- Note any alarms or messages as they appear.
- Prepare a written description of problem.
- Know your software version, board and optional part numbers.
Key symbols
The following symbols may be used frequently in this manual. These are intended
to catch your eye and draw your attention to important information.
Intended to draw your attention to useful information or to

clarify a statement made earlier.
Intended to draw your attention to a fact that may be useful or

helpful in understanding a concept.
Page x 2104349– rev. AD

Intended to draw attention to a statement that might keep the
user from making a mistake, keep them from destroying
equipment or parts, or keep them from creating a situation that
could cause personal injury if caution is not used. Please refer
to the Safety Practices and Precaution section for additional
information.
Intended to draw attention to a statement regarding the

likelihood of personal injury or fatality that could result from
improper access or techniques used while working in
hazardous locations. Please refer to the Safety Practices and
Precaution section for additional information.
Intended to draw your attention to information regarding

security access to equipment, software security, or software
security features.
Intended to draw attention to a statement warning the user

about adverse effects of executing a particular procedure.
Adverse effects may include: service performance
degradation, loss of configuration, or complete service
disruption.
Indicates procedures that are only valid if system design

includes an Environmental Enclosure.
Intended to draw attention to information that may require

further investigation or consideration prior to continuing.
Safety practices and precautions

This manual contains information and warnings which have to be followed by the
user to ensure safe operation and to retain the product in a safe condition.
Installation, maintenance and repairs should only be performed by a trained and
qualified technician. Please refer to the certification drawings shipped with this unit
for specific guidelines. Extra copies of the certification drawings, referenced on the
unit’s name tag, can be obtained, free of charge, by contacting Totalflow Technical
Support at the number listed in the Getting Help section.
To ensure safe installation and operation of the equipment, the instructions that
are presented in this manual should be read carefully prior to their execution. As it
is impossible to cover every installation scenario that exists for a given device, the
instructions do not contain all possible details and do not take into account every
conceivable scenario. What is presented represents the most common scenarios
that a user will find in the field. If the information here does not cover the user’s
specific site scenario, call Totalflow Technical Support for further help in
implementing the installation.
2104349– rev. AD Page xi
Additionally, it should be pointed out that the following instructions are neither part
of nor provided for changing a previous existing agreement, promise or legal
relationship. The obligations adhered to by ABB Totalflow result from the
respective sales contract which also comprises the complete and solely valid
warranty clauses. These contractual warranty clauses will not be limited or
extended by the content of this manual.
Safety guidelines
- DO NOT open the equipment to perform any adjustments, measurements,
maintenance, parts replacement, or repairs until all external power supplies
have been disconnected.
- For assembly, electrical connection, installation and maintenance of the
device, only a qualified and authorized specialist should attempt these
tasks. A specialist would be one who is experienced in either assembly,
electrical connection, installation or maintenance of a given device and
holds the necessary qualifications for the task.
- When opening covers or removing parts, exercise extreme care "live parts
or connections can be exposed".
- Installation and maintenance must be performed by person(s) qualified for
the type and area of installation according to National and Local codes.
- Capacitors in the equipment can still be charged even after the unit has
been disconnected from all power supplies.
Safety first
Various statements in this manual identified as conditions or practices that could

result in equipment damage, personal injury or loss of life will be highlighted using
the following Icons.
Exercise caution while performing this task. Carelessness could

result in damage to the equipment, other property and personal
injury.
Page xii 2104349– rev. AD

STOP. Do not proceed without first verifying that a hazardous
condition does not exist. This task may not be undertaken until
proper protection has been accomplished, or the hazardous
condition has been removed. Personal injury or fatality could
result. Examples of these warnings include:
- Removal of enclosure cover(s) in a hazardous location must

follow guidelines stipulated in the Certification Drawings
shipped with this unit.
- If unit is installed or to be installed in a hazardous location,
technician must follow the guidelines stipulated in the
Certification Drawings shipped with this unit.
- Access to unit via PCCU cable in a hazardous location must
follow guidelines stipulated in the Certification Drawings
shipped with this unit.
- Connecting or disconnecting equipment in a hazardous location
for installation or maintenance of electric components
must follow guidelines stipulated in the Certification
Drawings shipped with this unit.
DANGER indicates a personal injury hazard immediately

accessible as one reads the markings.
CAUTION indicates a personal injury hazard not immediately

accessible as one reads the markings, or a hazard to property,
including the equipment itself.
Equipment markings
Protective ground (earth) terminal
Grounding the product
If a grounding conductor is required, it should be connected to the grounding

terminal before any other connections are made.
Operating voltage
Before switching on the power, check that the operating voltage listed on the
equipment agrees with the power being connected to the equipment.
Danger from loss of ground
A grounding conductor may or may not be required depending on the hazardous

classification. If required, any interruption of the grounding conductor inside or
outside the equipment or loose connection of the grounding conductor can result
in a dangerous unit. Intentional interruption of the grounding conductor is not
permitted.
2104349– rev. AD Page xiii

Safe equipment
If it is determined that the equipment cannot be operated safety, it should be taken

out of operation and secured against unintentional usage.
Fuse replacement
Fuses used on Totalflow electronic boards are surface mount and field repair
should not be attempted. Most fuses automatically reset themselves, but if a
known problem exists, the board should be sent in for repair or replacement.
Compliance
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE)
ABB Industrial Automation, Measurement and Analytics, is committed to actively protecting the
environment. Do not dispose of WEEE as unsorted municipal waste. Collect WEEE separately.
Participation in the management of WEEE is critical to the success of WEEE collection.
Electrical and electronic equipment marked using the crossed-out wheeled bin symbol
shall not be mixed with general household waste. Correct disposal at a recycling
facility will help save valuable resources and prevent potential negative effects on
health and the environment. These steps ensure compliance with the Waste Electrical
and Electronic Equipment (WEEE) Directive.
Waste electrical and electronic equipment (WEEE) shall be treated separately using the national
collection framework available to customers for the return, recycling, and treatment of WEEE.
Page xiv 2104349– rev. AD

1 System description
1.1 Overview
The XFCG4 6200/6201EX (G4 EX) is a next generation solution for the pre-existing
generation 3 XFC6200/6201EX. The G4 EX now incorporates the same 32-bit
technology currently used by the G4 XSeries products. By using 32-bit technology,
Windows® CE OS and memory capabilities, the G4 EX is a versatile product
offering for production automation and DIV 1 custody measurement projects.
Along with this new functionality, the hardware capabilities are expanded to meet
the demands of targeted market applications in production automation and natural
gas distribution. These hardware features will be utilized to enhance the system
integration capabilities with existing Totalflow products as well as existing third-
party control SCADA systems. Additionally, the use of Bluetooth technology for
local MMI connectivity is poised to enhance the product for multi-tube and Class 1,
DIV 1 applications where this type of user interface is an advantage.
The G4 EX offers an explosion-proof product for differential (orifice) or linear
(pulse) metering and automation systems. The G4 EX is an accurate and reliable
gas flow computer with the capability to measure and monitor gas flow in
compliance with AGA, API and ISO standards.
The G4 EX is a low power, microprocessor-based unit designed to meet a wide
range of measurement, control, monitor and alarming applications for remote gas
systems located in DIV 1 hazardous areas.
See Table 1–1 for the XFC family genealogy. This highlights the main differences
between the various devices.
The XFC G4 6200/6201EX (G4 EX) is approved for installation

in Classified/Potential Hazardous Locations where an
explosive atmosphere may be present. Follow precautions and
requirements for installation, maintenance and service of
equipment according to Local and National Electrical Codes
and the “Warnings” contained in this manual.
Table 1–1 XFC family genealogy

Max.
XFC DIV Multi Orifice Pulse Battery Communication Max. TFIO
Battery
Model Class Tube Meter Meter Charger Equipment Modules
Capacity
12-Point I/O Opt.
6200EX 1 ● External External External
Expansion Card
12-Point I/O Opt.
6201EX 1 ● External External External
Expansion Card
6410 2 ● ● On board 26AH External N/A
6411 2 ● ● On board 26AH External N/A
6413 2 ● ● On board 26AH Internal 3
2104349 rev. AD Page 1–1

1.1.1 Capabilities
The G4 EX is packaged in a small, explosion-proof cast aluminum enclosure
which accommodates the processor board, termination board and display. The
power supply, charging source and radio communication applications must be
housed in separate accommodations. See Figure 1–1.
For the G4 EX, the integral multivariable transducer (EXIMV) is a separate unit
with no internal electronics and is attached to the bottom of the enclosure via a
threaded neck. This contains the wiring for the connection to the electronics that
are located in the enclosure.
The G4 EX defaults to the retention of daily and log period records for 40 days
and the retention of 200 events. These defaults can be extended, limited only by
the file storage spaces on the device.
The G4 EX may be used in conjunction with a laptop that is running PCCU32
software. PCCU32 is required for initial setup and setup of the advanced features.
The G4 EX maintains a history of alarms as well as average differential pressure
(DP), average static pressure (SP), average flowing temperature (Tf),
accumulated volume, energy and an average extension.
The G4 EX can be programmed to calculate flow rates and volumes in
accordance with AGA-3, AGA-7 or ISO-5167.
Supercompressibility calculations can be performed in accordance with either NX-
19, AGA-8 or ISO 12213-2.
Figure 1–1 Typical G4 EX installation
1.1.2 Functionality
Functions of the G4 EX reflect a design that is practical, straightforward and
efficient. It is simple to use and easy to learn. This functionality allows for saving
time that is usually allotted for calculations and report preparation. This flow
computer allows the user to perform the following with a minimum of effort,
maximum speed and greater accuracy.
Page 1–2 2104349 rev. AD

Complete log period flow and operational records that are reported hourly
(default), including:
- Average static pressure
- Average differential pressure
- Average flowing temperature
- Integral
- Corrected volume total
- Corrected energy total
- Operating status and alarms
- Flow time
Complete daily flow records, including:
- Average flowing temperature
- Average extension
- Corrected volume total
- Corrected energy total
- Operating status and alarms
Complete daily operation statistics, including:
- Percent flowing time
- Percent back flow time
- Percent out of limits (programmable) on SP, DP, Tf and flow rate
- Minimum and maximum values for SP, DP, Tf and flow rate
1.1.3 Flow computer calculations

The records and statistics generated are based on the following calculation
methods of the G4 EX:
- Calculation of flow rates and volumes in accordance with AGA 3–85, AGA
3–92, AGA-7 or ISO-5167.
- Calculation of flow rates and volumes in accordance with AGA-8 92 Gross
or Detail or NX-19 Supercompressibility Standards.
- Calculation of flow extension for the AGA3-92 equation is Dp* Sp ,

Tf  459.67
once per second.
- The flow extension reported for the log period is:
Dp* Sp
/ 3600 * flow time in sec onds
Tf  459.67
- Calculation of the flow extension for the AGA3-85 equation is Dp * Sp ,

once per second.
- Extrapolation of flow accumulation during transducer calibration or
calibration checks.
- Selection of all coefficients for calculation; the calculation of dynamic factors
(dependent upon DP, SP and Tf) using averages is based on one second
samples.
2104349 rev. AD Page 1–3

- Sample set of most recent calculations allowing subsequent verification.
- Monitoring of the operational limits, minimums and maximums to ensure
detection and reporting of malfunctions or abnormal site conditions.
- Acceptance and storage of system constants from the PCCU32 or remote
communications protocols.
- Storage of data records and operational events is determined by user
(based on available memory).
1.1.3.1 Additional features

Additional features of the Totalflow system’s flexibility include the following:
- Programmable differential pressure zero cutoff.
- Programmable bi-level security codes to prevent unauthorized access to
and configuration of the G4 EX or user-configurable Role Based Security
Access (RBAC).
- Internal 100 Ohm platinum RTD resistance curve fit with user-
programmable single point offset or 3/5-point user-calibration of the RTD
input.
- Quick, simple calibration procedures for transducer.
- Real-time clock providing a highly stable time base for the system.
- Proper battery and solar sizing is determined by geographic location of the
unit and total power consumption of the system. Totalflow project engineers
can select the appropriate battery and solar requirements for the user’s
specific application. Larger capacity batteries are available to increase
autonomy, if required.
- Three available power sources:
- External solar panel (standard)
- External AC or AC to DC power
- External 24/12 VDC power
- Liquid crystal display (LCD) programmable to allow monitoring of the G4 EX
operations and can display any variable that has a register (for example,
displays current static pressure).
- Three serial communication ports are available on the G4 EX: 1 dedicated
RS-232 Local and 2 user-programmable RS-232/RS-485 Remote
Communication ports.
- USB and 10Base T Ethernet port.
- USB or RS-232 serial may be ordered as local, externally accessible Local
Communication Interface port.
1.1.4 Log period records

Each record has entries that contain the following information (and more):
- Average flow temperature
- Calculated volume
1.1.4.1 Log period data entries

Log period data entries are made every 60 minutes, by default. The user may
change this period to any one of the seven (7) choices (1, 2, 5, 10, 20, 30, 60).
Page 1–4 2104349 rev. AD

Choosing a log period of less than 60 minutes will result in additional records
being logged. As a result, this requires more storage space to hold a full day’s
data. The log period must never be less than the volume calculation period.
1.1.4.2 Volume calculation period entries

Volume calculation period entries are made every second, by default. The user
may change this period up to 60 minutes. API 21.1 strongly suggests a volume
calculation period (QCP) of once per second.
The volume calculation period should never be greater than the log period and
should be evenly divisible into the log period.
Volume calculations are completed, following the top of the current period (i.e., top
of the hour, top of the minute, each second).
Display function
During operation, the front panel LCD continuously scrolls through the operating
parameters. Table 1–2 shows the typical displayed parameters; however, many
parameters with a register address can be displayed. The duration that the
parameter is displayed can vary from 1 to 255 seconds (default is five seconds); a
setting of zero seconds will set any item to Off. See the Program Display section
and the PCCU32 Help Files for additional information.
Table 1–2 Typical G4 EX display options

Display Description
DATE/TIME MM/DD/YY
Current date and time, 24 hour clock
HH:MM:SS
YEST DP LOW NN PERCENT Yesterday’s % time below DP Low Set Point
YEST DP HIGH NN PERCENT Yesterday’s % time below DP High Set Point
FLOW RATE NNNNNN.N SCF/HR Current flow rate, programmable SCF, MCF or MMCF
Total accumulated volume, programmable SCF, MCF
TOTAL ACCUM VOL NNNNNN.NN MCF
or MMCF
DIFF PRESS NNN.N IN. H2O Differential pressure, inches H2O
PRESSURE NNN.N PSIA Static pressure absolute, PSIA
FLOW TEMP NN.N DEG. F Flowing temperature, °F
Yesterday’s volume, programmable SCF, MCF or
YEST VOL NNNN.N MCF
MMCF
PERIOD VOL NNNN.N SCF Last volume calculation period volume
BATTERY VOLTAGE NN.N VOLTS Battery voltage as supplied by external unit
M_FLOWRATE NNNNNN.N SCF/HR Minute average flow rate
STATION ID ID of unit
ORIFICE DIAMETER N.NNNN INCHES Size of orifice plate
1.1.6 Display annunciators

Since a primary function of the G4 EX is to provide complete volume and
operational records, it is important to indicate unusual or alarm conditions as they
occur. This is supported on the LCD in the Annunciator display area shown in
Figure 1–2.
2104349 rev. AD Page 1–5

In the G4 EX computer, the status and alarm indicators are user programmable.
Table 1–3 identifies the default annunciator locations. Please consult the PCCU32
Help Files for additional instructions on programming the annunciators.
Whenever an alarm is indicated, the G4 EX records it in the appropriate log period
flow record. These are automatically retrieved when data is collected. Visual
alarms and status codes are described in Table 1-4.
Figure 1–2 Liquid Crystal Display (LCD) and indicators
Table 1–3 Default annunciator locations
Annunciator Application
A1 Measurement Tube 1
A2 CIM 0
A3 Valve Control
A4 COM2
A5 Plunger
A6 Local-COM0
A7 System
A8 TF Remote – COM1
Table 1–4 G4 EX status and alarm description
Indicator Description
System
LL Low Lithium Battery Alarm: When LL (low lithium) is displayed, lithium battery voltage is not
sufficient to maintain SRAM data. A new lithium battery measures approximately 3.6 VDC.
Display Application
1 A number represents the Display Group number currently being displayed.
The displayed item’s value is above the Data High Limit value specified on the display Item
↑
Setup screen.
The displayed item’s value is below the Data Low Limit value specified on the display Item
↓
Setup screen.
Page 1–6 2104349 rev. AD

Communications
 Transmitting Data: Sending a response.
 Receiving Data: Processing request.
! Negative Acknowledgement (Nak) w/packet list.
+ Positive Acknowledge (Ack) of receipt of request.
Waiting for Positive Acknowledgement: Waiting for response after transmission.
? Exception Alarm Processing.
ID Recognized: Recognized and receiving request.
Listen Cycle: Flashes if this remote port is active and running Totalflow Remote Protocol.
Flashes in sync with listening cycle that occurs at 1, 2 or 4 second intervals. May not be
visible if baud rate is faster than 2400. Annunciator will remain on if listen cycle is set to zero.
M MODBUS ASCII: MODBUS ASCII protocol selected for the port assigned to this annunciator.
m MODBUS RTU: MODBUS RTU protocol is selected for the port assigned to this annunciator.
L Local Protocol: Displayed when PCCU32 port is active and running Totalflow Local Protocol.
n Network (Ethernet).
u USB.
Measurement Application
BF Back Flow Condition: Visible only when DP variable displayed.
Z Zero Flow Condition: Visible only when Flow Rate displayed.
H Hold: Displayed when PCCU32 has entered Calibration mode on a Measurement Application.
Alarm Condition: Need to view alarm. The user may need to compare application limits to
A
current values to determine where the alarm condition is present.
A to D Failure: Displayed if A to D Converter’s differential pressure, absolute static pressure or
AD
temperature readings exceed maximum counts or are less than minimum counts.
1.2 Computer hardware

The G4 EX computers are housed in an explosion-proof enclosure. The
components that comprise this are as follows:
- G4 EX enclosure (3R/IP53 with breather drain installed; 4X/IP66 without
breather installed)
- G4 EX main processor board
- G4 EX termination board
- Lithium battery
- Engine Card
- G4 EX Liquid Crystal Display (LCD) Assembly
- PCCU Connector
- Internal Connector
- Explosion Proof External Connector – USB/Miltary (optional)
- Explosion Proof integral multivariable transducer with Raw Sensor board
Interface
- Resistive Temperature Detector
- Standard RTD (DIV 2)
- Explosion Proof RTD (DIV 1)
2104349 rev. AD Page 1–7

1.2.1 Enclosure
The custom-designed, explosion-proof enclosure consists of a cylinder shaped,
cast aluminum housing, powder coated, with front and rear end caps for access to
internal components (see Figure 1–3 through Figure 1–5). This enclosure may be
direct mounted, pipe mounted on the meter run using a pipe saddle or mounted on
a standalone pipe.
The enclosure features three (3) exterior hubs for wiring:
- Communication and power
- Resistive temperature detector (RTD)
- Input/output wires
The end caps have precision engineered threading and are susceptible to damage
if treated roughly. End caps are water tight, corrosion resistant and NEMA 4X
rated. Unauthorized removal of the end caps are protected with a 1/16”
countersunk hex head set screw on each end cap.
Remove power from the device, or insure the area is known to be

non-hazardous before removing any enclosure cover. For further
information, refer to the certification drawing indicated on the
device’s nametag and national and local electrical codes.
Do not attempt to loosen the end cap before loosening the set
screw. Doing so may damage threads on the unit.
1.2.1.1 Dimensions
Width
Unit w/o External w/ External Height Depth
PCCU PCCU
US 7.87” 9.50” 11.25” 8.34”
Metric 199.90 mm 241.30 mm 285.75 mm 211.84 mm
1.2.1.2 Installation and weight

W/ EX PCCU Pipe Mounted Direct Mounted
Unit Weight
Connector Depth Depth
US 15.65 lbs. 16.35 lbs. 9.69” 8.34”
Metric 5.84 kg 6.10 kg 246.13 mm 211.84 mm
Page 1–8 2104349 rev. AD

(9.50)
(7.87)
¾ NPT CONDUIT ENTRIES
¾ NPT CONDUIT ENTRIES
(01.53)
XFCG4 EX
(30º)
(01.84)
¾ NPT CONDUIT ENTRIES OPTIONAL EXTERNAL

PCCU FLAMEPROOF
HOUSING (2101416-001)
(3.76)
Figure 1–3 G4 EX enclosure
Figure 1–4 G4 EX enclosure left side
2104349 rev. AD Page 1–9

Figure 1–5 G4 EX enclosure right side
1.2.2 G4 EX main processor board

The G4 EX main processor board is mounted inside the front end cap, directly
behind the display assembly (see Figure 1–6 ).
User applicable connections on this board consist of the following:
- USD card (J3)
- Contrast display potentiometer (R1)
- LCD display connector (J2)
- Lithium battery connector (J5)
- Engine card connector (XA1)
- Sensor interface connector (J6)
- Termination board connector (J1)
The G4 EX transducer assembly utilizes a small electronic

board that contains the factory characterization data. This
allows the main electronics on the sensor assembly to be
individually field replaceable in the event of failures.
Installation and/or maintenance of electric components must

follow guidelines stipulated in the certification drawings
shipped with this unit and adhere to local codes.
Page 1–10 2104349 rev. AD

Figure 1–6 G4 EX main processor board
1.2.2.1 Engine card

An engine card plugs into the G4 EX board. All processor and memory
components reside on this engine card. The engine card uses a low power
processor running at 203 MHz with 16MB PSRAM for program execution and data
storage, 32MB Flash for application storage and 256 bytes of serial E2PROM. A
lithium backup battery is located on the main G4 EX board. Application programs
and configuration files are stored in non-volatile Flash.
1.2.2.2 G4 EX main processor board specifications

The G4 EX main processor board is designed as a general purpose motherboard
for the 6200/6201EX devices.
Table 1–5 G4 EX main processor board specifications
Component Description
Power 9 to 30 VDC
SWVBAT: 1 fused with 2.5 amp PTC
External Power
VBAT: 1 fused with 2.5 amp PTC
Charger No Charger
Application (Totalflow.exe) runs out of 16M SRAM. RAM memory has lithium
backup battery.
Memory Application and configuration files permanently stored in 32M Flash.
Registry (MAC address, etc.) is stored in 256 byte E2PROMSD Card
SD Card optional (512M/1G)
6 Ports Available
Dedicated PCCU/MMI (RS-232 or USB)
2 Onboard User Programmable RS-232/RS-422/RS-485 Ports
Comm. Ports USB (Client)
NOTE: A special cable is required, and the user must check with Totalflow for a
list of drivers to support Client peripherals.
Ethernet Bluetooth – Standard on the Main Electronics board
2104349 rev. AD Page 1–11

Component Description
Analog Inputs 1 (0-10 VDC)
1 (State Change or Pulse to 20 kHz) operating at a 50% duty cycle
Digital Inputs
with (Selectable De-bounce enabled 100 Hz)
Digital Outputs 1 FETs, sink = 2.5 Amp Max.Open Drain PTC, with 1500 W Transient protection
I/O Module Interface Optional plug-in I/O daughter card with 12 I/O (3 AI, 1 AO, 4 DI and 4 DO)
LCD Interface Dedicated interface for Liquid Crystal Display (LCD)
Security Switch On/Off Bi-level on-board Security (See Chapter 3 for details)
I/O Scan Rate 1 time per second
Time Base Stability  7.5 ppm (parts per million)
Pulse Input
Up to 20 KHz (Linear flow meter only)
Bandwidth
1.2.3 G4 EX termination board

The G4 EX termination board can be accessed by removing the rear end cap (see
Figure 1–7). All user connections should be routed through the cable entry hubs
and should adhere to local codes.
Located on the termination board, the user will find connectors for two (2)
communication ports: RS-232, RS-422 or RS-485 (software selectable). The user
should also note that there is a dedicated port for RS-232 local communications.
This is a plug type port and will connect to an internal PCCU connector or an
explosion proof external PCCU connector.
For more information on the explosion proof PCCU connector, see the
corresponding section. Additionally, for the internal PCCU connector, see the
section under Optional Equipment in this chapter.
Remote communication wiring for Port 1 is handled using the
COM 1 Port
J19 connector and the SW1 communication switch.
Remote communication wiring for Port 2 is handled using the
Com 2 Port
J20 connector and the SW2 communication switch.
The XFC G4 6200/6201EX (G4 EX) is approved for installation

in classified/potential hazardous locations where an explosive
atmosphere may be present. Follow precautions and
requirements for installation of equipment according to the
certification drawing indicated on the device’s nametag and
national and local electrical codes.
Page 1–12 2104349 rev. AD

Figure 1–7 G4 EX termination board
1.2.3.1 On-board I/O

The G4 EX termination board provides similar base I/O as earlier XSeries models
but with a reduced number due to enclosure restrictions. This includes:
- 1 user AI
- 1 user DO
- 1 user DI
- Interface for I/O daughter card: 3 AI, 1 AO, 4 DI (NAMUR rated) and 4 DO
1.2.3.2 Digital input

The G4 EX provides one digital/pulse input as a means to monitor external
equipment.
When connecting or disconnecting any wires to the G4 EX

boards, the user should remove all power sources and
insure that they are grounded properly.
The digital input reads an external contact. This is primarily used as a status input
to read external equipment. The contact must be closed to be considered “ON”.
The “ON” condition is recorded in the log period alarms and can trigger the action
of the G4 EX’s digital voltage output. OFF is defined as an open contact.
Selectable de-bounce can be enabled or disabled within PCCU32. See the
PCCU32 Help Files for additional information.
DI electrical specifications
- Open circuit voltage: 5 VDC (Internally pulled up to 5 VDC Nom.).
- Short circuit leakage current: -395 uA typical.
2104349 rev. AD Page 1–13

- Input capacitance: 0.1 ufd typical.
- Maximum allowable voltage range on input: -0.5 VDC to 15 VDC.
- Maximum frequency input: 100 Hz @ 50% duty cycle with de-bounce
enabled. 20 kHz @ 50% duty cycle with de-bounce disabled.
Input specifications
- Dry contact (form A), open collector or active voltage.
- Minimum contact resistance to activate input 1000Ω.
- Voltage threshold to deactivate the input: 3.1V (referenced to GND
terminal).
- Voltage threshold to activate the input: 0.5V (referenced to GND terminal).
- Conductor pairs must be shielded to prevent spurious signals.
Figure 1–8 Typical DI point schematic
Figure 1–9 DI connection example
Page 1–14 2104349 rev. AD

Figure 1–10 DI connection example
1.2.3.3 Digital output

The G4 EX provides one digital output (12 VDC or 24 VDC max.) as a means to
control external equipment.
When connecting or disconnecting any wires to the G4 EX

boards, the user should remove all power sources and
ensure that they are grounded properly.
The digital output can be used in conjunction with a measurement tube (AGA-3,
AGA-7 or liquid measurement) and triggered on the following measurement
parameters or conditions:
- Differential pressure over high limit
- Volume set point
- Differential pressure under low limit
- Flow temperature low
- Static pressure over high limit
- Flow temperature high
- Static pressure under low limit
- Flow rate low
- Low charger voltage
- Flow rate high
- Remote sense is on
- Trip on digital input
Custom programmable by Totalflow or user programmable with IEC 1131
programming language
DO electrical specifications
- Open circuit voltage: 0 VDC
- Short circuit leakage current: 0 uA typical
- Output capacitance: 1000 pF typical
- Maximum allowable voltage range on output: 0.5 VDC to 29.4 VDC
Output specifications
- Open drain FET type
2104349 rev. AD Page 1–15

- “ON” resistance (Including PTC fuse resistance): 0.1Ω Typical
- Maximum pulse current: 3A for 5 seconds
- Maximum continuous sink current: 1.2A at 60C or .75 at 85C
Typical DO point schematics
Figure 1–11 Typical DO point schematics

DO connection example
Figure 1–12 DO connection example
1.2.3.4 Analog input

The G4 EX provides one analog input as a means of receiving data, represented
by continuously varying voltage/current.
- Open circuit voltage: 0 VDC
- Short circuit leakage current: 0 uA typical
- Input impedance: 103.5KΩ typical (0 to 10V)
- Measurable input voltage range: 0 to 10.34 VDC
- Maximum voltage on input: 30 VDC
Page 1–16 2104349 rev. AD

Figure 1–13 Typical AI point schematic
Figure 1–14 AI example connections
1.2.4 Explosion proof multivariable transducer (EXIMV)

The EXIMV is an explosion proof version of the factory calibrated “smart” integral
multivariable transducer. The EXIMV is characterized over temperature so that
any changes occurring in the EXIMV or in the electronics can be compensated.
Providing the primary measurement capability for the G4 EX (see Figure 1–15 ),
the circuitry and characterization information are stored in the raw sensor board.
EXIMV specifications are discussed in Table 1–6.
2104349 rev. AD Page 1–17

The unit is designed to provide EMI/RFI protection of the low level signals and to
protect the circuitry from other environmental effects.
Figure 1–15 Explosion proof multivariable transducer (EXIMV)
Table 1–6 Explosion proof EXIMV specifications

Compensated: -20°F to 140°F (-29°C to 60°C)
Temperature limits Operational: -40°F to 140°F (-40°C to 60°C)
Storage: -40°F to 185°F (-40°C to 85°C)
Resolution 24 Bit A/D conversion (0.000012% FS) (0.0012% FS effective signal resolution)
Mounting spec. Change from perpendicular (front to back around X-axis) ≤0.5% URL
Static pressure
Linearity, Hysteresis and repeatability combined: ± 0.075% of user-calibrated spans from
Accuracy
20% to 100% of URL
Ambient temperature
effect within the
± 0.075% of URL +0.06% of Reading
operational
temperature limit
Stability ± 0.1% of URL (for 12 months)
Differential pressure
Linearity, Hysteresis and repeatability combined: ± 0.075% of user-calibrated spans from
Accuracy
20% to 100% of URL.
Ambient temperature
effect within the
± 0.075% of URL + 0.06% of Reading
operational
temperature limit
Stability ± 0.1% of URL (for 12 months)
Page 1–18 2104349 rev. AD

DP Zero per 1500 psi: ± 0.03% of URL (3200 psi maximum)
SP effect
DP Span per 1500 psi: ± 0.1% of Reading (3200 psi maximum)
Temperature
Operating range -80F to 750F (-62C to 339C)
± 0.35F (± 0.2C)over operating range (as shipped from factory)
Accuracy
± 0.2F (± 0.12C) repeatability over operating range (after single point field calibration)
1.2.5 Display assembly

The G4 EX display assembly (see Figure 1–16) has a dedicated interface to the
main processor board from the 4x16 LCD via a 14-pin connector.
The display utilizes four lines by 16 characters. The user can then customize the
annunciators based on their own specific needs. The alarm codes and
annunciators communicate a basic message(s) to the user and indicate a need for
further attention. These codes are location dependent and may mean different
things, based upon which character space the code appears in. These are also
user configurable.
Figure 1–16 Liquid Crystal Display (LCD) assembly
1.2.6 Resistive temperature detector (RTD)

Totalflow offers a choice of two RTD options. The 100 OHM Platinum RTD
measures real-time flowing temperature of the gas.
1.2.6.1 Standard RTD

The standard RTD is not DIV 1 approved; therefore, this RTD may only be
installed and used in general purpose areas.
2104349 rev. AD Page 1–19

1.2.6.2 Explosion proof RTD
The explosion proof RTD is available for use in DIV 1 areas (see Figure 1–17).
Two probe lengths are available: 10” and 16”. See Table 1–7 for standard probes,
based on Thermowell “U” lengths and Table 1–8 for standard Thermowells that
are based on thread diameter.
Figure 1–17 Explosion proof RTD
Table 1–7 Standard RTD probes
“U” Length Part Number “U” Length Part Number

2.00” 2101691–020 6.00” 2101691–060
2.50” 2101691–025 7.00” 2101691–070
3.00” 2101691–030 8.00” 2101691–080
4.00” 2101691–040 9.00” 2101691–090
5.00” 2101691–050 10.00” 2101691–095
Table 1–8 Standard Thermowells

Thread Diameter “U” Length Base Part Number
½” 2” through 10” 1622305
1” 2” through 10” 1622302
3/4” 2” through 10” 1622300
1.2.7 6270 Optional Equipment Unit (OEU)

The G4 EX unit is designed to be located in DIV 1 Hazardous areas; therefore,
many features and requirements of the unit are housed in a separate enclosure
that is located in DIV 2 or General Purpose areas.
Space is provided inside the enclosure to house a variety of remote
communication devices: transceiver, cellular phone, battery, changing source and
additional I/O (see Figure 1–18).
Page 1–20 2104349 rev. AD

The battery compartment shelf houses various optional battery packs that are
available for the OEU, from eight (8) ampere hours up to 26 ampere hours.
Installation of the battery is discussed later in the manual.
The 6270 OEU system with battery and solar panel is rated for
Class I, Division 2 locations only or can be installed in non-
hazardous locations.
Figure 1–18 Optional communication enclosure
1.2.8 Solar panel

A solar panel can be configured in the system to provide a charging source for the
battery. DIV 1 installations would require that the solar panel and battery pack be
installed in a General Purpose or DIV 2 area. Typically, the solar panel would be
connected through a charger regulator that is located in the 6270 OEU.
Depending upon power/charging requirements, the unit may be configured for a 5-
watt, 10-watt, 20-watt or 30-watt solar panel. The panel is designed to be mounted
on a 2-inch extension pipe.
2104349 rev. AD Page 1–21

Figure 1–19 Solar panel – typical installation
1.2.9 Lithium battery

The following information displays the technical information regarding the lithium
battery housed within the G4 EX.
When the G4 EX is in storage, it is recommended that the

lithium battery be disabled (unplugged from J5 connector) to
prevent power drainage. Not doing so can cause the battery to
lose power within six months.
Technical Data
Nominal capacity @
2.1 Ah
2 mA, to 2V
Rated voltage 3.6 V
Wires AWG 24
Enclosure UL 94V2
Mounting Hook and loop fastner
Operating
-55°C to +85°C/-67°F to +185°F
temperature range
1.3 G4 EX application licensing

The G4 (fourth generation) EX offers the user unrivaled power and flexibility. The
G4 EX units can support far more applications than the G3 (third generation)
devices. Various applications require that Totalflow pay a royalty to third party
vendors. As such, Totalflow has developed a credit system for handling
application loads beyond what would be required for a typical G3 meter run.
Application credits are required to enable many of the applications.
Page 1–22 2104349 rev. AD

From the factory, the G4 EX has four general credits installed. Several system
configurations are possible with these four general credits:
- AGA-3 with Plunger Lift and Trending (uses 3 general credits)
- Two AGA-3 (or AGA-7) tubes with Trending (uses 3 general credits)
- AGA-3 with Pad Control and Plunger Lift (uses 3 general credits)
Applications are divided into categories: standard, general, IEC and CO2. Other
application categories may be created in the future.
Standard applications typically support general applications as well as the basic
operation of the G4 EX unit. Standard applications do not require any credits to be
instantiated.
Standard applications include:
- System Application
- Communications
- I/O Subsystem
- Therms Master
- Therms Slave
- Analysis Trend System
- LevelMaster
- Pulse Accumulator
- NGC Client
- PID Controller
- Operations
- XMV Interface
- Holding Registers
- Units Conversion
- Host Interface
- Displays
General applications typically provide some type of measurement, control, logging
and/or archival function. General applications include:
- AGA-3 Measurement
- AGA-7 Measurement
- V-Cone Measurement
- Coriolis Gas
- Alarm System
- Shutdown
- Plunger
- PAD Controller
- Pump Interface
- Oil Custody Transfer Measurement
IEC applications are generally custom applications provided by Totalflow at the
customer’s request. This might include special control and/or measurement
algorithms required by the customer. Multiple IEC applications can be instantiated
with a single IEC credit.
- CO2 (NIST) applications each require a CO2 (NIST) credit.
2104349 rev. AD Page 1–23

1.3.1 Credit Key (USB)
The G4 EX comes with four general credits installed in the unit. If the system
configuration requires more application credits, they can be purchased from
Totalflow’s Order Entry (1-800-442-3097).
Credits (standard, general, IEC and CO2) are maintained on the credit key.
Credits can be purchased and kept on the USB credit key. The credit key is a
secure USB Flash drive (i.e., thumb drive). It cannot be written to or read by any
program other than PCCU32 7.0 or later. Credits can be added to the credit key
via a phone call to Technical Support or through email. Again, these credits are
used to run the various applications available in the G4 product line.
Credits can be transferred between the laptop and the G4 EX. If a G4 EX has
extra credits (more than required to be fully licensed), the extra credits can be
downloaded to the credit key to be used on other G4 units.
If the G4 controller is running an unlicensed application, that

fact is reflected in any reports generated from that
unlicensed meter. The meter will also log the fact that it is
unlicensed in the Event Log at the top of each contract day.
Unlicensed applications cause the meter to connect more
slowly.
1.4 Laptop computer running PCCU32

PCCU32 software running in a laptop Windows® environment offers the user the
most capabilities for programming the G4 EX. The Windows environment features
user friendly help files and easy to follow menus.
If configured with the USB option, the laptop computer connects via the cable
directly to the connector on the side of the G4 EX. Once this physical connection
has been made, the user may begin communicating through the software.
Remove power from device, or insure the area is known to

be non-hazardous before removing any enclosure cover.
For further information, refer to the certification drawing
indicated on the device’s nametag and national and local
electrical codes.
Connecting to the G4 EX meters with PCCU32 requires

version 7.05.5 or later.
Making a local connection to the meter may be accomplished one of three ways.
Traditionally, local connections have been made using the RS-232 PCCU cable
with the round military connector on one end and a serial port connector on the
other. The second method involves the local connection being made using a USB
cable. The third method utilizes the standard onboard Bluetooth wireless
connection. These methods are discussed below.
Page 1–24 2104349 rev. AD

1.5 Local G4 EX connectors
1.5.1 RS-232 serial PCCU cable (round military cable)
Remove power from device, or insure the area is known to

be non-hazardous before removing any enclosure cover.
For further information, refer to the certification drawing
indicated on the device’s nametag and national and local
electrical codes.
The local connection (serial military connector) requires an RS-232 serial port on
the host computer (generally a laptop). A PCCU cable is required to connect the
host computer to the meter’s round military connector (see Figure 1–20).
Connecting the PCCU cable to the meter will cause the annunciator in the LCD to
display an upper case letter “L” for local connect.
The G4 EX meter must be ordered to include serial

communication capability. A change over kit may be
purchased to adapt the G4 to USB capability.
Figure 1–20 RS-232 local communication cable
1.5.2 PCCU32 USB connection

The local USB connection requires use of a USB cable connected to the host
computer (generally a laptop). A USB PCCU cable is required to connect the host
computer to the meter’s client connector (see Figure 1–21). Connecting the PCCU
cable to the meter causes an annunciator in the LCD to display an upper case
letter “L” for local connect.
2104349 rev. AD Page 1–25

The G4 EX meter must be ordered to include USB
communication capability. A change over kit may be
purchased to adapt the G4 to serial capability.
Figure 1–21 USB local communication cable
1.5.3 Bluetooth connectivity

With the latest iteration of the G4 EX device, the user now has the option of
performing a local connecting using Bluetooth functionality. This option can be
accessed through PCCU32.
1.5.4 Network connectivity (dynamic IP with router)

When the user elects to operate the G4 EX in a network environment, using an
Ethernet is a practical solution. PCCU32 communication with the meter over an
Ethernet connection (TCP/IP) requires the use of a hub, switch or router along
with the appropriate cabling (see Figure 1–23). Ethernet (local) communication in
a remote area may also be utilized.
The Ethernet option is only available by removing the end

cap on the G4 EX device.
Page 1–26 2104349 rev. AD

Figure 1–22 Ethernet communication cable
Figure 1–23 Ethernet connectivity diagram
2104349 rev. AD Page 1–27

2 Installation
This chapter provides the user with the information for installation and setup of the
G4 EX. By the time the user has finished the chapter, they will have the G4 EX
unpacked, installed, field wired and ready for operation. For safe and trouble free
installation, follow all instructions and advisories.
Read through this chapter before beginning the installation.

This will give the user the ability to plan their specific
installation. Additionally, before beginning, refer to the wiring
diagrams delivered with the G4 EX. The user can store these
drawing under the Drawing tab in the back of the manual.
2.1 Unpacking and inspection
2.1.1 Unpacking
The G4 EX and RTD are shipped in a specially designed shipping carton which
contains the unit, mounting brackets, parts list and wiring and interconnect
diagrams. The solar panel and the battery pack with applicable hardware are
shipped in a separate carton.
Carefully remove the items from each carton.
2.1.2 Inspection
- Inspect the shipping carton for damage. If the shipping carton is damaged,
keep it until the contents have been inspected for damage.
- Inspect the unit’s exterior for dents, chipped paint, etc.
- Inspect the LCD window for breakage.
- Visually inspect the electronic boards, cables and EXIMV for damage.
2.1.3 Damaged components

If any components have been damaged or if there are noticeable defects, notify
the Totalflow representative. Keep all shipping materials for the carrier’s
inspection. Totalflow will arrange for immediate repair or replacement. See the
Getting Help section at the beginning of the manual.
2.2 2” Pole mount installation

The following information presented in this document will detail the steps for
mounting the G4 EX to a 2 inch mounting pipe using the mounting kit assembly
provided with the device. The G4 EX has three mounting types that can be
performed, based on the transducer that the user has received. It must be noted
that the transducer should be mounted above the meter run to allow adequate
slope between the manifold and the orifice fittings.
The installation instructions that follow can be used for either a side pole mount or
a stand-alone pipe mount configuration.
Before beginning these steps, review the procedures and the materials required
for installation.
2104349 rev. AD Page 2–1

2.2.1 Type A
2.2.1.1 Materials supplied

- G4 EX mounting kit assembly and associated hardware
2.2.1.2 Materials not supplied

- One 2” x 40” pipe
- Standard 3 or 5 valve manifold
- Stainless steel tubing
2.2.1.3 Step-by-step instructions
To install the G4 EX, it is recommended that two people

perform the installation. One to hold the unit in position and
the other to install and tighten the mounting brackets.
The method of installation must be consistent with the user’s

company policy.
1) Attach the pole mount bracket to the top of the 2” pipe with the U-bolts. Use
the provided hex nuts, flat washers and spring lock washers to tighten the
pole mount bracket to the 2” pipe.
Position the mounting bracket high enough on the pipe to

allow slope from the externally mounted manifold to the tap
valves.
2) Position the provided back clamp on the pole mount bracket, and align the
mounting holes between the two pieces.
3) Upon alignment, take the G4 EX and its attached transducer and set it
within the recessed groove on the back clamp.
4) Once the G4 EX and its transducer have been properly positioned, attach
the device to the brackets using the provided U-bolt. Use the hex nuts, flat
washers and spring lock washers to tighten the device to the mounting
brackets (see Figure 2–1).
Page 2–2 2104349 rev. AD

Back Clamp
Pole Mount Bracket
Figure 2–1 Type A Installation Configuration
2.2.2 Type B
The Type B installation configuration comes from the factory

with the transducer already enclosed in two attached
mounting brackets.




company policy.
2104349 rev. AD Page 2–3


valves.
6) Remove the lower two hex screws, hex nuts, flat washers and spring lock
washers from the transducer’s attached mounting brackets.
7) With the associated hardware removed, align the transducer’s bottom
mounting holes with those on the pole mount bracket.
8) Upon alignment, replace the hex screws, hex nuts, flat washers and spring
lock washers through their respective mounting holes on the mounting
brackets and into the pole mount bracket. Upon completion, tighten (see
Figure 2–2).
Figure 2–2 Type B Installation Configuration
It should be noted that if this is the type of installation

configuration that the user has received from the factory,
there may be additional parts within the provided mounting
kit assembly that are not used.
2.2.3 Type C


Page 2–4 2104349 rev. AD



company policy.

valves.
2) Position the provided back clamp on the pole mount bracket, and align the
mounting holes between the two pieces.
3) Upon alignment, take the G4 EX and its attached transducer and set it
within the recessed groove on the back clamp.
4) Once the G4 EX and its transducer have been properly positioned, attach
the device to the brackets using the provided U-bolt. Use the hex nuts, flat
washers and spring lock washers to tighten the device to the mounting
brackets (see Figure 2–3).
Back Clamp
Pole Mount Bracket
Figure 2–3 Type C installation configuration
2104349 rev. AD Page 2–5

2.2.4 Manifold input lines
The following instructions provide the procedural steps to install the manifold. The
meter run manifold high (+) and low (-) pressures terminate in the transducer’s
(EXIMV) + and – differential port cells. The differential port holes are located on
the bottom of the EXIMV (see Figure 2–4).

- Tubing fittings
A backup wrench should always be used when working with

stainless steel tubing and valves. This prevents the fitting from
turning and/or putting tension on stainless steel tubing.
Figure 2–4 G4 EX EXIMV ports

1) Install the isolation valves on the meter run.
2) Install the tubing between the meter run and the XFC. It should be noted
that the fittings are not supplied with the unit.
3) Leak check all connections.
Leaks in the tubing or manifold will introduce errors when

calibrating the transducer (EXIMV).
Page 2–6 2104349 rev. AD

2.2.5 Standard RTD probe installation
The standard RTD measures flowing gas temperature and should only be used if
the G4 EX is located in a General Purpose area, following local codes. The
procedures that are presented in this section will enable the user to install the
RTD into the meter run.
2.2.5.1 Optionally supplied materials

- RTD probe with 10’ of cable; optional lengths are 15’, 25’, 30’ 40’ and 50’
- One (1) Thermowell with ¾” npt threads; optional threads are ½” and 1”
- Nylon tie wraps

- Customer must specify Thermowell “U” length
- Teflon® tape

1) Install the Thermowell into the meter run (see Figure 2–5).
The power should be removed from the G4 EX before

performing any field wiring.
2) Using snap ring pliers, adjust the probe length so that it is spring loaded
against the bottom of the Thermowell.
3) Screw the probe connector into the Thermowell.
Figure 2–5 Thermowell installation into the meter run

4) At the G4 EX, remove the plug from the explosion proof RTD hub, and
screw the adapter bushing into the hub.
5) Remove the nut from the water tight cord connector. Leave the nylon
sealing ring in place.
2104349 rev. AD Page 2–7

6) Insert the wires through the cord connector, and continue through the
adaptor bushing into the enclosure (see Figure 2–6).
7) Screw the cord connector into the adaptor bushing, and tighten.
8) Inside of the G4 EX enclosure, begin by disconnecting the connector plug
from the RTD connection, J8, to begin field wiring.
Figure 2–6 RTD probe wiring

9) Using the supplied wiring instructions, make the field connections to the
connector plug, and re-insert into the J8 board connector.
10) Following the connection of the RTD Thermowell, secure the cable to the
meter run pipe with plastic tie wraps. Do not wrap cable around the meter
run pipe.
2.2.6 Explosion proof RTD probe assembly

If the G4 EX is installed in a DIV 1 area, the explosion proof RTD must be used
(see Figure 2–7). The following procedures assume that the explosion proof RTD
kit was purchased as an option. For additional information, refer to the Wiring
Interconnect and Application Instructions that were supplied with the kit.
HEAD
UNION
NIPPLE
THERMOWELL
CUSTOMER
SUPPLIED LINE
METER RUN
Figure 2–7 Explosion proof RTD overview

- RTD probe (see Table 1–7 in Chapter 1 for available parts)
- Optional Thermowell (see Table 1–8 in Chapter 1 for available parts)
- Explosion proof connection head
- Conduit union
- Nipple fitting
Page 2–8 2104349 rev. AD

- Certification tag
- Wiring instructions

- Teflon® tape
- Wiring cable/conduit from explosion proof RTD to flow computer (see local
codes for material specifications)
The following instructions assume that the Thermowell has

previously been installed. The end of the Thermowell should
penetrate the center 1/3 of the meter run.

1) Unpack the parts, and verify that all the supplied materials are present. If
parts are missing, contact Totalflow Customer Service at 800-442-3097 or
+1918-338-4880.
2) Screw the nipple fitting into the Thermowell, and tighten (see Figure 2–8).
3) Separate the top and bottom of the union. Screw the union bottom onto the
nipple fitting. Be aware that the union nut is on the union bottom. Tighten.
Figure 2–8 Explosion proof RTD disassembled

4) Screw the union top into the bottom of the connection head, and tighten.
5) Unscrew, and remove the cap from the explosion proof Connection Head.
6) Insert the RTD probe through the opening in the head. Holding the probe
from underneath, screw the spring clockwise down into the center of the
wiring block. Stop when the top edge of the spring is flush with the top of the
wiring block.
7) Insert probe and head assembly through the bottom half of the union that
was previously installed into the Thermowell. As the union halves meet, the
user should encounter some resistance. As the probe contacts the bottom
of the Thermowell, the user should see the top of the probe rise (3/4” max.).
If the probe assembly is too long or too short, the user may need
to change nipple lengths.
1) Lift the union nut up to the union top. Screw together.
2104349 rev. AD Page 2–9

2) Align the RTD head to the correct position for the conduit and wiring.
Tighten the union nut.
3) Using the supplied wiring interconnect drawings, wire the RTD probe at the
wiring block (see Figure 2–9).
4) Following local codes, run the RTD wiring to the G4 EX unit.
Figure 2–9 RTD probe wiring

5) Inside of the G4 EX enclosure, disconnect power from the termination
board. Remove the connection from J16.
6) Remove the connector plug from the RTD connection, J8, to begin field
wiring.
7) Using the supplied wiring instructions, make the field connections to the
connector plug. Re-insert into the J8 board connector.
8) Restore power to the unit.
2.2.7 6270 Optional Equipment Unit (OEU) installation

If the 6270 OEU enclosure is used, it may be configured to include other options,
including but not limited to, a battery pack to provide power to the G4 EX,
communication equipment and solar panel charger.
Following local codes for installation, this unit would normally be located in a DIV 2
or General Purpose area. The unit may be mounted on a 2” pipe or mounted on
flat surface such as a wall.
The battery and solar panel are packed and shipped separately from the 6270
OEU. Before installation, inspect all power cables where they terminate and
connectors for damage.
Before beginning, review the procedure and the materials required for installation.
The 6270 OEU system with battery and solar panel is rated for
Class I, Division 2 locations only or can be installed in non-
hazardous locations.
Page 2–10 2104349 rev. AD

2.2.7.1 Pipe mount
Enclosure mounting brackets and fastening hardware are supplied with the unit.
The customer must provide a 2” pipe of suitable length (see Figure 2–10).
If a charging source, such as a solar panel, is desired, this procedure may be
configured to mount the solar panel on the upper portion of the pipe.
Figure 2–10 6270 OEU pipe mounting installation

Step-by-step instructions
Instructions assume that the user has completed the installation of

the 2” pipe.
1) Using the instructions supplied with the mounting kit, attach the bracket to
the back of the enclosure unit.
2) Position the unit on the 2” mounting pipe, and secure in place with two U-
bolts, flat washers, lock washers and two bolts (see Figure 2–10).
2.2.7.2 Wall mount

Before beginning, review the procedures and the materials required for
installation. A typical installation should look similar to Figure 2–11.
The enclosure mounting brackets and fastening hardware are supplied with the
unit.
2104349 rev. AD Page 2–11

Figure 2–11 6270 OEU wall mount installation
1) Using the instructions supplied with the mounting kit, attach the bracket to
the back of the enclosure unit.
2) Prepare the wall surface for mounting, and mount the enclosure to the wall.
2.2.8 Battery Pack Installation

If the 6270 OEU is used (see Figure 2–12) and is configured to include a battery
pack, use the following procedures.
The battery is packed and shipped separately from the 6270 OEU. Before
installation, inspect the power cables that are located inside the 6270 OEU where
they terminate on the battery pack and the connector for breakage.
Before beginning, review the procedures and the materials required for
installation.
To extend the life of the battery pack, fully charge the battery
prior to installation. Systems using solar panels may not fully
charge the battery. Charging the battery fast will remove the
oxide buildup and will improve the life of the battery.
Do not over charge the battery pack.
Page 2–12 2104349 rev. AD

Figure 2–12 6270 OEU enclosure

1) Insert the battery pack into the battery compartment (see Figure 2–12) with
the long dimension of the battery facing outward.
2) Connect the battery pack connector to the battery connector mate that is
wired to the charger regulator.
3) If the G4 EX unit is already wired to the 6270 enclosure, the LCD screen
should display a warm start.
2.2.9 Lithium battery installation

The following are steps for installing and verifying the connection on the lithium
battery. The lithium battery is disabled when shipped from the factory. The user
will need to connect the battery before continuing.

1) To connect the battery, remove the front cover of the G4 EX. Look for the
battery connector behind and to the lower right side of the display (see
Figure 2–13).
2) On the G4 EX board, the lithium (+) red is on top (pin 1) and the (-) black
(pin 4) is on the bottom. It should be noted that this is a confined space. As
such, place the ground lead of a voltmeter on bare metal, such as the plate
behind the display, and place the positive lead on the bottom solder pad. Do
not place lead against ground.
2104349 rev. AD Page 2–13

Figure 2–13 Lithium battery
2.2.10 Solar panel installation

The solar panel is designed for outdoor mounting on a 2” extension pipe installed
on the upper end of the 6270 OEU 40” mounting pipe (see Figure 2–14). The solar
panel must be mounted within 12 feet of the 6270 enclosure (other lengths
available). For wall mounted enclosures, it can be mounted on the top or the side
of the meter house.
Do not connect the solar panel power cable to the charger

regulator that is located in the 6270 enclosure, unless the
main battery pack has been connected. Refer to the Battery
Pack Installation section.
Exercise caution when installing the solar panel so as not to

damage it.
For solar panel installations where the panel is mounted on

the top or to the side of a meter house, please insure that
the panel receives full sun all day. When mounted, the solar
panel will face up from the horizon at a 50° angle and face
in a southern direction.
The 6270 OEU system with battery and solar panel is rated
for Class I, Division 2 locations only or can be installed in
non-hazardous locations.

- One solar panel
- Two U-bolts and fastening hardware
- Solar panel cable (if not already attached)
- Solar panel mounting bracket (if not already attached to the solar panel)
- Pipe mounting kit

- Cable ties
Page 2–14 2104349 rev. AD

Figure 2–14 Solar panel installation

1) Attach the 2” pipe coupling to the top end of the 6270 OEU mounting pipe.
Securely tighten.
2) Install the 2” pipe extension into the coupling. Securely tighten.
3) Check the solar panel using the Digital Multi-meter to verify polarity and
output voltage. Voltage varies depending on the amount of sun, angle to the
sun, etc.
4) Install the solar panel on the mounting bracket, if required, with the provided
hardware. Install the solar panel cable, if required.
5) Attach the solar panel mounting plate to the top end of the 2” extension pipe
with U-bolts and associated mounting hardware. Do not tighten the U-bolts
until the solar panel has been correctly oriented.
6) For northern hemispheres, position the solar panel facing south; for
southern hemispheres, position the solar panel facing north. For optimum
charging, the solar panel should not be in shadows for any portion of the
day. The panel should be kept clean for maximum charging.
The sun’s orientation in the sky varies from summer to

winter. Keep this in mind when installing the solar panel to
make sure there are no obstructions during the entire year.
7) Do not connect the other end of the cable to the 6270 OEU until the main
battery pack has been connected and the user has been instructed to do so.
8) Remove the hole plug from the OEU, and install the cord connector.
2104349 rev. AD Page 2–15

9) Remove the nut, sealing ring and grommet from the cord connector. Slide
the nut, sealing ring and grommet over the end of the cable, and insert the
cable through the body of the cord connector. Leave enough of the cable on
the outside of the unit to allow the cable to dip below the level of the access
hole. This provides a path for moisture to run away from the unit to the
lowest point of the cable.
10) On the inside of the enclosure, allow enough cable to comfortably extend to
the input terminals on the charger regulator (see Figure 2–14).
11) Slide the nut, sealing ring and grommet to the cord connector on the side of
the unit, and tighten.
12) Before making connections to the charger regulator, trim the wire ends back
¼”.
13) Verify that the main battery pack is connected.
14) Loosen the securing screws on the charger regulator, insert the wire and
then retighten. Connect the solar panel (+) lead to the + terminal and the (-)
wire to the – terminal.
15) Following the connection of the solar panel power cable, secure the cable to
the 2” extension and mounting pipe cable with the provided plastic tie-
wraps.
2.2.11 AC charging unit installation

The AC power charging unit maintains a constant voltage charge on the installed
battery pack (see Figure 2–15).

- AC charging unit
- Pipe nipple

- Plastic cable ties
- AC wiring, conduit (rigid or flexible)
To maintain system certification, all wiring must comply with

NEC 501 code and applicable ABB certification drawings.
To prevent injury, only a licensed electrician should install

AC power wiring to the user supplied primary AC power
source.

1) The AC charging unit is shipped separately. When the unit is received,
unpack, and inspect all components for evidence of damage. Report
damage to the shipping carrier and to Totalflow’s Service Department.
2) Remove one of the plugs from the side of the 6270 OEU so that the AC
charging unit can be mounted without obstruction. See Figure 2–15.
Page 2–16 2104349 rev. AD

3) Remove the outside of the lock nut from the nipple. Leave the sealing ring
and inside lock nut.
Figure 2–15 AC charger installed
Figure 2–16 AC charger outlet box installation

4) Feed the AC charger’s DC power lines into the enclosure (see Figure 2–16).
2104349 rev. AD Page 2–17

5) Insert the nipple through the side of the enclosure, and install the removed
lock nut.
6) To prevent moisture from entering the enclosure after installing the AC
battery pack charger, be certain the “O” ring side of the metal backed
sealing “O” ring is against the enclosure.
7) Loosen the terminal screws, and insert the red wire into the plus (+) array
terminal and the black wire in the negative (-) array terminal (see Figure 2–
17). Retighten the screws.
8) Connect the green wire to one of the grounding screws that are located on
the bottom of the enclosure.
9) Pipe the conduit and associated AC wiring into the AC charger conduit box.
The AC charger is rated at either 120 VAC 60 Hz or 240 VAC 50 Hz.
Connect the 120 V hot and neutral or the two hot wires for 240 V to the
terminals of the AC charger. Connect the ground wire to the green screw.
10) Verify that the DC power wires are terminated properly inside the 6270 OEU
cabinet and that the main battery pack plug is already connected. Apply AC
power to the AC charger.
Figure 2–17 AC charger inside the conduit enclosure
2.2.12 Uninterrupted power supply (UPS) to the G4 EX

The G4 EX can be powered directly from any UPS that is supplying 9-30 VDC.
See Figure 2–18 for instructions on how to wire the G4 EX termination board to a
UPS.
Page 2–18 2104349 rev. AD

Figure 2–18 G4 EX to UPS
2104349 rev. AD Page 2–19

3 G4 EX start-up
The following chapter describes the steps required to get a newly installed G4 EX
system up and running. Specific information required to complete each step
(depending on equipment choice) is discussed more thoroughly in the PCCU32
Help Files.
All references in older materials to absolute pressure (AP)

have been converted to static pressure (SP). This reflects
the difference of including barometric pressure during
calibration.
3.1 PCCU32 installation and setup

Totalflow PCCU32 7.05.5 (or later) software is required to communicate with the
G4 EX. Previous versions of PCCU32 are not compatible.
PCCU32 software running in a laptop Windows® environment offers the user the
most capabilities for programming. The Windows environment features user
friendly Help Files and easy to follow menus. Easy to follow menus and icons step
the user through many required choices.
3.1.1 Step-by-step instructions

1) Insert the PCCU32 disk into the PC drive. The Install Program should
automatically load (assuming the Auto Insert Notification has not been
turned off).
If the Install Program does not automatically load, click on Start and then
Run.
- Type the CD/DVD drive letter plus ‘setup. For example: E:setup.
- Click the OK button.
2) The Install Program will load followed by a Welcome message. Click the
Next button.
3) A screen will display that asks for user information. Complete entering in the
relevant information, and enter the serial number in the appropriate space
(the user needs to ensure that they enter both the numbers and dashes for
the serial number). Click the Next button.
4) Change the destination directory, if desired. Click the Next button.
5) Change the program folder, if desired. Click the Next button.
6) The installation process will load all the required software. If the install
program asks the user to restart the computer, the user will need to do so
before running the PCCU32 software.
7) If there is no message that asks for a restart of the computer, the installation
is complete. Click the Finish button.
3.2 Establishing local communication

As discussed previously, local communication can be established in different
ways: RS-232 MMI cable, Bluetooth or USB cable. The unit can be configured for
one or the other or all. TCP/IP is available but is designed for use over a network
setup.
2104349 rev. AD Page 3–1

With each selection, the user will see options that pertain only to that connection
method.
3.2.1 Connecting to a local port via a RS-232 cable

If the unit is configured to include the local RS-232 Communication port, the
connection is made using the RS-232 cable. This connects the laptop computer to
the local port on the meter.

1) Connect the MMI cable to the designated port on the PC (default is COM 0)
and to the local port located on the unit.
2) The user needs to open PCCU32. Upon selection, PCCU32 will open.
3) With the MMI cable connected, click the Connect icon on the PCCU32 main
toolbar. The Local Connect screen will display.
If the invalid security code screen displays, enter four zeroes

(0000) for the new code, and click the OK button. The G4 EX
should have defaulted to 0000 on start-up.
If the meter has been given a security code, the user needs to
ensure they have entered that code in PCCU32’s System Setup
screen (see Figure 3–1). However, if the meter has been cold
started, the security code will be reset to factory default, and
historical data will be lost.
Figure 3–1 System Setup Screen
Page 3–2 2104349 rev. AD

4) The Local Connect screen displays six buttons. From the button selections,
click Entry Setup to move to the Station Setup screen. Links within the
PCCU32 tree-view will move the user to screens for setup and daily
operations.
3.2.2 Connecting to local USB port

If the user’s unit is configured to include the local USB communication port, the
connection is made using the USB cable. This connects the laptop computer to
the Local port on the meter.
Before the user is able to communicate to the G4 EX using a USB cable, they
must install the Totalflow USB driver: Totalflow.inf.

1) If the G4 EX and laptop are powered up when the connection is made, the
user will receive the Found New Hardware Wizard screen (see Figure 3–2).
When this screen displays, the user needs to select the No, not this time
radio button. Click Next.
Figure 3–2 Windows found new hardware wizard

2) To install Totalflow.inf, select the Install from a list or specific location (i.e.,
the PCCU32 folder) radio button (see Figure 3–3). Click Next.
3) Select the Include this location in the search checkbox. Browse to the
PCCU32 folder. In Figure 3–4, the folder was named PCCU605 to draw
attention to the necessity to run PCCU32 version 7.05.5 or later with the G4
EX. After browsing to the folder that contains the Totalflow.inf, click the Next
button.
2104349 rev. AD Page 3–3

Figure 3–3 Specific location selection window
Figure 3–4 Specify location for USB driver (Totalflow.inf)
Page 3–4 2104349 rev. AD

4) At this point, the user may receive a Windows® message that warns that the
Totalflow USB driver has not passed Windows Logo testing. If the user
wishes to use their laptop’s USB port, they will need to click on Continue
Anyway, and proceed on with the installation.
5) The installation procedure begins loading the Totalflow.inf. This should only
take a few seconds. This will complete the Found New Hardware Wizard.
Click the Finish button. The Totalflow USB driver is now installed.
If the user sees the Found New Hardware Wizard on

subsequent connects to the meter, click the Cancel button.
6) The user will need to open PCCU32.

7) With the USB cable connected, click on the Connect icon within the
PCCU32 main toolbar. The Local Connect screen displays six buttons.
From the button selections, click Entry Setup to move to the Station Setup
screen. Links within the PCCU32 tree-view will move the user to screens for
setup and daily operations.
3.2.3 Setup of the G4 EX for Bluetooth connectivity

The following instructions will show the user how to set up the G4 EX for Bluetooth
connectivity.

1) Plug the Bluetooth adapter into the computer. Ensure that all the relevant
drivers are installed, and the device is working properly.
2) Open PCCU32. From the PCCU32 main toolbar, select the System Setup
icon. This will take the user to the System Setup dialog box.
3) The user will need to click the Bluetooth radio button to establish that this is
the method by which they are connecting.
4) Once this has been accomplished, the screen will populate with the relevant
fields that pertain to the Bluetooth connection method. If the Bluetooth
adapter is supported by the G4 EX, the Search for Bluetooth Devices button
is activated along with a drop-down list of Bluetooth devices that have
previously been selected (see Figure 3–5).
5) The user may select a previous Bluetooth device in the drop-down list or
search for a device (see Figure 3–6). If the user searches for a Bluetooth
device, the list will contain previously paired devices and not just the
devices in range.
6) The user may select the preferred Totalflow Bluetooth device, or if that one
was not found after the search, the user can initiate another search. Upon
selection, the device will be populated in the drop-down list in the System
Setup dialog box.
7) The user must provide the Bluetooth pairing code to automate the
connection. This is typically a 4-digit authentication code set in the device
and is defaulted to 0000.
2104349 rev. AD Page 3–5

Figure 3–5 System setup - Bluetooth
Figure 3–6 Select a Bluetooth device dialog box

8) The user can close out of the System Setup dialog box, and press the
Connect button. PCCU32 will attempt to pair with the selected Bluetooth
supported Totalflow device and establish communication with it.
Page 3–6 2104349 rev. AD

9) It should be noted that if the Bluetooth adapter plugged into the computer is
one that is not supported, the user will receive a different screen in the
System Setup dialog box (see Figure 3–7). At this point, the user must use
their Windows software that came with the Bluetooth adapter, and set up a
pair/connection to the preferred Totalflow Bluetooth-enabled device.
Figure 3–7 System Setup dialog box - Bluetooth

10) Once the pair/connection has been made, the user will need to assign a
communication port to it. After this is accomplished, the user can set the
com port in the drop-down list provided on the System Setup dialog box.
11) The user will then need to close the System Setup screen, and connect to
PCCU32 to communicate with the device.
3.2.4 Setup of the G4 EX for Ethernet connectivity

To set up the G4 EX for an Ethernet connection, the user must first connect locally
using either the RS-232 or USB cable. Using the local connection allows the user
to setup the device for Ethernet connectivity.
Currently, there are a variety of methods for completing this task. The following
will cover two such methods.
3.2.4.1 Method one

1) Connect locally using either the RS-232 instructions or the USB instructions
covered in the previous section(s).
2104349 rev. AD Page 3–7

2) In PCCU32 Entry mode, select Communications from the tree-view. Upon
selection, click on the Network tab (see Figure 3–8).
Figure 3–8 Network tab

3) The user will need to enter a Network ID, and set the Enable DHCP
parameter field value to Yes. The other fields within the tab will auto-
populate. Click the Send button.
4) Next, the user will need to locate the Totalflow – TCP selection under
Communications in the PCCU32 tree-view (see Figure 3–9). Once selected,
the user is taken to the Setup tab. In this tab, the user needs to set the
Protocol parameter value to Totalflow/TCP. When done, click the Send
button.
Page 3–8 2104349 rev. AD

Figure 3–9 Communication setup
5) While still in PCCU32, the user needs to click the Operate selection on the
main PCCU32 toolbar. From the drop-down menu, select Setup. From the
fly-out menu, select System Setup.
6) Within the System Setup dialog box (see Figure 3–10), click the TCP/IP
radio button. Next, enter the network ID or IP address for the meter in the
corresponding parameter field. The network ID is the same ID that the user
entered earlier within the meter setup.
7) Upon finishing, click the Close button.
2104349 rev. AD Page 3–9

Figure 3–10 System Setup window
8) Exit PCCU32 and the local connection.
9) With the Ethernet cabling installed, connecting to the meter is no different
than when using the PCCU cable or military connector. Click on the
Connect to Totalflow icon in the PCCU32 toolbar. To connect and move
directly to Entry mode, click on Entry instead of the Connect icon.
If the user has several meters on their network, they may find it
helpful to create a desktop shortcut for each meter. For
instructions on how to accomplish this task, follow steps 10 – 12;
otherwise, the user may continue on to the next section.
10) Create a desktop shortcut, and assign a name to it. For the sake of the
example, the following will use the meter’s ID for the shortcut name.
11) The user will now need to point to the version of PCCU32 that they want to
use (the user may have multiple versions of PCCU32 on their laptop). It
should be noted that it must be PCCU32 version 7.05.5 or later.
12) The user will then need to identify the network protocol to be used (TCP)
and the network ID (see Figure 3–11).
For example:
- Point to the folder with PCCU32 in it.
- Point to PCCU32.exe.
- Point to the protocol (TCP).
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- Point to the specific network address (XFC-148).
- String the enter address together: C:\PCCU605\pccu32.exe TCP:XFC-
148.
Figure 3–11 Windows desktop Shortcut dialog box
3.2.4.2 Method Two

1) Connect locally using either the RS-232 instructions or the USB instructions
covered in the previous section(s).
2) In PCCU32 Entry mode, select Communications from the tree-view (see
Figure 3–12). Upon selection, click on the Network tab.
3) In the Network tab, set the Enable DHCP parameter field value to No. Click
the Send button. The remaining parameter fields within the Network tab will
auto-populate.
2104349 rev. AD Page 3–11

Figure 3–12 Network tab
4) Move to the IP Address parameter field, and type in the IP address that is
reserved for the device. Click the Send button.
5) Close PCCU32.
6) Open the door to the unit, and locate the Reset button on the board. When
located, press the Reset button. This will set the IP address on the board.
7) The user will need to reopen PCCU32, but do not connect.
8) From the PCCU32 toolbar, click the Setup icon. This will take the user to the
System Setup dialog box (see Figure 3–13).
9) Within the System Setup dialog box, the user needs to select the TCP/IP
radio button.
10) Move to the Network ID or IP parameter field, and type in the IP address
that was established in step 4.
11) Click the Close button.
12) Reconnect to PCCU32, and move back into Entry mode. This establishes
the Ethernet connection.
Page 3–12 2104349 rev. AD

Figure 3–13 System setup
3.3 Setting up the G4 EX

Once the user has physically connected to the G4 EX, they must then instruct the
software of the programming device to connect to. At this time, the software will
actually read the device default values that are programmed at the factory. These
preset values are based on the type of product that the user has ordered and
programmed for the most widely used configuration.
Depending on the programming device that is being used, the following are
minimum required entries. Specific information required to complete each step is
discussed in the PCCU32 Help Files.
3.3.1 Date/time
The G4 EX date and time should be set before other tube parameters are entered.
This insures that events are properly dated and time tagged. Attention should be
given that the date and time are set correctly and should agree with the collection
equipment. PCCU32 or WinCCU can be used to update the date and time of the
device.
2104349 rev. AD Page 3–13

Description Format Note
Date MM/DD/YY Must enter 2 digits each
Time HH:MM:SS 24-hour clock
3.3.2 Station ID
The station identifier code should uniquely identify one G4 EX from that of any
others.
Station ID XXXXXXXXXX 10-digit alphanumeric
3.3.3 Location
The location field can hold up to 24 alphanumeric characters to describe its
location. An example would be the lease name, county name or road number.
Station ID XXXXXXXXXXXXXXXXXXXXXXXX 24-digit alphanumeric
There are additional fields stored in WinCCU for uniquely

identifying the meter, including fields for entering the lease
holder, producer, operator and buyer. These fields reside on
the host computer in the ID Manager not in the G4 EX.
3.4 Security system

Data and configuration security in the G4 EX is spread across three elements: the
flow meter, PCCU32 and WinCCU32. Currently, there are three types of security
that are possible:
- Device enforced legacy level 1-2 security
- WinCCU enforced legacy security
- Device and PCCU32 enforced Role Based Access Control (RBAC) security
The following sections will cover these security options.
3.4.1 Device legacy bi-level security

The G4 EX has a security switch (S2) on the termination board. Password security
is bi-level: read only (security code level 1) or read/write (security code level 2). To
establish meter security, the user must have the security switch in the OFF
position, and locally connect with PCCU32. Enter a four digit number level 1 and
level 2 security code, and click Send.
3.4.1.1 Establishing meter security

To establish a meter security, the user must have the security switch in the OFF
position, and locally connect with PCCU32.
1) Enter a four digit number for level 1 and level 2 security codes (see Figure
3–14), and click Send.
2) Turning the security switch (S2) ON will activate the security codes.
Page 3–14 2104349 rev. AD

Figure 3–14 Station Setup tab
The level 1 code (Figure 3–14, 1234) will allow data and configuration values to be
read but not altered. The level 2 code (in the above screenshot, 5678) will allow
full access to read and write.
These security codes must be entered into PCCU32 and WinCCU32 to provide
the appropriate access to the meters. However, WinCCU32 will always need the
proper security code, regardless of the position of the security switch (S2). Turning
the security switch off does not allow unprotected access for a WinCCU32
operator.
Modbus access to the meters is not protected by the security

codes.
3.4.1.2 PCCU32 software security

PCCU32 will require the appropriate security code to be entered.
1) To enter the security code, the user will need to move to System Setup in
PCCU32.
2) Enter the appropriate security code and select Close.
In the provided example (see Figure 3–15), the operator has been provided with
read only access to the meter.
The security code level of 1234 (per Figure 3-15) provides read only access to the
meter. If 5678 was entered, the user would have full read/write access to the
meter.
If the security level is breached, the meter will give no

indication. Any data that the user attempted to change will
simply remain unchanged.
2104349 rev. AD Page 3–15

Figure 3–15 Security Setup dialog box
If the Security Switch (S2) on the termination board is in the

Off position, no security code has to be entered to access
the operating parameters, even if there is one programmed
into the device.
3.4.2 WinCCU32 software security

WinCCU32 also requires the appropriate security codes be entered in the Device
ID (see Figure 3–16).
1) Highlight the appropriate meter in WinCCU, and click Edit ID.
2) Enter either the level 1 or level 2 security code.
3) Click OK.
Page 3–16 2104349 rev. AD

Figure 3–16 WinCCU32 Edit a Device ID dialog box
The security code level 2 of 5678 (per Figure 3–16) has been entered. This gives
the WinCCU32 user full read/write access to the meter.
Modbus access to the meters is not protected by the security

codes.
3.4.3 Role Based Access Control (RBAC)

Role Based Access Control (RBAC) is a feature in PCCU32 that is designed to
allow an administrator to designate roles and control access levels to various
applications and processes in G4 devices.
Beginning with a set of default roles, it is possible to duplicate, rename and delete
these items to create a working list of access roles that are relevant to the user’s
company hierarchy. From this role list, it is then possible to create user accounts
with various assigned roles. The user is also given the ability to take the newly
created configuration and save it in the form of a security file to their PC. The
security file can then be sent to a G4 device, where it is then implemented.
RBAC is enforced by both the device and the PCCU32

interface for G4 devices. Enforcement on devices is on a
port-by-port basis. When RBAC is enforced, type 1 and 2
security is superseded.
3.4.3.1 Security file configuration

RBAC configurations can be defined and saved in a security file. This mainly
includes Role Definition, User Configuration and Port Configuration.
The following instructions provide information for creating and editing a security
file.
2104349 rev. AD Page 3–17

1) After PCCU32 has been opened, move to the Security option under the
Operate menu option from the PCCU32 toolbar. Select Role Based Access
Control and then Role Administration from the fly-out menu (see Figure 3–
17).
Figure 3–17 Role administration menu path

2) Once Role Administration has been selected, the Security Editor dialog box
displays (see Figure 3–18).
Figure 3–18 Security Editor dialog box

RBAC security files are supported by G4 and NGC devices. The user is given the
ability to select the device type that the security file is specifically intended for.
For each role, it is possible to set the access level for each function that is listed.
The Entry View function sets the highest selectable level and has the options of
None, Basic, Advanced or Expert. Other functions have either a Yes | No option or
Page 3–18 2104349 rev. AD

a No Access | Read Only | Read/Write option. If an existing role definition does not
provide the proper capabilities, a new one can be created by clicking the Browse
button next to the Role drop-down list. This brings up the Roles dialog box (see
Figure 3–19).
Figure 3–19 Roles dialog box
3.4.3.2 Role definition

Default roles are automatically installed with PCCU32. These default roles are as
follows:
- Administrator
- Expert
- Advanced
- Basic
- File Admin
The Administrator role has the highest level access rights to all functions. Expert,
Advanced and Basic roles have decreasing levels of access rights.
The File Admin role has access rights of the Basic role plus minimum rights
required for sending/reading RBAC security files to and from G4 devices.
3.4.3.3 Role creation

The following instructions will walk the user through the steps for creating a new
role.
1) Select the row that has the corresponding access level that the user wants.
Upon location, click the Copy button.
2) A dialog box displays and asks for the name of the new role. Assign a name
to the role. The new role is then available in the Roles dialog box.
3) Modify the access levels to complete the modification of the created role:
- To change the name of an existing role, select the cell, and click the
Rename button.
- To delete an existing role, click the Delete button.
- The Default button resets the Role list to the factory defaults.
3.4.3.4 User configuration

When adding a new user, the default role is the one that is currently displayed in
the Role drop-down list at the time the Add User button is clicked. The following
dialog box displays to set the user name and password (see Figure 3–20).
2104349 rev. AD Page 3–19

Figure 3–20 User Name and Password dialog box
A security key is generated and displayed after the configuration is saved to a
security file. The Security Key file is displayed with “n/a will be generated on
save”, before a configuration is saved or after any modifications are made to a
saved configuration. The security key is logged in the Security Log every time the
security file is sent to a device or the device warm boots. Additionally, it can be
used to verify the security file on the device is the one created by the security
administrator.
The PC file name of the security file is saved in the security file and displayed in
the Security Editor dialog title bar, when the file is read from a device. It will also
be used as a default file name, suggested for saving.
The Open button opens a security file from the PC for editing (see Figure 3–18).
The New button clears all users and starts editing a new security configuration
with default roles and no users.
RBAC security files are saved with a unique extension (.rba), by default. There is
also a default directory that hosts these files. The directory is configurable by
selecting the menu item Operate > Setup > System Setup (Figure 3–21).
Figure 3–21 System Setup dialog box

When connected to a Totalflow G4 device, the Read button is enabled for all
users. Additionally, the Send button is enabled only for users with Administrator
rights. The Read button reads a security file from the device for editing. The Send
button is used to send and apply the security configuration to a device.
Another way to send a security file is to select the menu item (Operate > Security
> Role Based Access Control > Send Security File). This menu item is only
Page 3–20 2104349 rev. AD

enabled for users with Administrator rights. Clicking the menu item displays the
Send Role Based Access Control File dialog box (Figure 3–22).
In the dialog box, the user can click the Browse button to select the required file.
Upon selection, the user can click the Send button to send the security file.
Figure 3–22 Send Role Based Access Control File dialog box
3.4.3.5 Port configuration

Entry mode is available in the Advanced and Expert view modes and can be used
to configure RBAC for ports that are not specified in the security file or can be
used to override what is specified in the security file. Under each port which has a
protocol specified is a parameter field called Authentication. This parameter can
be set to Disabled, Enabled or Enable by Security Switch (See Figure 3–23).
- Disabled – Does not perform any RBAC functions on the port.
- Enabled – If the administrator name and/or password are lost or forgotten, it
will be necessary to use TfLoader to delete TfCold and TfData, and then
cold start the device to gain access. This will reset the device to the default
factory configuration.
- Enable by Security Switch – If the administrator name and/or password are
lost or forgotten, RBAC may be disabled using the legacy security switch.
By setting the switch to the Off position, a user may log in and reconfigure
the security access. This will not result in the loss of any data.
Figure 3–23 Totalflow-TCP Setup tab
2104349 rev. AD Page 3–21

3.4.3.6 User login
When the user tries to connect to an RBAC enabled port on a G4 device, they are
first asked to login (see Figure 3–24).
The user can elect to save the user name/password as default credentials to be
used for subsequent logins. To change or disable the default RBAC credentials,
select the menu item, Operate > Setup > System Setup (see Figure 3–25).
After a security file is sent to a Totalflow G4 device, the user is disconnected from
the device and asked to re-login under the following circumstances:
- RBAC security was not enabled on the connected port before the security
file is downloaded.
- The user is not defined in the new security file.
- The user has different access rights in the new security file.
Figure 3–24 Login dialog box
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Figure 3–25 System Setup dialog box
3.4.3.7 Security log

To track access to Totalflow G4 devices, a security log is kept that indicates the
date and time when a user logs in, the user name, the port where the access was
made and the actions taken before logout. Log entries are also generated when a
security file is downloaded and/or processed. Additionally, the results of applying
the configurations will also be logged every time a new security file is downloaded.
This tab is available in Advanced and Expert view modes (see Figure 3–26).
2104349 rev. AD Page 3–23

Figure 3–26 Security Log tab
3.4.3.8 Remote communications

While it is currently possible to enable RBAC on a remote port, this will block any
access to the port since no host software currently supports RBAC.
3.4.3.9 Access rights for common functions

Restricted applications
Applications not accessible to the currently connected user are not seen in the
left-hand tree-view within PCCU32. Functions that are restricted to the user are
disabled. When an application with Read Only functionality is accessed, the Send
button is also grayed out.
Calibration
In order for the user to perform a calibration, in addition to Calibration access
rights, a user must also have read/write access to the following applications:
- System
- Flow measurement
- I/O subsystem
- Display application
- For calibrating wireless I/Os, the user must have Read/Write access to the
Wireless I/O application and the Communication Ports application.
- For calibrating the XMV, the user must also have Read/Write access to the
XMV Interface application and the Communication Ports application.
Collection
In order to perform a collection, in addition to Collection access rights, a user must
also have Read access to the System application.
- For collecting tube data, the user must have Read access to the Flow
Measurement application.
- For collecting trend data, the user must have Read access to the Trend
application.
- For collecting analysis trend data, the user must have Read access to the
Analysis Trend application.
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- For collecting analyzer stream data, the user must have Read access to the
Analyzer Stream application and the Analyzer Operation application.
3.5 Application licensing Credit Key
3.5.1 Credit Key driver installation

1) Plug the USB credit key into an available USB port.
2) The Windows operating system will recognize the credit key as new
hardware and attempt to install the appropriate driver with the Found New
Hardware Wizard.
3) Click the Next button.
4) It may be necessary to point the wizard to the PCCU32 directory in the Files
Needed screen. Select Browse, and locate the driver (usbkey.sys) in the
PCCU32 directory.
5) Upon location, click the OK button.
6) The software driver installation will begin. When it is completed, click the
Finish button.
If the user inserts the credit key in a different USB port on

the computer, it will need to be installed for that new USB
port. In other words, the credit key must be installed on each
available port, if the user does not intend to use the same
USB port each time they use the credit key.
3.5.2 Access/view the Credit Key with PCCU32 7.0 (or later)
To access and view the credit key, the user must use PCCU32 7.0 (or later). The
credit key is a secure device and only accessible through PCCU32.

1) Install the credit key in an available USB port.
2) Open PCCU32, but do not connect to the unit.
3) Go to the Credit Key License Utility (Operate > File Utilities > Credit Key
License Utility).
To move to the Credit Key License Utility, the user cannot

be connected to the G4 EX. The user must have PCCU32
running and the initial Totalflow PCCU32 screen displayed.
4) When the Credit Key License Utility screen displays, click Load to view
available credits on the USB key (see Figure 3–27).
2104349 rev. AD Page 3–25

Figure 3–27 Credit Key License Utility
5) The number of credits will display.
This is the same dialog box that the user would use to add more
credits to the credit key.
Figure 3–28 Credit Key License Utility – Status
Page 3–26 2104349 rev. AD

3.5.3 Adding credits to the Credit Key by telephone
The user may have ordered the credit key from Totalflow with a specified number
of the various credits; however, the user may need to add more or different credits
in the future.
1) Open PCCU32 version 7.0 or later, but do not connect to the unit.
2) Go to the Credit Key License Utility (Operate > File Utilities > Credit Key
License Utility).
3) Insert the credit key into an available USB port.
4) Select Do Phone Update (see Figure 3–28).
5) The user is then asked to call Totalflow Order Entry. Insure that the credit
key is plugged in.
6) Upon connection with a Totalflow Order Entry representative, click the OK
button.
7) The representative will ask the user to read the five (5) encrypted codes that
appear directly beneath the Do Phone Update button. Read them from top
to bottom (see Figure 3–29).
Figure 3–29 Application Credit Key entry screen

8) The representative will give the user four codes to enter in the provided
fields.
9) After the codes have been entered (from top to bottom), click the Update
button (see Figure 3–30).
10) After the button has been clicked, three more codes are displayed directly
beneath the Do Phone Update button. The Totalflow representative will ask
the user to read the codes to verify that the credits have been properly
written to the credit key.
11) When completed, click the Update button.
2104349 rev. AD Page 3–27

Figure 3–30 Application Credit verification codes
3.5.4 Transferring credits to the G4 EX from the Credit Key

Credits can be transferred to the G4 EX. The user selects the type of credits and
the amount of those credits to be transferred.
If the G4 EX has a surplus of credits, these credits can be

transferred to the credit key to be used on the other meters. This
is discussed in a later section.
To transfer application credits to the G4 EX, the user will need to connect to the
G4 EX with PCCU32 7.0 or later.
1) Open PCCU32. Once open, move to the top of the tree-view, and click on
the App Licensing tab (see Figure 3–31).
3) Click the Load button to view the available credits.
This screen enables the user to see the licensing status of the G4
EX as well as the available credits on the credit key. The left pane
shows the type and amount of the available credits on the credit
key. The upper right pane is for information purposes only. It
shows the various available applications and the type/amount of
credits necessary to run the application. The standard credits (and
four general credits) are free with the purchase of the G4 EX. The
lower right pane displays the licensing status of the G4 EX. It
shows what credits are in the machine, what credits are being
used and any surplus or deficit of credits. A surplus of credits is
highlighted in green. A deficit of credits is highlighted in red.
Page 3–28 2104349 rev. AD

Figure 3–31 App Licensing tab
4) Select the Transfer to Device radio button.
5) From the Type drop-down menu, select the type of credit from the available
options.
6) Next, select the number of credits to transfer.
7) Upon completion, click the Transfer button.
3.5.5 Transferring Credits to the Credit Key from the G4 EX

As has been mentioned before, excess credits (credits beyond those that are
required to be fully licensed) can be taken from the G4 EX and returned to the
credit key to be used on other G4 devices.
Credits can be transferred from the G4 EX. The user selects the type of credit and
the amount of those credits to be transferred.
If the G4 EX has a surplus of credits, these credits can be

transferred to the credit key to be used on other meters.
If the G4 EX requires additional credits, these credits can be

transferred from the credit key. See the previous section for the
steps on how to accomplish this.
To transfer application credits to the G4 EX, the user needs to connect to the G4
EX unit with PCCU32 7.0 or later.
1) Open PCCU32. Once open, move to the top of the tree-view, and click on
the App Licensing tab.
3) Click the Load button to view the available credits.
2104349 rev. AD Page 3–29

This screen enables the user to see the licensing status of the G4
EX as well as the available credits on the credit key. The left pane
shows the type and amount of the available credits on the credit
key. The upper right pane is for information purposes only. It
shows the various available applications and the type/amount of
credits necessary to run the application. The standard credits (and
four general credits) are free with the purchase of the G4 EX. The
lower right pane displays the licensing status of the G4 EX. It
shows what credits are in the machine, what credits are being
used and any surplus or deficit of credits. A surplus of credits is
highlighted in green. A deficit of credits is highlighted in red.
4) Select the Transfer to Credit Key button (see Figure 3–32).

5) In the Type drop-down field, select the credit type from the available
selections.
6) In the Amount field, set the number of credits to transfer.
7) Upon completion, click the Transfer button.
8) The transferred credits will display to the left of the screen.
Figure 3–32 Transfer to Credit Key
3.6 G4 EX configuration
3.6.1 Contact hour

The user can program the G4 EX to begin the contact day based on their contract
or company standards. When the G4 EX first powers up, the contract is preset to
begin at midnight.
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Midnight is 00 o’clock. If any value entered is greater than
23, the user will receive an error message, and the G4 EX
forces the value to 00 (midnight).
3.6.2 Log period

The Log Period is the specified length of time between writing the calculated
accumulated volume to record. The user may record volumes as often as every
minute and as seldom as every hour. The default is 60 minutes. The G4 EX can
normally store 960 log periods (40 days x 24 logs). A five minute log period will
consume available memory in eight days.
Description Options
Log Period 1,2,5,10,20,30,60 (Minutes)
3.6.3 Volume calculation period

Volume Calculation Period is the specified length of time between volume
calculations. The Volume Calculation Period must be equally divisible into the Log
Period. The default is 1 second.
Description Options
1 sec, 2 sec, 5 sec, 10 sec, 20 sec, 30 sec
Volume Calculation Period 1 min, 2 min, 5 min, 10 min, 20 min, 30 min and 60 min.
It is recommended to leave at the default of 1 second.
3.6.4 Calculated method

When the G4 EX is initially powered up, the calculation method must be set. The
user has the option of setting the calculation method to AGA-3 1985, AGA-3 1992,
AGA-7 or ISO-5167. Once the calculation type has been determined, the user
may toggle specific factors on or off depending upon their availability (see Table
3–1).
Calculation types, and many of the factors involved with setting up

the calculations, are usually dictated by the user’s sales contract
or company policy.
Table 3–1 Configurable calculation factors
AGA-3 AGA-3
Calculation Parameter AGA-7 ISO-5167
1985 1992
Fpb (Pressure Base Factor) Yes N/A N/A N/A
Ftb (Temperature Base Factor) Yes N/A N/A N/A
Fg (Specific Gravity Factor) Yes N/A N/A N/A
Fb (Orifice Factor) Yes N/A N/A N/A
Ftf (Flowing Temperature Factor) Yes N/A N/A N/A
Y (Expansion Factor) Yes Yes N/A Yes
Fr (Reynolds Number) Yes N/A N/A N/A
Fa (Orifice Thermal Expansion
Yes N/A N/A N/A
Factor)
2104349 rev. AD Page 3–31

AGA-3 AGA-3
Calculation Parameter AGA-7 ISO-5167
1985 1992
Fpv (Supercompressibility Factor)1 Yes Yes Yes2 Yes3
Fw (Water Vapor Factor)4 Yes Yes Yes Yes
Faux (Full Well Stream Factor)5 Yes Yes Yes Yes
Cd (Coefficient of Discharge) N/A Yes N/A Yes
Fp (Fpv method = NX19 Fixed) Yes Yes Yes Yes
Ft (for Fpv method = NX19 Fixed) Yes Yes Yes Yes
Coefficient of Discharge Calc N/A Yes N/A Yes6
Fpc (Pressure Correction Factor) N/A N/A Yes N/A
Ftc (Temperature Correction Factor) N/A N/A Yes N/A
Fs (Fpv2 Compressibility Factor) N/A N/A Yes N/A
3.6.5 Supercompressibility calculation (Fpv)

When the G4 EX is powered up, the calculation method needs to be set. The user
has the option of changing the formula method to any one of several other choices
(see Table 3–2). Once the calculation has been determined, the user may toggle
specific parameters on or off depending upon whether they would like to use fixed
or live analysis data.
Many decisions involved with setting up the Fpv are dictated by

the user’s sales contract or company policy.
Table 3–2 Fpv analysis data

Default NX19 Fixed AGA-8 1992 All
Analysis Data Units
Value Ft/Fp Detail Others7
Fp (for Fpv method NX19 Fixed) 1.000 Yes No No
Ft (for Fpv method NX19 Fixed) 1.000 Yes No No
Heating Value8 1000.0000 BTU/SCF Yes Yes Yes
Argon 0.0000 mol % No Yes No
Carbon dioxide CO2 0.0000 mol % Yes Yes Yes
Carbon monoxide 0.0000 mol % No Yes No
Ethane 0.0000 mol % No Yes No
H2S 0.0000 mol % No Yes No
1 NX19 GCN, NX19 GCNM, AGA-8 1992 Gross and AGA-8 1992 Detail
2 See Fs for AGA-7 Fpv2
3 Only AGA-3 1992 Gross and Detail
4 Not an AGA factor. Fw is a factor which compensates for water vapor in the gas stream and its effect on volume
measurement.
5 Not an AGA factor. Faux is a user set multiplier to compensate for liquids in the gas stream. Defaults to 1.
6 Discharge Coefficient Type-only AGA-3 1992 and ISO-5167-1
7 NX19 GCN, NX19 GCNM, AGA-8 1992 Gross
8 Enter the Heating Value in Btu per SCF. Not used in volume calculations. Only used for calculating MMBTU for reports.
Page 3–32 2104349 rev. AD

Default NX19 Fixed AGA-8 1992 All
Analysis Data Units
Value Ft/Fp Detail Others7
Helium 0.0000 mol % No Yes No
Hydrogen 0.0000 mol % No Yes No
iButane 0.0000 mol % No Yes No
iPentane 0.0000 mol % No Yes No
Methane 100.000 mol % No Yes Yes
nButane 0.0000 mol % No Yes No
nDecane 0.0000 mol % No Yes No
nHeptane 0.0000 mol % No Yes No
nHexane 0.0000 mol % No Yes No
nitrogen N2 0.0000 mol % Yes Yes Yes
nNonane 0.0000 mol % No Yes No
nOctane 0.0000 mol % No Yes No
nPentane 0.0000 mol % No Yes No
Oxygen 0.0000 mol % No Yes No
Propane 0.0000 mol % No Yes No
Water H2O 0.0000 mol % No Yes No
Specific Gravity 0.6000 N/A Yes Yes Yes
3.6.6 Constants
On a single tube gas orifice meter, there are certain constants or parameters that
may need to be entered or changed from the default values. Table 3–3 displays
the list of these constants.
Table 3–3 Gas Orifice Constants

Default AGA-3 AGA-3
Parameters Units AGA-7 ISO-5167
Value 1985 1992
Configurable
Auxiliary Factor (Faux) 1.0 Yes Yes Yes Yes
Barometric Pressure PSIA Yes Yes Yes Yes
DP Zero Cutoff 0.0000 In H2O Yes Yes No Yes
Meter Factor (Fb Basic Orifice
210.2300 Yes No No No
Factor)
In per Deg.
Orifice Coefficient of Expansion 9.2500 No Yes No Yes
F
Orifice Diameter 1.0000 Yes Yes No Yes
Orifice Material Stainless Yes No No No
Inches per
Pipe Coefficient of Expansion 6.2000 No Yes No Yes
Deg. F
Pipe Diameter 2.0670 Yes Yes No Yes
Pressure Base (Contract) 14.7300 PSIA Yes Yes Yes Yes
Specific Heat Ratio 1.3000 Yes Yes No Yes
Tap Location Upstream Yes Yes No Yes
2104349 rev. AD Page 3–33

Default AGA-3 AGA-3
Parameters Units AGA-7 ISO-5167
Value 1985 1992
Flange
Tap Type Yes No No Yes
Taps
Temperature Base (Tb) 60.0000 Degrees F Yes Yes Yes Yes
Viscosity 0.0103 Centipoises Yes Yes No Yes
Z of Air at Base Condition 0.9996 No Yes No Yes
Fixed Cd .6 No Yes No Yes
Barometric Pressure 14.73 PSIA Yes Yes Yes Yes
K Factor (Vol. of Gas Per Pulse) 1.0 No No Yes No
3.6.7 Alarm Limits

The user has the ability to set the G4 EX alarm limits for the parameters listed in
Table 3–4. There are many purposes for setting these limits, i.e., controlling well
output or sending digital signals.
Table 3–4 Alarm Limits

AGA-3 AGA-3 ISO-
Parameter Default Value Units AGA-7
1985 1992 5167
Configurable
Dp High Limit 2047.9688 In H2O Yes Yes N/A Yes
DP Low Limit 0 In H2O Yes Yes N/A Yes
Flow Rate High Limit 1,000,000 SCF/Hr Yes Yes Yes Yes
Flow Rate Low Limit 0 SCF/Hr Yes Yes Yes Yes
RTD High Limit 420 Degrees F Yes Yes Yes Yes
RTD Low Limit 0 Degrees F Yes Yes Yes Yes
SP High Limit 2047.9688 PSIA Yes Yes Yes Yes
Uncorrected Vol High
ACF N/A Yes Yes Yes
Limit
Uncorrected Vol Low
ACF N/A Yes Yes Yes
Limit
3.6.8 Reset Volume

When the user resets the volume accumulator, the G4 EX will:
- Store time, date and previous accumulated partial calc period volumes into
the historical record file.
- Zero the remaining partial calc period accumulations.
- Complete all computations for the present flow file daily records.
- Begin a new flow file daily record.
- Zero total volume accumulator, and log the event with an accumulator value
before zeroing out the accumulator.
Page 3–34 2104349 rev. AD

Since the G4 EX volume calculations are made each vol calc
period, any changes that are made during the period would
effect the volume calculations (such as changing the orifice
plate size) and be introduced into the calculations. To avoid
introduced errors, it is recommended that the Reset Volume
command be used. This command forces the G4 EX to
perform volume calculations for the elapsed time since a
previous volume calculation was made. A new partial period
volume is added to the volume accumulator. This is logged
as an event before it is reset to zero (0).
3.7 Start Up the G4 EX
3.7.1 Putting the G4 EX On Line
To avoid a calibration shift, carefully follow these

instructions.

1) Open both the bypass valves, and close the vent to the atmosphere valve.
This stabilizes the pressure on both sides of the cell.
2) Begin to slowly open the high side orifice tap valve from the meter run.
3) Begin to slowly open the low side valve.
4) Once both the high and low sides are completely open, close both bypass
valves.
3.7.2 Setting G4 EX Temperature Calculation

The G4 EX temperature calculations can be set to the following conditions:
1) RTD Installed – This uses the RTD temperature input and stores the RTD
temperature unless the RTD fails. Additionally, it then uses and logs the
Fixed GF value.
2) Use Fixed TF – This uses and stores the fixed temperature.
3.8 G4 EX Standard Displays
3.8.1 Program Display

The single tube G4 EX comes from the factory with a set of default displays (see
Table 3–5). By default, each display item remains on the display for five seconds.
The user has the ability to change this default to zero (item not displayed) or any
value from 1 to 255 seconds. The user is also able to change the engineering
units and data format for display purposes. Further instructions on programming
the display system can be found in the PCCU32 Help Files. All display items and
item groups are user programmable and may be displayed by user defined
parameters.
Table 3–5 G4 EX Displayed Items
2104349 rev. AD Page 3–35

MM/DD/YY
DATE/TIME 24-hour clock
HH:MM:SS
Yesterday’s percent DP low limit percent time
YEST DP LO NN PERCENT
below DP low setpoint
Yesterday’s percent DP high limit percent time
YEST DP HI NN PERCENT
below DP high set point
Current flow rate programmable SCF or MCF
FLOWRATE NNNNNN.N SCF/HR
or MMCF
Total accumulated volume programmable SCF
ACCUM VOL NNNNNN.NN MCF
or MCF or MMCF
BATTERY NN.N VOLTS Battery voltage volts
DIFF PRESS NNN.N IN. H2O Differential pressure inches H2O
STATIC PRESSURE NNN.N PSIA Static pressure static PSIA
FLOW TEMP NN.N DEG. F Flowing temperature °F
Yesterday’s volume programmable SCF, MCF
YEST VOL NNNN.N MCF
or MMCF
Previous period volume last volume
PERIOD VOL NNNN.N SCF
calculation period volume
Orifice Diameter N.NNNN INCHES Diameter of installed orifice
STATION ID XXXXXXXXXX 10 character alphanumeric identifier
10 character alphanumeric application or tube
DEVICE ID XXXXXXXXXX
identifier
Page 3–36 2104349 rev. AD

4 G4 ex Maintenance
4.1 Overview
The following chapter will provide the user with standard maintenance information
and instructions on how to remove and install G4 EX components.
4.1.1 Maintenance Support

If installation, calibration and maintenance assistance is required, the user can
contact the Totalflow Service Department.
USA: (800) 442-3097 International: 001-918-338-4888
4.1.2 How to Use This Chapter

It is recommended that the user develop a regularly scheduled maintenance
program. By establishing a maintenance program, the G4 EX downtime can be
minimized.
Record all items within this chapter in the maintenance practice procedures.
Practical experience permits updating this schedule over a period of time. This
results in many maintenance items being handled on a routine basis before
potential problems result in a failure.
4.1.3 Cleanliness
Because a G4 EX installation is primarily exposed to external environmental
conditions, it is important that it be regularly inspected for cleanliness, both
externally and internally. Foreign contaminants can cause damage to interior
mounted components that can render the G4 EX inoperable.
4.1.4 Front Mounted LCD

The user is informed of operational problems and operational limit violations by
observing the alarm codes on the LCD display. Troubleshooting techniques for
dealing with these alarm codes is presented later in the manual.
4.1.5 Returning Parts for Repair

If a Totalflow component is to be returned to Totalflow for repair, securely wrap it
in protective anti-static packaging. Before returning a component, call Totalflow for
a Return for Authorization (RA) number. Affix this number to the outside of the
return package.
Part shipments must be prepaid by the customer. Any part that is not covered by
the original system warranty will be shipped to the customer, F.O.B.
4.2 Backing Up Configuration Files

Before beginning any maintenance on the G4 EX, the user should collect the data,
and back up all configuration files to the laptop’s hard drive or disk. This upload
safeguards data and allows the user to restart the unit without the obstacles
associated with reconfiguring the G4 EX should any problem arise.
Although there are Save buttons within the Entry mode screens in PCCU32 that
allow the user to back up Entry model data items, a complete system backup is
only accomplished by using the Save and Restore Utility or the 32-Bit Loader.
2104349 rev. AD Page 4–1

When using this utility to back up files, the user should also download the files to
the tfCold drive in the event of a cold start.

1) Collect the data from the unit.
2) While in PCCU32, click the Save and Restore Utility icon in the main
window toolbar.
3) When the Save and Restore window displays, click the Save Station Files
button. The Save Station Files dialog box will display.
4) When the Save Station Files dialog box displays, verify the default name
and path for the files. Click the OK button. This will save the tfData drive
files.
5) When finished saving the station files, a new dialog box offers the user the
option to Restore the Station Files to the tfCold drive. If the user selects
Yes, the station files will be downloaded to the tfCold drive.
4.3 Restoring Configuration Files

The Restore function enables the user to download configuration files to the G4
EX.
If prior to performing maintenance the Save Configuration Files was used, these
files were downloaded to the laptop’s hard drive or disk. The Restore function
downloads these files into the G4 EX’s tfCold drive. This safeguards the data and
allows the user to restart the unit without the obstacle of reconfiguring the G4 EX
should any problem arise.
4.3.1 Step-by-Step Instruction

1) While the user is in PCCU32, click the Save and Restore Utility icon on the
window’s main toolbar.
2) When the Save and Restore window displays, click the Restore Station
Files button. The Restore Station Files dialog box will display.
3) When the Restore Station Files dialog box displays, verify the default name
and file path. Click the OK button. This will restore the files to the tfCold
drive.
4) Verify that the unit is functioning properly.
4.4 Performing a Warm Boot

A warm boot signifies that the user has cycled power off the board without
disconnecting the lithium battery. This method enables the user to not lose any
stored data. A warm boot can be initiated from a hardware or software standpoint.
The following will take the user through the steps for both methods.
4.4.1 Hardware Warm Boot

There are two methods of warm booting the system from a hardware standpoint:
4.4.1.1 Method 1
1) The user will need to open the door to the unit. Locate the Reset button on
the G4 EX termination board.
Page 4–2 2104349 rev. AD

J19
COMM1
9
8
7
6
J9
5 1
4
3 3
2 S3
1
RESET
2 -
1 +
J16
PWR
Figure 4–1 Reset Button Location

2) Upon location, press the Reset button for approximately five seconds. The
unit will warm boot.
4.4.1.2 Method 2
1) Open the door to the unit. Ensure that there is voltage on the battery and
that the jumper is enabled.
If either of these conditions are not met, do not attempt a

warm boot. Continuing with this process without both
conditions being met will result in a cold boot and all
historical data will be lost.
2) Remove power to the board, and then reconnect. This will initiate a warm
boot.
4.4.2 Software Warm Boot

There are three methods of warm booting the system from a software standpoint:
4.4.2.1 Method 1
1) Open PCCU32. The user needs to ensure that they are not connected
initially and are at the Totalflow splash screen.
2) Click the 32-Bit Loader icon on the toolbar. This takes the user to the 32-Bit
Loader screen.
3) Within the screen, the user needs to select the Reload radio button.
4) Ensure that all of the checkmarks are removed from the various software
option. Once this has been accomplished, place a check in the options list
beside Shutdown Flash and Start Flash.
5) Select the needed connection type from the available drop-down menu.
6) Upon completion, click the Start button.
2104349 rev. AD Page 4–3

There is a chance that the user will see a PCCU32 dialog
box display that informs them that the Target Device Loader
is not working. The user will need to follow the dialog box
instructions to warm boot the system.
4.4.2.2 Method 2
The user must be in Expert view.
1) Move into Entry mode within PCCU32.

2) Upon completion, click on the Meter ID in the PCCU32 tree-view. By
default, this will take the user to the Station Setup tab.
3) Locate the System Shutdown/then Reset parameter field. Once located, set
the parameter value to Yes.
4) Click the Send button. This will initiate a warm boot.
4.4.2.3 Method 3
2) Once this has been completed, click the Terminal icon on the PCCU32
window toolbar. This will bring up the Terminal window.
3) Once in the Terminal window, move to the terminal prompt (->), and type in
the following: BOOT=WARM. Press Enter on the keyboard to initiate the
warm boot.
4.5 Performing a Cold Boot

A cold boot occurs when the user cuts power to the board, including the lithium
battery backup. This causes a loss of all historical data. A cold boot can be
initiated from a hardware or software standpoint. The following will take the user
through both methods.
4.5.1 Hardware Cold Boot

1) Open the door to the unit. Locate the lithium battery connector.
2) Upon location, disconnect the battery.
3) Press the Reset button for approximately five seconds. The unit will cold
boot.
Page 4–4 2104349 rev. AD

J5
1
4
LITHIUM
Lithium Battery
L1 Connector
Figure 4–2 Lithium battery Connector
4.5.2 Software Cold Boot

There are two methods for initiating a software cold boot:
4.5.2.1 Method 1
1) Open PCCU32. The user needs to insure that they are not connected
initially and are at the Totalflow splash screen.
2) Click the 32-Bit Loader icon on the toolbar. This takes the user to the 32-Bit
Loader screen.
3) Within the screen, the user needs to select the Reload radio button.
4) Make sure that all of the checkmarks are removed from the various software
options. Once this has been accomplished, place a check in the options list
beside Shutdown Flash, Delete tfData and Start Flash. A prompt will display
that warns that a cold boot is occurring. Click the Yes button to initiate a
cold boot.
There is a chance that the user will see a PCCU32 dialog

box display that informs them that the Target Device Loader
is not working. The user will need to follow the dialog box
instructions to cold boot the system.
4.5.2.2 Method 2
2) Once this has been completed, click the Terminal icon on the PCCU32
window toolbar. This will bring up the Terminal window.
3) Once in the Terminal window, move to the terminal prompt (->), and type in
the following: BOOT=COLD. Press Enter on the keyboard to initiate the
warm boot.
2104349 rev. AD Page 4–5

4.6 Changing the G4 EX Clock
When any measurement applications are instantiated on the G4 EX, changing the
clock could affect the time when log period entries are made. To protect the
integrity of the accounting audit trails, the G4 EX handles these types of clock
changes as follows:
4.6.1 Clock Change Not Crossing an Hour Boundary

When the next log period entry is made, the clock is not altered.
Example: If the present time is 4:14 pm and the clock is changed to 4:05 pm of
the same day, the daily flow record is the same. Entry reflects averages
accumulated over a 70 minute time period (15 minutes plus 55 minutes).
4.6.2 Forward Clock Change Crossing an Hourly Boundary

Forces a log period entry for part of the hour that has accumulated since the last
hourly entry. The G4 EX then advances to the newly defined data flow record
boundary and begins maintaining the balance of the day’s data in a newly defined
boundary.
the same day, the entry reflects only a 55 minute average accumulation. A new
flow record is then written. This period is also based on a 55 minute accumulation.
4.6.3 Backward Clock Change Crossing an Hourly Boundary

Hourly entry is made for part of the hour that has accumulated since making the
last hourly entry. This is the same as a Forward Clock Change Crossing an Hourly
Boundary. The G4 EX advances to a new day’s data flow record and maintains
the balance of the day’s data in a new record.
the same day, the log period entry reflects only a five minute average
accumulation. A new flow record is then written. This log period is based on a 60
minute accumulation.
A backward clock change uses two records to maintain data

integrity. This assures that previously recorded data is not
overwritten.
If it is necessary to make small backward time changes of

less than one (1) hour, the user should wait until the current
hour has progressed far enough to make a change that does
not cross an hour boundary.
4.7 Replacing the G4 EX battery Pack

This chapter presents the procedures for removal and installation of the G4 EX
battery pack that is located within the 6270 OEU. To access the battery pack,
open the door (see Figure 4–3). The battery pack is located in the upper portion of
the chamber.
Page 4–6 2104349 rev. AD

To extend the lift of the battery pack, fully charge the battery
prior to installation. A system using solar panels may not fully
charge the battery. Additionally, a fast charge, which the
solar panel cannot provide, improves the life of the battery.
To recharge a battery, a quick charge will remove buildup in

the battery much more effectively than a trickle charge. A
battery slowly drained by low light conditions on a solar
charged system or setting in storage will be less likely to
recover than a battery pack that was quickly discharged from
a short. Store batteries in a cool environment for less
drainage.
Figure 4–3 6270 OEU Configuration

1) Collect the data from the unit.
2) Back up the configuration files following the instructions listed previously in
this chapter.
3) Verify the “LL” alarm battery alarm is not being displayed on the G4 EX’s
display. This prevents any data stored in RAM from being lost when power
is removed.
4) Disconnect the charging source from the charger regulator.
2104349 rev. AD Page 4–7

5) Disconnect the battery pack cable connector going to the charger regulator.
6) Remove the battery pack from the battery compartment.
7) Remove the terminal lugs from the battery, and place it on the new battery.
Be sure to connect the red wire to the positive (+) side and the black wire to
the negative (-) side.
8) Insert the battery pack into the compartment. Insert the battery pack so that
its terminals are not touching any metal inside of the unit.
9) Reconnect the battery pack cable connector to the charger regulator.
10) Reconnect the charging source to the charger regulator.
11) Monitor the LCD for normal operational reading and battery voltage.
4.8 Replacing the G4 EX board

The G4 EX board is mounted inside of the G4 EX front end cap. To access and
remove the G4 EX board, perform the following procedures.
Remove power from the device, or insure the area is known to

be non-hazardous before removing any enclosure cover. For
further information, refer to the certification drawing indicated on
the device’s nametag, national and local electrical codes.
Installation and/or maintenance of electric components should

follow guidelines stipulated in the certification drawings shipped
with this unit and adhere to local codes.
Page 4–8 2104349 rev. AD

Figure 4–4 G4 EX Front End Exploded View

1) Collect data from the unit.
this chapter.
3) Verify that the “LL” battery alarm is not being displayed on the G4 EX LCD.

4) Gain access to the rear termination board by loosening the countersunk hex
socket locking set screw in the rear end cap. Use a 1/16” hex wrench to
perform this task. Upon completion, unscrew the end cap.
5) Disconnect the power connector (J16) from the board mounted connector
(see Figure 4–5).
2104349 rev. AD Page 4–9

J13 Jumper:
Jumper Pin1 to Pin 2 for DOUT
Jumper Pin 2 to Pin 3 for AI2
Jumpers for RS-485 Mode Only
AIs/DIs/DOs
If this is the last board on the bus, or if it is the
only board, jumper J9, Pin 1 to Pin 2.
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
There are a pair of jumper wires required for
RS-485 only: wire J19, Pin 9 to Pin 7 and
Wire Pin 8 to Pin 6 on the terminating board.
J12 Jumper:
Jumper Pin1 to Pin 2 for AI For all intermediate boards, Jumper J9, Pin 2
Jumper Pin 2 to Pin 3 for DOUT2 J5 to Pin 3
J3
+ AI - + DI - + DO -
J9 Terminates RS-485
on COMM1
J12 J6 J13 COMM1
1 3 1 3
J19 (RS-232/RS-485)
J8 COMM1
(WHT) RTD OUT 5 I/O EXPANSION 9 CTS/RBUS(-)
(WHT) RTD + 4 6 9 8 RXD/RBUS(+)
(BLK) RTD - 3
RTD PROBE 1 5
7 TXD/TBUS(-)
(BLK) RTD IN 2 6 RTS/TBUS(+)
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET
1 OPERATE COMM1
4
RTD
3 COMM2 SW
3
SECURITY J7 2 S3 GND
1 VBATT
USB CLIENT RESET

2 (-)
-
J4 J21 1 (+)
+
J16
1
PWR
MMI
J20 Note:
COMM2 Pinouts are shown to the outside for clarity,
but all of the Phoenix connectors are wired
XFCG46200EX and attached to the inside.
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
CTS/RBUS(-) Jumpers for RS-485 Mode Only
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
RRTS COMM2
OPERATE COMM2
on COMM2
COMM2 SW
GND
VBATT
COMM2
(RS-232/RS-485)
Figure 4–5 Termination board

6) Gain access to the G4 EX board by loosening the countersunk hex socket
locking set screw in the front end cap. Use a 1/16” hex wrench to perform
this task. When completed, unscrew the end cap.
7) After the end cap has been removed, gently pull the graphic overlay plate
away from the snap on standoffs.
8) Using a small slot head screw driver, remove the four screws that hold the
LCD board to the G4 EX device.
9) Gently disconnect the LCD board from the G4 EX board, J2 connector (see
Figure 4–6). Lift the board from the device.
Page 4–10 2104349 rev. AD

Potentiometer
R1
Processor Card
CONTRAST
1
SD CARD
J2
1 16
SD CARD
J3
JTAG
J5
1
4
J4 LITHIUM
XA1
Lithium Battery
L1 Connector
Primary Component Side
Figure 4–6 G4 EX board

10) After the LCD board is disengaged, gently remove the lithium battery
connector (J5) from the G4 EX board.
11) Upon removal of the lithium battery connector, gently snap the board out of
the device. Please note that the board is still connected to the device
through the cables in the back.
12) Unplug the sensor connector cable (J6) and the ribbon cable (J1) from the
G4 EX board (see Figure 4–7). Remove the board from the G4 EX device.
2104349 rev. AD Page 4–11

2 50
1 49
J1
SENSOR
13 1
14 2
J6
Sensor Connector
Secondary Component Side
Figure 4–7 G4 EX board Secondary Component Side.
If the user has the 2104353–503 motherboard, they will need

to remove the processor card from the removed
motherboard and place it into the new one. This is
accomplished by pulling back the attachment brackets and
gently unsnapping the processor card from its housing.
Once completed, take the processor card and snap it into
the replacement motherboard. Continue to step 13.
13) Take the replacement G4 EX board and attach the sensor cable and the
ribbon cable to their corresponding connectors.
Please note that both the sensor cable and ribbon cable pin
1 wire are red. The red edge (pin 1) of the cable should plug
into the outer most edge of the connector (pin 1).
14) Take the lithium battery cable and attach the cable to its corresponding
connector (J5).
15) Align the mounting holes on the G4 EX board with the standoffs,. Once
aligned, snap the board into place within the device.
16) Once in place, line up the LCD board mounting holes to the G4 EX board.
Gently connect the LCD board into the G4 EX board via the J2 connector.
17) Take a small slot head screwdriver and attach the LCD board to the G4 EX
board using the four mounting screws.
Page 4–12 2104349 rev. AD

4.9 Replacing the G4 EX termination board
The termination board is mounted inside of the G4 EX back end cap. To access
and remove the display board, perform the following procedures.
Rear Cap
Term Board
Ribbon Cable
Note: The single red wire on the cable goes
to Pin 1 of both connectors
Stand-off
(4 places)
MMI Connector
Figure 4–8 G4 EX Back End Exploded View

this chapter.

2104349 rev. AD Page 4–13

5) Upon unscrewing the end cap, the user will see the termination board (see
Figure 4–5). Using a ¼” socket wrench, unscrew the four socket mounting
screws that hold the termination board in place.
6) Depending on the configuration that the user selected from the factory,
remove either the USB cable (J4), Ethernet cable (J7) or MMI cable (J21).
7) Next, remove the Comm 1 (J19), Comm 2 (J20) and power (J16)
connectors.
8) Upon completion, remove the ribbon cable from the J1 connector (Figure 4–
9). This will enable the user to remove the termination board from the G4
EX device.
2 50
1 49
J1
Figure 4–9 Termination board secondary component side

9) Take the replacement termination board and attach the ribbon cable to the
J1 connector.
Please note that the ribbon cable pin 1 wire is red. The red
edge (pin 1) of the cable should plug into the outer most
edge of the connector (pin 1).
10) Depending on the configuration that the user selected from the factory,
attach either the USB cable (J4), Ethernet cable (J7) or MMI cable (J21) to
their respective connection.
11) Next, attach the Comm 1 (J19), Comm 2 (J20) and power (J16) connections
to their respective connectors.
12) Upon completion, take the four socket mounting screws, and attach the
termination board in the G4 EX device.
Page 4–14 2104349 rev. AD

4.10 Replacing the Liquid Crystal Display (LCD) board
The LCD board is mounted inside of the G4 EX front end cap. To access and
remove the display board, perform the following procedures.
Do not remove the lithium battery, since it provides power to

the RAM. It is recommended that historical flow data be
downloaded before accessing and removing the LCD board
to prevent the potential loss of stored data.

this chapter.
Remove power from the device, or insure the area is known to

be non-hazardous before removing any enclosure cover. For
further information, refer to the certification drawing indicated
on the device’s nametag and national and local electrical
codes.
5) Disconnect the power connector (J16) from the board mounted connector
(see Figure 4–5).
6) Gain access to the LCD assembly by loosening the countersunk hex socket
8) Using a small flat head screw driver, remove the four screws that hold the
LCD board to the G4 EX device.
9) Gently disconnect the LCD board from the G4 EX board, J2 connector (see
Figure 4–6). Lift the board from the device.
10) To reinstall the LCD board, repeat steps 8 through 9 in reverse order. Do
not over tighten screws.
11) Once the LCD board is reinstalled, apply power to the G4 EX (step 5), and
verify that the information displayed on the LCD is correct.
12) Adjust the contrast potentiometer, R1, for optimum display.
To adjust the display contrast, use an extra small screwdriver

to turn the potentiometer, R1, completely clockwise. After
completing this, turn the screw back counter clockwise until
the screen is readable.
13) Replace the graphic overlay plate that was removed earlier.
2104349 rev. AD Page 4–15

4.11 Replacing the lithium battery
Do not remove power to the unit. Loss of power to the unit

will initiate a cold start. All data and configuration files will be
lost.

this chapter.

5) Upon completion, gently remove the lithium battery connector (J5) from the
G4 EX board.
6) Once the lithium battery connector is removed, snap the board out of the
device. Please note that the board is still connected to device through the
cables in the back.
7) After the G4 EX board has partially been removed, unplug the sensor
connector cable (J6) and the ribbon cable (J1) from the G4 EX board. This
will allow the board to be completely removed from the device.
8) The user will now see a manufacturing plate. The lithium battery assembly
is located on the back of this plate in a small battery enclosure. Carefully
remove the plate from the snap on standoffs.
9) The lithium battery assembly is attached to the manufacturing plate by a
Velcro strip. Gently remove the lithium battery from the Velcro strip.
10) Take the new lithium battery, and attach the Velcro edge of the battery to
the Velcro strip in the battery enclosure on the manufacturing plate.
11) Once the lithium battery is attached to the manufacturing plate, snap the
plate back into the device using the appropriate standoffs.
12) Take the G4 EX board, and attach the sensor cable and the ribbon cable to
their corresponding connectors.
Please note that both sensor cable and ribbon cable pin 1
wire is red. The red edge (pin 1) of the cable should plug into
the outer most edge of the connector (pin 1).
13) Attach the lithium battery cable to its corresponding connector.
Page 4–16 2104349 rev. AD

14) Align the mounting holes on the G4 EX board with the standoffs, and snap
the board into place within the device.
15) Replace the display and graphic overlays that were removed earlier.
4.12 Replacing the transducer (EXIMV)

The EXIMV is specifically designed for the G4 EX device. The transducer
characterization files are stored in the G4 EX raw sensor interface board. As such,
replacement/repair involves removing both the transducer and the G4 EX raw
sensor interface board from the actual G4 EX device. Contact Totalflow to return
both pieces for replacement under warranty or for repair.
Entry into the interior of the transducer voids the transducer

warranty. If the transducer requires servicing, the entire
assembly must be removed from the unit, packaged
securely for shipping and returned to Totalflow. Contact
Totalflow Customer Service for instructions.
Figure 4–10 EXIMV installation overview

this chapter.
3) Once the user has finished backing up the configuration and data files, they
will need to open the manifold high/low equalizer valves.
4) Using the orifice tap valves, close off both upstream and downstream.
These two valves connect the meter run high/low output lines to the
transducer.
5) Open the vent valve to atmosphere.
6) Completely disconnect the high/low manifold lines from the transducer.
2104349 rev. AD Page 4–17

7) If the user is able to do so at this point, remove the external power that is
feeding the unit. If this can be done, skip to step 10; otherwise, continue to
the next step.
XFCG4EX
- +
HIGH SIDE
LOW SIDE EQUALIZER VALVE
EQUALIZER VALVE
VENT TO
ATMOSPHERE
Figure 4–11 G4 EX with block manifold

9) Disconnect the power connection (J16) from the termination board mounted
connector.

Page 4–18 2104349 rev. AD

11) After the end cap has been removed, gently pull the display overlay and
graphic overlay plate away from the snap on standoffs.
12) After the graphic overlay plate is off, gently remove the lithium battery
connector (J5) from the G4 EX board.
13) Upon removal of the lithium battery connector, snap the board out of the
device. Please note that the board is still connected to the device through
the cables in the back.
14) Unplug the raw sensor connector cable (J6) and the ribbon cable (J1) from
the G4 EX board.
15) Gently remove the board from the G4 EX device.
16) Loosen the 2” mounting pole U-bolts. Rotate/lower the unit a sufficient
distance so that the transducer can be removed.
17) Loosen the hex socket head set screws on the neck of the unit using a 3/32”
hex wrench. Continue until the transducer turns freely. Gently turn counter-
clockwise until the transducer is free from the enclosure.
18) Replace the transducer and raw sensor board with a new/repaired/spare
unit of the same type and pressure rating.
19) Reconnect the high/low manifold lines, and restore pressure.
20) Reassemble the unit by performing steps 10-14 in reverse order.
21) Following the instructions in section 4.3, restore the station files.
4.13 Calibration
The calibration mode allows the user to calibrate, check and zero the static and
differential pressure. Additionally, this mode allows the user to set the bias for the
resistance temperature detector (RTD). During the initial calibration, the
parameters shown in Table 4–1 will need to be configured.
Table 4–1 Calibration configurable parameters

Parameter Default Value Units
RTD Installed No
RTD Bias 0.00 Degrees F
Temperature Base (Tb) 60.000 Degrees F
Used Fixed Temperature (TF) No
4.13.1 Required test equipment

The following test equipment is required to calibrate the G4 EX EXIMV:
- PCCU32 version 7.17 or later
- Deadweight tester or equivalent calibration standard
- Test gauge capable of dual range measurement (PSIG and inches)
- Barometer or another means which can determine barometric pressure
- Nitrogen or compressed air source
2104349 rev. AD Page 4–19

If a method other than compressed nitrogen/deadweight
tester is used to calibrate the static pressure cell, the user
must ensure that the prescribed flange type valves are
blocked to prevent false differential pressure from being
applied to the DP cell. Additionally, ensure that both high and
low sides are pressured up during SP calibration.
4.13.2 Hold mode

When calibrating the transducer or setting up a fixed temperature, PCCU32 will
instruct the G4 EX to ignore live values for the flow calculations for the period of
time that the G4 EX is being calibrated. During this time, the G4 EX uses SP, DP
and temperature captured at the time that calibration mode was entered. This is
referred to as the Hold mode.
To exit Hold mode:
1) Exit Calibration mode.
2) Unplug the PCCU cable at the G4 EX connector.
Totalflow recommends performing a five point check before

and after calibration. The host software (WinCCU) is capable
of recalculating the volume based on the differences
between the previous five point check and the current five
point check.
After a secure audit trail is archived, WinCCU recalculates

the flow volumes based on the previous and current markers.
This allows more accurate results of the flow volume.
4.13.3 Static pressure (SP) calibration checks

The G4 EX allows the user to check the static pressure calibration and log
pressure marker check points. The user should perform this check prior to and
directly following the calibration.
During normal operation of the G4 EX, the display provides continuous SP
readouts; however, during this procedure, the G4 EX is placed in a temporary
Hold mode.
A minimum of three SP markers should be set; however, the user can enter as
many SP markers as they want. Recording too many markers could cause the G4
EX to overwrite existing older events. Only the last five checks are used by the
WinCCU editor for calibration adjustment. Enter a low, mid-low, mid, mid-high and
high value.
The resulting comparison pressure must not be greater than

the static pressure cell’s maximum pressure.

1) Enter the Calibration menu’s Checks screen. This will place the G4 EX on
Hold. Select the preferred measurement tube from the tree-view.
Page 4–20 2104349 rev. AD

2) Select SP from the Calibration drop-down menu to the left of the Pressure
Marker table.
3) Select the SP type: Absolute or Gauge.
Absolute will display values with the barometric pressure

added in. Additionally, entered values will need the
barometric pressure added. Gauge will display values in
gauge pressure. Additionally, entered values will need to be
in gauge pressure.
4) Click on the Enter Pressure Check Value, and select Continuous to update
the current reading.
5) Verify that the vent valve is closed (see Figure 4–12).
6) Open both the high and low equalizer valves.
7) Close both the downstream and upstream tap valves.
8) Open the atmospheric vent valve.
9) Enter a pressure marker for atmospheric pressure (PSIA). Enter zero if in
Gauge mode or the barometric pressure (or contract value) if in Absolute
mode. Click the OK button.
10) Close the atmospheric vent valve.
11) Click on the Enter Pressure Check Value.
12) Connect Calibration Standard to the calibration test port.
13) Pressure to the next preferred verification pressure.
14) When the current reading stabilizes, enter the pressure value from the
calibration source. Remember to add the barometric pressure if the
pressure type is Absolute. Click the OK button.
15) Repeat steps 11 through 14 for each pressure check value.
16) When all the static pressure markers have been set, determine if calibration
is required. If no calibration is required, return the manifold to service before
exiting Calibration mode.
For additional information regarding Static Pressure

Calibration Checks, see the PCCU32 Help Files.
2104349 rev. AD Page 4–21

Figure 4–12 Calibration diagram
4.13.4 Differential pressure (DP) calibration checks

As discussed in section 4.13.3, it is recommended that checks of the differential
pressure (DP) be performed prior to and directly following calibration.
A minimum of three differential pressure markers should be set; however, the user
may enter as many DP pressure markers as they prefer. Recording too many
markers may cause the G4 EX to overwrite existing older events. Only the last five
checks are used by the WinCCU editor for calibration adjustment. Enter a low,
mid-low, mid, mid-high and high value.
During normal operation of the G4 EX, the display provides continuous DP
readouts; however, during this procedure, the G4 EX is placed in a temporary
Hold mode.

1) Enter the Calibration menu’s Check screen. This places the G4 EX on
HOLD. Select the preferred measurement tube from the tree-view.
2) Select DP from the Calibration drop-down menu to the left of the Pressure
Marker table.
3) Click on Enter Pressure Check Value, and select Continuous to update the
current reading.
Page 4–22 2104349 rev. AD

8) Enter a pressure marker for differential pressure “0.0”. Click the OK button.
9) Close the high side equalizer valve, and verify that the low side is vented to
atmosphere.
10) Connect Calibration Standard to the calibration test port.
11) Pressure to the next preferred verification pressure.
12) When the current reading stabilizes, enter the pressure value from the
calibration source. Click the OK button.
13) Repeat steps 11 through 12 for each pressure check value.
14) When all the differential pressure markers have been set, determine if
calibration is required. If no calibration is required, return the manifold to
service before exiting Calibration mode.
For additional information regarding Differential Pressure

Calibration Checks, see the PCCU32 Help Files.
4.13.5 Calibrating static pressure (SP)

A three or five point pressure method is used to calibrate the G4 EX static
pressure cell. These different pressures are applied to the cell from a known,
traceable source. The resultant pressure values are entered into the G4 EX using
PCCU32 software.
When performing the following procedures, wait for the G4 EX display to stabilize.
If the G4 EX is not in Calibration mode, the display will not necessarily match
applied cell pressures.
The G4 EX uses an absolute static pressure (SP) cell.

Absolute pressure measures the pressure referenced to a
vacuum or sealed chamber. This is different than a gauge
cell which measures the pressure referenced to the
atmosphere.
Since the static pressure cell is an absolute device, it always

measures the true pressure relative to a vacuum or sealed
chamber. As such, when vented, it measures true
barometric pressure.
For other points of calibration, add the reading of PSI and

barometric pressure to arrive at PSIA. Upon completion,
enter this reading.
4.13.5.1 Absolute versus gauge

It is recommended that the initial calibration point be at vented conditions. When
this is done, the barometric reading (in PSI) should be used as the initial point.
When operating in PCCU32’s Absolute mode, other points of calibration are
arrived at by adding the PSI reading and the barometric pressure to arrive at
PSIA. Once this has happened, enter this reading.
When operating in PCCU32’s Gauge mode, readings may be entered in as read,
and then a barometric pressure reading is entered.
2104349 rev. AD Page 4–23

4.13.5.2 Calculating PSI
To convert barometric pressure measured from inches of mercury to barometric
pressure (PSI), perform the following calculation:
Barometric pressure, in inches of mercury x .4912 or (2.036) equals barometric
pressure in PSI.
1) Enter the Calibration menu’s Calibration screen. This places the G4 EX in
Hold. Select the preferred measurement tube from the tree-view.
2) Select SP from the Calibration drop-down box to the left of the Pressure
Marker table. Select 3 or 5 Point Calibration.
3) Set the Transducer SP Pressure Range in the Calibration window. This
should match the range reading from the tag or label attached to the
transducer.
4) Select the SP type: Absolute or Gauge.
Absolute will display values with the barometric pressure

added in. Additionally, entered values will need the
barometric pressure added. Gauge will display values in
gauge pressure. Additionally, entered values will need to be
in gauge pressure.
5) Enter the barometric pressure in the bottom window before proceeding.

9) Open the atmosphere vent valve.
10) Click on the Low Cal Point button. Verify the current reading is continuously
updated. This should represent the lowest calibration point.
11) When the current reading stabilizes, click the OK button; otherwise, enter a
different value, and then click the OK button.
12) When the previous reading was accepted, notice that the 100% Cal Point
button is activated. To select, press Enter.
13) Connect calibration standard to the calibration test port.
14) Close the atmosphere vent valve.
15) Pressure to 100% of the transducer range (100% of the target value).
16) When the current reading stabilizes, accept the target value already
showing in the window; otherwise, enter the pressure value from the
17) Again, notice that the next Cal Point is activated. To select, press Enter.
18) Pressure the transducer to the next target value as shown in the Calibration
window.
20) Repeat steps 17 through 19 until all calibration points have been entered.
Page 4–24 2104349 rev. AD

21) Upon completion of the SP calibration, new calibration markers should be
set.
22) Return the manifold to service before exiting Calibration mode.
4.13.6 Calibrating differential pressure (DP)

A three or five point pressure method is used to calibrate the G4 EX differential
pressure cell. These different pressures are applied to the cell from a known,
traceable source. The resultant pressure values are then entered in the G4 EX
using PCCU32 software.
During factory calibration, any differential pressure (DP) shift due to static
pressure effect is corrected. This is not user configurable and will not be modified
due to field or user calibration. This ensures that the readings received in the field
are accurate. The user may not change the factory set shift. If readings appear
incorrect, the user may need to check for leaks and then recalibrate the DP.
When calibrating, wait for the readings to stabilize before entering the new values.

1) Enter the Calibration menu’s Calibration screen. This places the G4 EX in
HOLD.
2) Select DP from the Calibration drop-down box to the left of the Pressure
Marker table. Select 3 or 5 Point Calibration.
3) Set the Transducer DP Pressure Range in the Calibration window before
proceeding. This should match the range reading from the tag or label
attached to the transducer. Target values based on the selected range will
display in the Calibration table.
8) Click on the Low Cal Point button. Verify the current reading is continuously
updated.
9) When the current reading stabilizes, click the OK button; otherwise, enter a
different value, and click the OK button.
10) When the previous reading was accepted, notice that the 100% Cal Point
button becomes activated. To select, press Enter.
11) Connect the Calibration Standard to the calibration test port.
12) Close the high side equalizer valve, and verify that the low side is vented to
atmosphere.
13) Pressure to 100% of the transducer range (100% of target value).
15) Again, notice that the next Cal Point is activated. To select, press Enter.
16) Pressure the transducer to the next target value as shown in the Calibration
window.
2104349 rev. AD Page 4–25

showing in the window; otherwise, enter the pressure value from calibration
source. Click the OK button.
18) Repeat steps 15 through 17 until all calibration ports have been entered.
19) Upon completion of the DP calibration, new calibration markers should be
set.
20) Return the manifold to service before exiting Calibration mode.
For additional information regarding Differential Pressure

Calibration mode, see PCCU32 Help Files.
4.14 Onboard I/O calibration overview

The Calibration mode enables the calibration of the analog inputs, analog outputs
and pulse inputs.
4.14.1 Hold mode

When calibrating, PCCU32 will instruct the G4 EX to ignore live values for the
period of time that the G4 EX is being calibrated. This prevents real-time G4 EX
calculations from being effected during calibration. During this time, the G4 EX
uses the last known value at the time Calibration mode was entered. This is
referred to as a Hold mode.
To exit Hold mode:
1) Exit Calibration mode.
2) Unplug the PCCU cable at the G4 EX connector.
4.14.2 Calibrating onboard analog inputs

The G4 EX comes standard with two analog inputs on the G4 EX board. As the
user enters Calibration mode, the G4 EX moves into Hold mode and displays the
current values.
When the user selects the Update checkbox, the Current Values section will
display the current values continuously. When different analog inputs are selected,
their assigned register numbers are displayed on the top of the screen.
Follow the instructions in the PCCU32 Help Files for specific software steps.
Generally, the user will need perform the following procedures:
If the user intends to use a 4-20 mA transmitter on the analog

input, please refer to Appendix X. Manufacturer’s
specifications can often lead to confusion. In some
instances, the manufacturer’s specifications will claim to
operate from 10 to 30 VDC. They are not always clear that
this 10-30 VDC must be applied across the 4-20 mA
transmitter only (and not across the transmitter/load resistor
series combination). Again, refer to the explanation in the
appendix.
Page 4–26 2104349 rev. AD

4.14.2.1 Calibration
1) Connect an accurate power source capable of 1-5 volts to the AI terminals
that are to be calibrated.
2) In Calibration window for the AI that is being calibrated, select either 3 or 5
Point calibration for the number of preferred calibration points. 3 Point for
low (50% and 100% values) and 5 Point for low (25%, 50%, 75% and 100%
values).
3) In the Current Value field, place a check in the Update checkbox. This
causes the AI to look for the source at the terminals instead of a test value.
4) Begin the calibration by starting with the first selection, Low Cal Point.
5) Apply one volt to the AI terminals.
6) Enter a value (typically zero) that represents the low calibration point and
represents the desired engineering units. Upon completion, click the OK
button.
The current reading value on the pop-up entry screens will

be placed in the Reading column and represent values from
the previous calibration. User entered values will be
displayed in the Entry column.
7) Move to the 100% Cal Point parameter field. Once there, apply five volts to
the AI terminals.
8) Enter a value that represents the full range and represents the desired
engineering units. Upon completion, click the OK button.
9) If 3 Point calibration was selected, move to the 50% Cal parameter field.
Once there, apply three volts to the AI terminals.
10) Enter a value that represents 50% and represents the preferred engineering
units.
If performing a 5 Point calibration, the user will need to add

additional values for both 25% and 75% calculation points.
4.14.3 Onboard pulse and digital inputs

The Totalflow G4 EX comes standard with one high speed pulse input on board.
This may also be used as a digital input. The following procedure will enable the
user to set the digital input.
Follow the instructions in the PCCU32 Help Files for specific software steps.

1) The user will need to click on the Calibrate icon in the PCCU32 main
toolbar. Once completed, click on the AGA-7 tube in the tree-view.
2) Click on the Setup tab.
3) If the device was ordered as a Pulse Input meter, the register addresses
(Static Pressure, Pulse Input and Temperature) are listed and fixed. If,
however, a new tube application was added by the user, they will need to
manually enter the register addresses.
2104349 rev. AD Page 4–27

4) Next, the user will need to click on the K-Factor button. Enter a value, and
click the OK button. Input pulses are multiplied by the K-Factor. To have a
one-to-one pulse count, user a factor of 1.
Please take into consideration that these inputs may have

the de-bounce enabled or disabled. This feature is
discussed in the PCCU32 Help Files and is also turned on
or off within PCCU32.
4.15 Zero transducer

During the process of setting pressure markers to determine the need for a
calibration of either the static pressure (SP) or the differential pressure (DP), the
user may conclude that the SP or the DP pressures are out of alignment at exactly
the same amount at each pressure marker (linear shift). When this occurs, the
user may either recalibrate the G4 EX or they can set the transducer to zero. The
preferred method is to recalibrate the G4 EX. This maintains the G4 EX records in
a manner that assures accountability and continuity when other measurement
issues arise. By using the Zero Transducer command, all references to previous
pressure markers are non-existent, eliminating the ability to adjust volumes based
on previous markers.
Using the Zero Transducer capability assumes that the shift

is linear. This means that at different levels of pressure the
transducer is off by exactly the same amount. If this is not
the case, the user needs to recalibrate the transducer
instead.
4.15.1 Static pressure

The SP can be zeroed without recalibrating. If the SP shifts, the user can enter a
new barometric pressure value. This shifts the SP transducer curve. After the Hold
state initiates, select Zero Transducer.
4.15.2 Differential pressure

The DP can be zeroed without recalibrating. If DP shifts, the user can enter a new
zero (0). This shifts the DP curve. After the HOLD state begins, select Zero
Transducer.
4.16 RTD calibration and bias

The Totalflow G4 EX has one onboard RTD input. The registers representing the
RTD input is normally assigned to a measurement tube. The RTD tab is located in
the Calibrate screen within the Onboard I/O tree-view. The user will need to click
the Analog Inputs sub-menu, and move to the RTD tab (see Figure 4–13).
Page 4–28 2104349 rev. AD

Figure 4–13 RTD calibration screen
The Current Value parameter will display the current value of the selected RTD by
placing a check mark in the Update field.

1) Connect the variable resistor or RTD calibration equipment to J7 on the G4
EX board.
Terminal J7
1 SHLD
2 Out
3 Plus (+)
4 Minus (-)
5 In
If the user elects to calibrate using an 100 OHM RTD probe,

refer to the PCCU32 Help Files to view resistance and
corresponding temperature readings.
2) Select the RTD tab within the Analog Inputs tab sub-menu under Onboard
I/O in the Calibration window.
3) Select whether to perform a 3 Point, 5 Point or Bias calibration. Note that if
a 3 Point is selected, there will be 3 Target values and 3 Cal Point buttons.
If 5 Point is selected, there will be 5 Target values and 5 Cal Point buttons.
2104349 rev. AD Page 4–29

4) Click inside the Range window, and enter a range. The range can be
anything and represent any units (percent, volts, etc.) that the user prefers.
Target values will be updated to reflect the new calibration range.
5) Click on the Low Cal Point button, and apply the voltage (typically 1 volt) for
the low calibration point. Verify the current reading on the Enter Low
Calibration Value screen is stable.
6) Enter the Target value for the Low Cal Point, and click the OK button.
7) Click on the 100% Cal Point button, apply the voltage (typically 5 volts) that
represents the full range and verify the current reading is stable.
8) Enter the Target value for the 100% Cal Point, and click the OK button.
9) Click on the next highest Cal Point button, and apply a voltage representing
its range. Verify the current reading is stable.
10) Enter the Target value for that Cal Point, and click the OK button.
11) Repeat Steps 9 - 10 for any remaining Cal Points. After the last point is
entered, PCCU32 will automatically calibrate the AI.
4.16.2 Calibrating RTD temperature bias

If the user elects to use Bias as a calibration method, select Bias from the
Calibration drop-down menu.
To change, click in the Bias parameter field. The RTD Bias dialog box will display.
This allows the user to enter a new value. The RTD's temperature will always be
biased by this value; however, the RTD Installed box on the Setup tab must be
checked for the RTD temperature and bias to be used. If the bias needs to be
negative, enter a minus sign (-) before the value. The current temperature value
under the Tf heading will increase or decrease to reflect the effect of the bias. The
bias does not affect the Fixed Temperature that is specified on the Setup tab. The
user can select Sp, Dp, etc., in the drop-down Calibration window to return to the
selected Calibration screen.
4.17 Changing the orifice plate

Use one of the following procedures when changing the orifice plate:
4.17.1 Taking meter run out of service (simplex fitting)

1) Take the meter run out of service.
2) Replace the physical orifice plate.
3) If the user wants to end the current log record and begin a new record with
the new orifice size (as stated in API21.1), they need to first move into Entry
mode within PCCU32. Next, select the preferred measurement tube, and
then click on the Commands tab. Change the value for the Reset Log
Period to Yes. This forces a new record to be written based on the old
orifice plate size. Additionally, if the user wants to simultaneously zero the
accumulated volume, they can use the Reset Volume command instead.
It is recommended to perform either the Reset Log Period or the Reset
Volume command to enhance the audit trail created by the event (API 21.1
requirement).
4) In PCCU32, enter the new orifice plate diameter.
5) Return the meter to service.
Page 4–30 2104349 rev. AD

4.17.2 Leaving meter run in-service procedure (senior fitting)
1) Place the G4 EX in HOLD by entering Calibration mode. This enables
constant SP, DP and Temperature values to be used, while the orifice plate
is being changed.
2) Replace the orifice plate.
3) Exit Calibration mode. This releases HOLD of the SP, DP and Temperature.
4) If the user wants to end the current log record and begin a new record with
the new orifice size (as stated in API 21.1), they need to first move into
Entry mode within PCCU32. Next, select the preferred measurement tube,
and then click on the Commands tab. Change the value for the Reset Log
Period to Yes. This forces a new record to be written based on the old
orifice plate size. Additionally, if the user wants to simultaneously zero the
accumulated volume, they can use the Reset Volume command instead.
It is recommended to perform either the Reset Log Period or the Reset
Volume command to enhance the audit trail created by the event (API 21.1
requirement).
5) In PCCU32, enter the new orifice plate diameter.
At the top of the Volume Calculation Period, the G4 EX will

perform calculations based on the new orifice plate diameter
for part of the period after the log was reset.
2104349 rev. AD Page 4–31

5 Troubleshooting
5.1 Overview
To serve as an aid in troubleshooting the G4 EX, the following chapter will provide
guidelines for the various subsystems within the device.
The chapter contains a troubleshooting flowchart (see Figure 5–1). As the user
follows the logic in this flowchart, they will be directed to specific test instructions
that are found in this chapter or may be directed to the Power Troubleshooting
section or the Communication Troubleshooting flowchart (see Figure 5–7). In
addition to the flowchart, this chapter contains step-by-step procedures for
troubleshooting the G4 EX with or without an installed radio communication unit.
5.1.1 Troubleshooting support

If troubleshooting instructions do not lead to a resolution and assistance is
required, the user can contact the Totalflow Service department:
USA: (800) 442–3097 International: 001-918-338-4880
5.1.2 Visual alarm codes

As noted in Chapter 1, the unit’s LCD annunciator displays many different status
indicators that are related to device operations. This section contains information
on those codes that reflect errors or provide information that is useful in
troubleshooting the device. Alarm codes indicate that an operational problem
exists.
The user is informed of operational problems and operational limit violations by
observing the alarm codes on the right side of the LCD display.
5.1.3 Sleep mode

Totalflow units are designed to move into a low power mode, Sleep, when an
insufficient supply voltage is present for a period of time. The issue that needs to
be addressed is the reason for the Sleep alarm; waking up the unit will be
insufficient for correcting the problem. As such, issues relating to the system’s
power supply should be investigated.
5.1.4 Solar panel

When a solar panel is attached to the 6270 OEU to provide a charging source for
the battery, cleanliness and positioning play an important part as do proper
electrical and cabling techniques. More detailed information on power
consumption can be found at www.abb.com/totalflow.
5.1.5 Communication
Troubleshooting the communications for this unit requires that both pieces of
equipment be tested: the G4 EX comm ports and the communication device. This
is discussed in more detail in the Communications Overview section. Other
communication troubleshooting information is shared in the following categories:
RS-232, RS-485, and RS-422 Communications.
2104349 rev. AD Page 5–1

Figure 5–1 Troubleshooting flowchart
5.2 Troubleshooting visual alarm codes

When a visual indicator is present (see Figure 5–2), the following section will
assist in determining the probable cause and the steps required to correct the
condition.
For the purposes of troubleshooting, only those codes considered alarms or codes
used to assist troubleshooting are discussed here. The entire list of status and
alarm codes can be found in Chapter 1. Table 5–1 contains a description of each
G4 EX alarm code. An alarm can be a word, character, letter or symbol.
Page 5–2 2104349 rev. AD

An application can be assigned to an annunciator, and any alarms or status codes
associated with that application will be displayed.
Figure 5–2 LCD and indicators
Table 5–1 Visual alarm codes

Indicator Description Alarm
I/O Subsystem
Low Lithium Battery Alarm: When displayed, the lithium battery voltage is
L
L below 2.5 VDC. If battery voltage is above 2.5 VDC, A1 appears shaded. A Y
new lithium battery measures approximately 3.6 VDC.
Low Charger: This is displayed if the G4 EX battery charging voltage is less
L
C than (+)0.4 VDC higher than the battery voltage. If charging voltage is (+)0.4 Y
VDC greater than the battery voltage, the annunciator is shaded.
Measurement Application
A to D Failure: Displayed if the A to D Converter absolute differential pressure,
absolute static pressure or temperature readings exceed maximum counts or
A
D Y
are less than the minimum counts. If the A to D Converter readings are within
range, AD is shaded.
Communication Protocols
 Transmitting Data: Sending a response. N
 Receiving Data: Processing request. N
! Nak: Negative Acknowledgement w/packet list. N
+ Ack: Positive Acknowledgement of receipt request. N
Waiting for ACK: Waiting for response after transmission. N
? Exception Alarm Proceeding. N
ID Recognized: Recognized and receiving request. N
Listen Cycle: Flashes if this remote port is active and running Totalflow
Remote Protocol. Flashes in sync with listening cycle that occurs at 1, 2 or 4 N
second intervals.
MODBUS ASCII: MODBUS ASCII protocol selected for the port assigned to
M N
this annunciator.
MODBUS RTU: MODBUS RTU protocol is selected for the port assigned to
m N
this annunciator.
¥ ID Recognized: The ID has been recognized but is waiting for Sync. N
2104349 rev. AD Page 5–3

5.2.1 Troubleshooting a blank LCD screen
When the LCD is blank, this means that the unit has entered S mode. This
indicates that the battery voltage has dropped below 10.9 VDC.

1) Make a local connection with the G4 EX. This will wake the unit up so that
the user can check all alarm conditions and determine the problem.
2) Check the power supply cable. It must make a good, secure electrical
connection with the connector, J16 (see Figure 5–3).
3) If voltage is low, investigate power supply source.
Figure 5–3 Power supply – G4 EX termination board
5.2.2 Troubleshooting a Low Lithium alarm (LL)

When the Low Lithium alarm displays, the lithium battery should be replaced
immediately. Failure to replace the lithium battery could result in a loss of data
following a power loss. Instructions for replacing the lithium battery can be found
in Chapter 4.
5.2.3 Troubleshooting an Analog to Digital Failure alarm (AD)

The G4 EX must have a Measurement Tube application running to receive this
error. If the A to D Failure alarm is present or if the device is in Sleep mode but is
still receiving minimum voltage, it may be necessary to test the data link between
the main electronic board and the transducer. Use the following instructions to
check the transducer.
Probable causes of receiving the A to D failure include:
Page 5–4 2104349 rev. AD

- A/D Converter is over or under range (DP, SP or Tf)
- Loose wiring connections
- Faulty RTD probe
If the A to D Converter readings are within range, AD is shaded.

1) Begin by collecting data from the unit.
2) View the Event log in PCCU32 for codes (see PCCU32 Help Files for more
information).
- 99 A/D converter could not be read.
- 100 A/D converter could be read again.
3) If the event code is found, follow the guidelines for returning the transducer
to Totalflow for repair or replacement. If the event code is not found,
continue to the next step.
4) In the PCCU32 Entry screen, monitor the readings by clicking on the I/O
Subsystem in the tree-view and selecting Onboard and Analog Inputs.
Check SP, DP and temperature to determine which measurement channel
is causing the alarm.
- If the alarm is caused by the SP or DP channel, equalize and vent the
manifold.
- If the alarm disappears: the SP or DP cell is not ranged properly, or
the manifold may have blockage.
- If the alarm is still present, replace the transducer.
- If the alarm is caused by the temperature channel, move to Step 9;
otherwise, move to the next step.
5) Set the EXIMV back to Factory calibration. If this corrects the alarm,
recalibrate the EXIMV to correct field calibration. If the alarm is not
corrected, continue to the next step.
6) Perform a Warm start on the unit. Verify that the unit is not displaying a LL
(Low Lithium) alarm, and then remove power from the unit. Restore power
to the unit. If the A/D Failure alarm is not corrected, continue to the next
step.
7) Perform the Save and Restore function. Follow the procedure in Chapter 4
for backing up configuration files. The user must ensure that they restore
these files to the tfCold drive.
8) Following the reset procedures covered in this chapter, perform a Cold start
on the unit. If the problem is not corrected, continue to the next step.
9) Check the RTD wiring at the EXIMV.
10) Perform the following three procedures found next in this chapter.
- RTD Continuity Test
- RTD Resistive Test
- RTD Impedance Test
11) Contact Totalflow to repair or replace the EXIMV.
2104349 rev. AD Page 5–5

5.2.4 Resistive Temperature Detector (RTD) Continuity test
Should the readings from the RTD be suspect, follow the instructions below to test
the RTD probe.
5.2.4.1 Required equipment

- Digital Multi-meter (DMM) with alligator clip leads

1) Begin by disconnecting power and communications from the EXIMV.
2) Disconnect the RTD from the EXIMV.
3) Perform continuity test of the wires leading to the probe. Set DMM to 200
OHM or Continuity Audio.
4) Check the continuity of the first wire pair (typically red or black) by
connecting one lead to each wire. The meter should read zero or close to
zero.
5) If there is continuity, move to step 7. If there is no continuity, verify the
wiring at the RTD head is correct.
6) If the wiring at the connection head is correct, the RTD is defective. Replace
the probe; otherwise, continue to the next step.
7) Check the continuity of the second wire pair (typically white) be connecting
one lead to each wire. The meter should read zero or close to zero.
8) Check the continuity of each wire (first pair either red or black, as identified
in step 4) to the probe or shield. If there is continuity, the RTD is defective.
Replace the probe. If there is no continuity, continue to the next step.
9) Check the continuity of each second wire pair (white, as identified in step 7)
to the probe or shield. If there is continuity, the RTD is defective. Replace
the probe. If there is no continuity, continue to the next step.
10) Check the continuity of each first wire pair (as identified in step 4) to each
second pair wire (as identified in step 7). The meter should read
approximately 100 to 140 OHMs. If this is the case, continue to the next
step. If not, the RTD is defective and should be replaced.
11) If the probe is still not functioning properly, recheck the wiring using the
supplied diagram. If no wiring error was found, perform the RTD Current
Source Troubleshooting test.
5.2.5 RTD Current Source (Resistive) test

If the readings from the RTD are still suspect following the RTD Probe Continuity
test, follow the instructions below to test the current source on the termination
board to verify that it is receiving power.

- Totalflow Diagnostics Kit
- Digital Multi-meter with alligator clip leads

1) Begin by disconnecting power and communications from the termination
board, if not already done.
Page 5–6 2104349 rev. AD

2) Disconnect the RTD from the termination board, if not already done.
3) Set the DMM to 200 mVDC.
4) Select the RTD test resistance value by selecting the resistor test
connection from the FCU Diagnostic kit, or make one using a resistor
appropriate for the unit.
- Substitute the RTD probe wiring by connecting either a 100 OHM or
123 OHM resistor across connector terminals 3 and 4.
- Connect a jumper wire between terminals 2 and 3.
- Connect a jumper wire between terminals 4 and 5.
5) Clip the positive lead of the DMM to the upper side of the RTD test resistor.
6) Clip the negative lead of the DMM to the lower side of the RTD test resistor.
7) Supply power to the unit.
8) Once running, the measured value across the RTD test resistor should be
either:
- 100 OHM Resistor – Min of 100mv to a maximum of 125mv
- 123 OHM Resistor – Min of 123mv to a maximum of 155mv
9) The RTD measurement temperature on the G4 EX display should read
either:
- 100 OHM Resistor – 31.0°F to 33.0°F
- 123 OHM Resistor – 140.8°F to 142.8°F
10) If either of the measured values are outside of the range, remove power and
replace the RTD.
11) Return power, and perform steps 9 and 10 again. If either of the measured
values are outside of range, remove power, and replace the main
termination board.
12) Return power, and perform steps 9 and 10. If either of the measured values
are outside of the range, remove power, and replace the EXIMV.
5.2.6 RTD Impedance test

If readings from the RTD are still suspect following the RTD Probe test, follow the
instructions below to test the current source on the termination board to verify that
it is receiving power.

- Ice Bath
- Digitial MultiMeter

1) Immerse RTD probe in ice bath.
2) Perform a continuity check between any two similarly colored wires.
Measured resistance should be 1 OHM or less.
3) Perform a continuity check between any two dissimilar colored wires.
Measured resistance should be approximately 100 OHMs.
4) Perform a continuity check between shield wire and any other wires.
Measured resistance should be in the Megohm range.
2104349 rev. AD Page 5–7

5) If any values are returned out of range, the RTD probe is defective. Replace
the RTD.
5.3 Power troubleshooting
5.3.1 Overview
This section focuses on determining what was has caused the G4 EX to lose
power. Generally, loss of power can be attributed to only the power supply
system. However, if the power supply system is used for powering a transceiver or
other peripheral equipment, a problem with that equipment may drain the battery
and cause the G4 EX to lose power.
The following procedures represent tests that the user can implement to deduce
the problem that exists with the powering of the unit.
5.3.2 Power supply test

Various equipment configurations will necessitate moving to one or more
additional tests from this location.

1) Check that the power supply voltage setting, the power supply current rating
and the cables used for the installation meet the recommended
requirements.
2) If this is a new installation and external power is being powered from the G4
EX, call Totalflow Technical Support for help in evaluating the cable and
power supply installation requirements.
3) Correct and retest, as necessary.
4) Check for a poor cable connection between the G4 EX board and the
lithium battery pack.
5) Verify that all field wiring screw terminals on the termination board are tight
(see Figure 5–4).
Page 5–8 2104349 rev. AD

J13 Jumper:
Jumper Pin1 to Pin 2 for DOUT
Jumper Pin 2 to Pin 3 for AI2
Jumpers for RS-485 Mode Only
AIs/DIs/DOs
If this is the last board on the bus, or if it is the
only board, jumper J9, Pin 1 to Pin 2.
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
There are a pair of jumper wires required for
RS-485 only: wire J19, Pin 9 to Pin 7 and
Wire Pin 8 to Pin 6 on the terminating board.
J12 Jumper:
Jumper Pin1 to Pin 2 for AI For all intermediate boards, Jumper J9, Pin 2
Jumper Pin 2 to Pin 3 for DOUT2 J5 to Pin 3
J3
+ AI - + DI - + DO -
on COMM1
J12 J6 J13 COMM1
1 3 1 3
J19 (RS-232/RS-485)
J8 COMM1
(WHT) RTD OUT 5 I/O EXPANSION 9 CTS/RBUS(-)
(WHT) RTD + 4 6 9 8 RXD/RBUS(+)
(BLK) RTD - 3
RTD PROBE 1 5
7 TXD/TBUS(-)
(BLK) RTD IN 2 6 RTS/TBUS(+)
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET
1 OPERATE COMM1
4
RTD
3 COMM2 SW
3
SECURITY J7 2 S3 GND
1 VBATT
USB CLIENT RESET

2 (-)
-
J4 J21 1 (+)
+
J16
1
PWR
MMI
J20 Note:
COMM2 Pinouts are shown to the outside for clarity,
but all of the Phoenix connectors are wired
XFCG46200EX and attached to the inside.
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
CTS/RBUS(-) Jumpers for RS-485 Mode Only
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
RRTS COMM2
OPERATE COMM2
on COMM2
COMM2 SW
GND
VBATT
COMM2
(RS-232/RS-485)
Figure 5–4 G4 EX termination board

7) Verify that there are no other devices that may drop and excessive voltage
across them in the power supply circuit to the G4 EX.
9) Replace the lithium battery with a known good battery using the Replacing
the Lithium Battery instructions in Chapter 4.
5.3.3 Charger Circuit test

If the system setup includes a battery pack, solar panel or AC charging source
connected to the 6270 Optional Equipment Unit (OEU) and the unit’s battery is not
remaining charged, the user will need to test the battery pack, AC charger and/or
the solar panel.
The following instructions contain the steps required to perform the circuit testing.

1) Disconnect power from the charger regulator located in the Optional 6270
enclosure.
2104349 rev. AD Page 5–9

2) Replace the battery with a known good battery using the Battery Pack
Installation procedure in Chapter 2.
3) Reconnect power to the charger regulator. If the battery pack is charged
through an AC charger, move to step 5; otherwise, continue to step 4.
4) Measure the charging voltage from the solar panel at the charger regulator.
Use a DMM that connects the (+) and (-) leads to the (+) and (-) solar panel
wires. Loaded voltage should be greater than or equal to the specifications
listed in Table 5–2. If the voltage is within range, the battery was bad.
If the loaded voltage is not above the minimum, perform the Solar Panel
Troubleshooting Test found within this chapter.
5) If the unit receives charging voltage from the AC charger, perform the AC
Charger Troubleshooting Test found within this chapter.
Table 5–2 Specifications for solar panels
Panel Max Volts @ PMax Open Circuit Load Resistance Loaded Voltage
5 4.5W 16.5V 20.5V 50 Ω 25W 13.5V
10 10W 16.8V 21V 30 Ω 25W 17.5V
20 20W 16.8V 21V 15 Ω 25W 17.8V
30 30W 16.8V 21V 10 Ω 40W 17.8V
5.3.4 Solar panel charging system test

If the system setup includes a solar panel charger connected to the 6270 Optional
Equipment Unit (OEU) and is not supplying the required voltage and current to the
G4 EX unit, the user may need to test the solar panel.
The following instructions contain the steps required to test the solar panel.

- Digital Multi-meter with 0-20 VDC range
- Required resistors for testing specific panels as listed in Table 5–2
In continuous low sunlight conditions, the unit may not

supply the required voltage. The solar panel should be
positioned so that it receives the most sunlight. Do not place
in a shaded area.

1) Measure the solar panel voltage at the charger regulator. Use a DMM
connecting the (+) and (-) leads to the (+) and (-) solar panel wires. Loaded
voltage should be greater than or equal to the specification listed in Table
5–2. If the solar panel is not above the minimum, replace the solar panel,
and continue to step 2.
2) Check the solar panel angle and direction. In the northern hemisphere, the
panel should face due south. In southern hemispheres, the panel should
face due north.
Page 5–10 2104349 rev. AD

3) Check the solar panel for any physical damage or obstructions to sunlight.
Sunlight obstructions prevent the solar panel from receiving enough sunlight
to charge the installed battery pack. Clear any debris from the cell face of
the panel.
4) Check the solar panel wiring to ascertain that it is correctly connected to the
associated termination pins that are located in the 6270 OEU enclosure
(see Figure 5–5).
5) Disconnect the solar panel from the field device.
6) Set the DMM to 20+ VDC.
7) Determine if the open circuit voltage is greater than or equal to the
specification listed in Table 5–2 by clipping the positive lead of the DMM to
the first wire and clipping the negative lead of the DMM to the second wire.
If the solar panel is not above the minimum, continue to the next step.
8) Using the selected resistor from Table 5–2 for the solar panel wattage,
attach the selected resistor between the two solar panel wires.
9) Clip the positive lead of the DMM to the upper side of the test resistor.
10) Clip the negative lead of the DMM to the lower side of the test resistor.
11) Determine if the loaded voltage is greater than or equal to the specification
listed in Table 5–2. If the solar panel is not above the minimum, replace the
solar panel, and return to Step 3.
Figure 5–5 6270 OEU charger regulator
5.3.5 AC charging system unit test

If the system setup includes an AC charger connected to the 6270 OEU Optional
Equipment Unit and is not supplying the required voltage to the G4 EX unit, the
user may need to test the AC charger.
2104349 rev. AD Page 5–11

The following instructions will take the user through the steps for performing this
task.

1) Check the AC charger wiring to the 6270 OEU enclosure termination board
connector. Ensure that the wiring is correct.
2) Check the input AC voltage to the external AC charging unit. Ensure that
the primary AC voltage is correct.
3) Correct, and retest as necessary.
4) If the input primary AC voltage level is correct, wiring to the 6270 OEU
enclosure termination board is correct, and there is no DC output from the
charger; replace the charger fuse.
6) If the fuse is not faulty or there is no charger DC output voltage after
replacing the fuse, replace the AC charging unit.
5.3.6 Auxiliary equipment isolation test

This test will need to be performed if the battery pack output voltage is not
remaining consistent and no errors were found during the previous Power Supply,
Solar Panel Charging System or AC Charging Circuit troubleshooting tests.

1) Disconnect the solar panel charger or AC charger located in the Optional
6270 enclosure.
2) Disconnect the battery pack cable from the charger regulator. This is
located in the Optional 6270 enclosure, and substitute know good battery.
3) Disconnect any auxiliary equipment that draws power from the G4 EX or
battery pack.
4) Connect the current measurement troubleshooting cable (see Figure 5–6) to
a known good battery, and reconnect to the charger regulator.
BLACK DMM CONNECTOR
TO CHARGER REGULATOR
RED DMM CONNECTOR
TO BATTERY CABLE
Figure 5–6 Current measurement troubleshooting cable

5) Using a DMM, connect to the troubleshooting cable, and measure the
average current. If it is equal to or greater than 80 mA at 12 VDC,
disconnect the battery pack, and reconnect one auxiliary item. Continue to
the next step.
Page 5–12 2104349 rev. AD

6) If the average current is equal to or greater than the specification, no
problem is found with the remote equipment. Return to the test sequence in
the Power Troubleshooting section.
7) Reconnect the known good battery pack using the troubleshooting cable.
8) Using the DMM, connect the troubleshooting cable, and measure the
average current during start up. If the current is higher than 33-40 mA,
return to the Power Troubleshooting section above, and continue. If the
current is within acceptable limits, continue to the next step.
9) When the unit reaches normal operating status, measure the average
current. If the current is higher than 26-30 mA, return to the test sequence in
the Power Troubleshooting section. Move past the sequential testing, and
go directly to the Remote Communications troubleshooting.
5.3.7 Sleep mode

The Sleep mode is a safety feature which maintains the RAM but discontinues
data measurement calculations and control functions. When the G4 EX is in Sleep
mode, the word Sleep is displayed on the LCD. If the G4 EX battery voltage falls
below 11 VDC, the G4 EX enters Sleep mode.
If the battery voltage is still below 10.9 VDC when the user disconnected locally,
the G4 EX returns to Sleep mode. If the battery voltage is above 11 VDC, the G4
EX remains awake.
The G4 EX has a real-time clock which maintains time and date during Sleep
mode and writes an event record when entering and leaving the Sleep mode.
Upon wake-up, the G4 EX performs the following functions:
- Stores present calculation period accumulations in the historical record.
- Zeroes present calculation period accumulations.
- Ends the current daily record and starts a new daily record.

1) Connect locally to the G4 EX. This should wake up the unit for the user to
determine the cause.
2) Check the lithium battery cable. Ensure that it has a good, secure electrical
connection to the G4 EX board.
3) If the lithium battery cable is securely connected, check the lithium battery.
If voltage is low, replace with another lithium battery.
5.3.8 Reset procedures

The G4 EX operating system can be reset through either a cold or warm start
procedure. The decision to use these procedures should only be made by an
experienced technician.
5.3.8.1 Cold start

A cold start clears all the data that is stored in RAM as well as resetting all entered
variables to their factory default values or to the values last written to the tfCold
drive by the Save and Restore utility. A cold start should be used for new G4 EX
installations. This will ensure that all memory is clear and the operating program is
at its default settings. Discretionary use of this procedure is advised.
2104349 rev. AD Page 5–13

Refer to Chapter 4 for steps on performing both a hardware and software cold
start.
5.3.8.2 Warm start

A warm start does not clear the data stored in RAM. The warm start will only reset
the G4 EX microprocessor and not disturb any data that has been stored in RAM.
A warm start should be used when taking a unit out of service to perform
maintenance or troubleshooting. A warm start can be used when a power or
communication interruption caused the G4 EX microprocessor to lock up.
Refer to Chapter 4 for steps on performing both a hardware and software warm
start.
5.4 Communications troubleshooting
5.4.1 Overview
These troubleshooting procedures are applicable to the G4 EX with an installed
radio in the optional 6270 OEU Enclosure unit. Use Figure 5–7 as an aid in
troubleshooting communication problems. The three basic types of radio
communication that can be used between the G4 EX and a radio receiver are:
- RS-232 Communications port programmable
The radio/modem may be powered one of two ways: always on or switched. The
user’s specific system set up will determine what steps are needed to power the
radio/modem.
When switching power to a radio with Inhibit (Sleep) mode, the communication 1
port or switched power line will move to the radio’s Inhibit(Sleep) mode input.
Power out will move to the radios.
It is important that the user disconnect the G4 EX battery

cable from the G4 EX board.
Page 5–14 2104349 rev. AD

START
Verify unit
ID#, Security
Code and
Protocol are
Correct.
Verify jumper
and terminal &
pin wiring are
correct.
NO
Does Unit Transceiver
YES NO Transceiver
Respond to Host Supply voltage Investigate
END Supply voltage
Comm Request? Test Transceiver
within Specs?
Issues
YES
Investigate NO
Voltage supply
Power Supply
from unit
Issues
> 11.9 VDC?
Figure 5-4
YES
Substitute
YES
Unit Respond to Communication
Host Comm Test Cable
Request?
NO
Contact
Is NO Is NO
Totalflow
Communication Communication Technical
RS-232? RS-485? Support
YES YES
RS-232 RS-485
Communication Communication
Test Test
Does Unit
Respond?
YES
NO
Transceiver
NO
Comm Check
Test Passed?
YES
Figure 5–7 Communication troubleshooting flow chart
5.4.2 Setting up communication

After the installation of the communication equipment and before placing the
communication system into operation, the user should note the following:
- Verify the field wiring terminations on the G4 EX termination board.
- Verify the field wiring from the G4 EX unit to the termination board inside the
6270 OEU enclosure.
- Verify the field wiring from the termination board to the radio.
2104349 rev. AD Page 5–15

- Check the G4 EX identifier (ID). Log the ID for future reference.
- Log G4 EX access security code, baud rate, listen cycle, protocol and
interface for future reference.
The following helpful hints will aid the user after the
communication equipment has been installed and set up:
- When the communication equipment is powered/switched

on, the G4 EX displays the  after it recognizes the
G4 EX ID.
- Check the baud rate of the G4 EX transmission and Listen
time settings. The baud rate and time settings can
be changed when PCCU32 is in Entry mode. Default
settings are 1200 baud, the listening time is 4
seconds and the communications interface is turned
off.
- Minimum power required for operating remote
communications is 11.9 VDC (default) or as set by
the user. Should the power fall below this level,
remote communications will be terminated.
- Test remote communications using the RS-232
troubleshooting cable. Use the RS-232 to RS-485
communication converter in conjunction with the RS-
232 troubleshooting cable to test RS-485 remote
communications.
5.4.3 Transceiver supply voltage test

Using the wiring information and guidelines supplied by the transceiver’s
manufacturer, verify that the transceiver is receiving the manufacturer’s suggested
voltage. If the unit is receiving sufficient voltage, continue to the 6270 OEU Wiring
Voltage Test.
If the transceiver is not receiving sufficient voltage,

investigate the power supply issues. These may involve
wiring irregularities at either the charger regulator,
termination board, terminal strip or at the power relay if using
relay for switching power to the radio.
5.4.4 6270 OEU supply voltage test

If the transceiver does not feature a Sleep mode and power is supplied through an
optional relay, begin with step 1.
If the transceiver features a Sleep mode or is continuously powered, begin with
Step 2.
Wire color/origination inside the 6270 enclosure should

comply with WI drawings. For the purposes of these
instructions, wire color name and designation should
coincide with the Totalflow drawings. The user may need to
adapt, as appropriate, for their individual installation.
Page 5–16 2104349 rev. AD

1) If the transceiver does not feature a Sleep mode and receives power
through an optional relay, activate COM1SW or COM2SW, and using a
Digital Multi-meter (DMM) set to Volts DC, measure the voltage at the relay
between the relay coil terminals.
If the voltage reads the same as the supplied voltage (12 VDC) and the
transceiver is still not receiving power, the relay may be incorrectly wired
(use normally open contacts), or the relay may be bad.
If the relay is not receiving power, continue to step 2.
2) If the transceiver features a Sleep mode or is continuously powered,
activate COMSW1 or COM2SW, and using a DMM set to Volts DC,
measure the voltage at the next supply junction. If the next junction is
located on the termination strip, verify the wiring is firmly connected;
otherwise, continue to the charger relay, and measure the voltage between:
Terminal 1 (Batt +) and Terminal 4 (Batt -)
Voltage should be greater than or equal to 11.9 VDC for this unit. If the
voltage is less than 11.9, return to the test sequence outlined in the Power
Troubleshooting section.
5.4.5 Transceiver check

1) If available, use a wattmeter to check the transceiver output power. Refer to
the manufacturer’s documentation for measuring instructions.
2) If available, use two hand-held transceivers, and verify the communication
path between the master and remote sites. Voice-activated interface can be
used, if available.
3) Verify that the transceiver is set to the correct frequency. Refer to the
manufacturer’s documentation for checking the frequency instructions.
4) If a directional antenna is used, verify the orientation to the antennae to the
master site.
If a communication problem still exists and the unit has

passed the transceiver check test, contact Totalflow
Technical Support for additional help.
5.4.6 Termination board supply voltage test

1) Using a DMM set to Volts DC, measure the power supply voltage from the
OEU enclosure to J16 on the termination board (see Figure 5–4) between:
Pin 1 (+) and Pin 2 (-)
Voltage should be equal to or greater than the amount specified as low
voltage input in PCCU32 for this unit (9 volt minimum, default is 11.9 VDC).
2) If the supplied voltage falls in the correct range, return to the test sequence
outlined in the Power Troubleshooting section.
2104349 rev. AD Page 5–17

5.4.7 RS-232 communication
The following test procedure is directed from Figure 5–7 and will assist the user in
what may be the possible cause for an indicated error message.
With the exception of the field wiring directly on the G4 EX termination board, all
other wiring is located inside the 6270 OEU enclosure; therefore, two separate
procedures are required for testing.
5.4.8 RS-232 termination board test

Before performing the voltage test on the termination board located inside the rear
end cap, verify that the wiring is correct (see Table 5–3).
Table 5–3 RS-232 field wiring on the G4 EX termination board
Description ABRV Description ABRV

J19 – COMM 1 J20 – COMM 2
Pin 1 V-Battery VBATT V Battery VBATT
Pin 2 Ground GND Ground GND
Pin 3 Switched VBATT COMM1SW Switched VBATT COMM2 SW
Pin 4 Operate Comm1 Operate Comm1 Operate Comm2 Operate Comm2
Mirror Request to Mirror Request to
Pin 5 RRTS COMM1 RRTS COMM2
Send Send
Pin 6 Request to Send RTS Request to Send RTS
Pin 7 Transmit Data TXD Transmit Data TXD
Pin 8 Receive Data RXD Receive Data RXD
Pin 9 Clear to Send CTS Clear to Send CTS
When troubleshooting RS-232 mode, verify the settings of

COMM 1 SW 1 and COMM 2 SW2 on the termination board
are configured properly (see Figure 5–4).
Voltage on the following steps may be hard to see using a

Digital Multi-meter (DMM). If available, an oscilloscope will
provide a more accurate reading. To verify, the WinCCU
software must be continuously polling the meter
Generally speaking, these tests performed on the

termination board will only verify incorrect or damaged
wiring. If all previous testing passed and all wiring, jumpers
and terminations have been verified correct, the board will
need to be replaced. Contact Totalflow Customer Service.
See the Getting Help section for instructions.
Page 5–18 2104349 rev. AD

1) Using an oscilloscope, measure the receiving data voltage on the
termination board, J19 or J20, between:
COMM 1, J19–Pin 2 (GND) and Pin 8 (RXD) or
COMM 2, J20–Pin 2 (GND) and Pin 8 (RXD)
When the unit is transmitting to WinCCU, the voltage should vary between -
5 VDC and +5 VDC. This would indicate that the unit is receiving data;
continue to step 2. If the unit is not receiving data, investigate the wiring
issues (see Table 5–3).
2) Using an oscilloscope, measure the request to send voltage on the
termination board J19 or J20 between:
COMM 1, J19–Pin 2 (GND) and Pin 6 (RTS) or
COMM 2, J20–Pin 2 (GND) and Pin 6 (RTS)
When the unit is communicating to WinCCU, the voltage should be +5
VDC and remain at +5 VDC until the G4 EX transmit stops. This
would indicate that the unit is transmitting data; continue to step 3. If the unit
is not receiving data, investigate the wiring issues (see Table 5–3).
3) Using an oscilloscope, measure the transmit data voltage on the termination
board, J19 or J20 between:
COMM 1, J19–Pin 2 (GND) and Pin 7(TXD) or
COMM 2, J20–Pin 2 (GND) and Pin 7 (TXD)
When the unit is transmitting to WinCCU, the voltage should vary between -
5 VDC and +5 VDC. This would indicate that the unit is transmitting data. If
the unit is still not responding, continue to the next test as directed in Figure
5–7.
5.4.9 RS-232 OEU termination strip test

termination strip will only verify incorrect or damaged wiring.
If all previous testing passed and all wiring, jumper and
terminations have been verified as correct, the termination
strip may need to be replaced but does not typically fail.
Contact Totalflow Customer Service. See the Getting Help
section for instructions.
Please note that NO wire colors are referenced. Individual

units may vary.
Voltage on the following steps may be difficult to see using a

Digital Multi-meter (DMM). If available, an oscilloscope will
provide a more accurate reading. To verify, the WinCCU
software must be continuously polling the meter.

1) Using a oscilloscope, if available, measure the receiving data on the G4 EX
side of the OEU termination strip (see Figure 5–8) between:
GND and RXD
2104349 rev. AD Page 5–19

When the data is being transmitted to the G4 EX unit, the voltage should
vary between -5 VDC and +5 VDC.
When the unit is receiving data from WinCCU, the voltage should vary
between -5 VDC and +5 VDC. This would indicate that the unit is receiving
data.
2) On the OEU G4 EX side of the termination strip (see Figure 5–8), measure
the request to send voltage between terminals:
GND and RTS
When the G4 EX is sending communication data to WinCCU, the voltage
should be +5 VDC.
3) On the OEU termination strip, measure the transmitting data voltage
between terminals:
GND and TXD
When the data is being transmitted from the G4 EX unit, the voltage should
vary between -5 VDC and +5 VDC.
4) Repeat steps 1 through 3 on the transceiver side of the termination strip.
5) If any inaccuracy exists, investigate wiring errors.
Figure 5–8 OEU termination strip
5.4.10 RS-485 communication test

The following RS-485 serial communication test procedure is directed from Figure
5–7 and will assist the user in what may be the possible cause for an indicated
error message.
With the exception of the field wiring directly on the G4 EX termination board, all
other wiring is located inside the 6270 OEU enclosure. As such, there are two
separate procedures required for testing.
5.4.11 RS-485 termination board test

Before performing this test on the termination board, verify that the wiring is
correct.
Page 5–20 2104349 rev. AD

Table 5–4 RS-485 field wiring on the G4 EX termination board
Description ABRV Description ABRV

J19 – COMM 1 J20 – COMM 2
Pin 1 V-Battery VBATT V Battery VBATT
Pin 2 Ground GND Ground GND
Pin 3 Switched VBATT COMM1SW Switched VBATT COMM2 SW
Pin 4 Operate Comm1 Operate Comm1 Operate Comm2 Operate Comm2
Mirror Request to Mirror Request to
Pin 5 RRTS COMM1 RRTS COMM2
Send Send
Pin 6 Receive Bus (+) TBUS(+) Receive Bus (+) TBUS(+)
Pin 7 Receive Bus (-) TBUS(-) Receive Bus (-) TBUS(-)
Pin 8 Receive Bus (+) RBUS(+) Receive Bus (+) RBUS(+)
Pin 9 Receive Bus (-) RBUS(-) Receive Bus (-) RBUS(-)
When troubleshooting RS-485 mode, verify the settings on

COMM 1 SW1 and COMM 2 SW2 on the termination board
are configured properly (see Figure 5–4).

Digital Multi-meter. If available, an oscilloscope will provide
a more accurate reading. To verify, the WinCCU software
must continuously be polling the meter.

termination board will only verify incorrect or damaged
wiring. If all previous testing passed and all wiring, jumper
and terminations have been verified correct, the termination
board may need to be replaced but does not typically fail.
Contact Totalflow Customer Service. See the Getting Help
section for instructions.
1) Using an oscilloscope, measure the line driver voltage on the termination

board, J19 and J20, between:
COMM1, J19–Pin 9 (BUS-) and Pin 8 (BUS+) or
COMM 2, J20–Pin 8 (BUS+) and Pin 9 (BUS-)
When the unit is receiving data from WinCCU, voltage should vary between
+5 VDC and 0 VDC. This indicates that the unit is receiving data.
2) Using an oscilloscope, measure the remote request to send voltage on the
termination board J19. On J20, RRTS is not directed:
COMM 1, J19–Pin 2 (GND) and Pin 5 (RRTS)
When the unit is transmitting receiving data, the voltage should vary
between -5 VDC and +5 VDC. This would indicate that the RRTS is working
correctly.
3) If any inaccuracy exists, investigate the wiring errors or damaged wires.
2104349 rev. AD Page 5–21

If a communication problem still exists and the unit has
passed the required test, additional testing is required.
5.4.12 RS-485 OEU termination strip test

Digital Multi-meter. If available, an oscilloscope will provide
a more accurate reading. To verify, the WinCCU software
must continuously be polling the meter.

termination strip will only verify incorrect or damaged wiring.
If all previous testing passed and all wiring, jumper and
terminations have been verified correct, the termination strip
may need to be replaced but does not typically fail. Contact
Totalflow Customer Service. See the Getting Help section for
instructions.
When designating the wire colors in the following

procedures, color/origination complies with Totalflow wiring
instruction drawings. For the purposes of these instructions,
the user may need to adapt for their individual installation.
1) Using an oscilloscope, if available, measure the line driver voltage on the

G4 EX side of the OEU termination strip (see Figure 5–8) between:
BUS+ and BUS-
When the unit is receiving data from WinCCU, the voltage should vary
between +5 VDC and 0 VDC. This indicates that the unit is receiving data.
2) Using an oscilloscope, measure the request to send voltage on the G4 EX
side of the OEU termination strip between:
GND and RRTS
When the data in the G4 EX is sending communication data to WinCCU, the
voltage should be +5 VDC for the duration of the transmission.
3) Using an oscilloscope, measure the transmitting data voltage on the G4 EX
side of the OEU termination strip between:
GND and BUS-
And
GND and Bus+
When data is being transmitted from the G4 EX unit, the voltage should vary
between +2 VDC and +5 VDC.
4) Repeat steps 1 through 3 on the transceiver side of the termination strip.
5) If any inaccuracy exists, investigate the wiring errors.
Page 5–22 2104349 rev. AD

6 Reference material
6.1 Reference materials on ABB/Totalflow website
Additional information about the ABB Explosion Proof Flow Computer can be
found on our website http://www.abb.com/totalflow. The following chart has direct
links to many documents on-line that the user may find helpful concerning this
product.
Item Description Part #

ABB document Location on the web for all documents available for
Download Center
download center downloads.(with search capabilities)
Data Sheet XFC G4 6200/6201EX OVERVIEW 2104390
Start-up Guide XFC6200/6201EX START-UP GUIDE 2104263
XFC G4 EX TERM BD COMM 1 & COMM 2
User Drawing 2104215
GENERIC RS232 WIRING
XFC G4 EX TERM BD COMM 1 & COMM 2
GENERIC RS-485 WIRING
XFC G4 EX (2103344 BD) COMM1 TO MICRO
MOTION 1700/2700 CORIOLIS (RS-485)
User Drawing XFC G4 EX CIRCUIT BOARD ELEMENTS 2104217
User Drawing XFC G4 EX ILLUSTRATED PARTS BREAKDOWN 2104346
User Drawing XFC G4 EX POLE-MOUNT BRACKET 2104424
XFC G4 EX (2103344BD) AI TO 2-WIRE
TRANSMITTER (ANALOG INPUT)
2104349 rev. AD Page 23

6.2 I/O daughter card
The following information provides an outline for the installation and application of
the I/O daughter card within the G4 EX.
The I/O daughter card may already be installed in new units, if configured, or can
be added as an upgrade kit to pre-existing units. The following information will
address the installation for the upgrade kit.
Do not install the I/O daughter card until told to do so in these

instructions. Installation prior to flashing the unit may cause
some older models units to not boot.
6.2.1 Materials supplied in the upgrade kit

- 1 each I/O Daughter Card
- 4 each #6 .25 OD Flat Washer
- 4 each #6 Flat Washer
- 4 each 6–32 x .625 ¼ Hex Female Spacer
- 4 each 6–32 x .75 LG, M-F Standoff
- 1 each I/O Daughter Card Generic Wiring Diagram
- 1 each CD-ROM with Specified Flash and Configuration Files
6.2.2 I/O daughter card specifications

This card expands the capabilities of the explosion-proof flow computer by adding
an additional 12 points of fixed analog and digital I/O points. Specifications for the
I/O daughter card are as follows:
Analog Points
- 3 each 0-10V (10K ohm impedance) analog inputs
- 1 each 0-20 mA (SINK mode) analog output
Digital Points
- 4 each Digital inputs/pulse inputs
- 4 each Digital outputs (optically-isolated type 1A switches capable of
switching 200 mA of 48 VDC or 40 VAC)
6.2.3 Installation
If the unit is currently operating, data must be collected from the unit and the
configuration files saved prior to beginning this procedure.
Page 24 2104349 rev. AD

Termination
Board
J21 PCCU
Connector
I/O Daughter
Card
Figure 6–1 Termination panel with I/O daughter card installed
6.2.4 Upgrading the flash

1) Open PCCU32, but do not connect.
2) Once PCCU32 has loaded, click on the 32-Bit Loader icon on the window’s
main toolbar. The 32-Bit Loader screen will display.
Figure 6–2 32-Bit Loader screen
2104349 rev. AD Page 25

3) Select the ExFC radio button to designate that the G4 EX is the device that
will receive the new Flash.
4) Next, select the Update radio button.
6.2.5 Unit operating status shut down instructions

2) Back up all of the configuration and data files.
3) While in PCCU32, click the Save and Restore Utility icon from the main
window toolbar. The Save and Restore Utility window will display.
4) Within the Save and Restore Utility, click the Save Station Files button.
5) When the Save Station Files dialog box displays, verify the default name
and path for the files. Click the OK button. This will save the tfData drive
files.
6) When finished saving the station files, a new dialog box will offer the option
to Restore the Station Files to the tfCold drive. Select No.
7) Remove power externally from the unit.
6.2.6 Internal PCCU connector disassembly (if installed)

1) Gain access to the termination board by loosening the countersunk hex

socket locking set screw in the rear end cap. Use a 1/16” hex wrench, and
then unscrew the end cap.
2) Remove the four 6-32 x .625 standoffs located at the four corners of the
termination board.
3) Gently lift the termination board out of the unit. Be careful to not disconnect
the PCCU ribbon cable from the termination board.
4) Disconnect the cable from the termination board.
6.2.7 I/O daughter card installation

1) Gain access to the termination board by loosening the countersunk hex

socket locking set screw in the rear end cap. Use a 1/16” hex wrench, and
then unscrew the end cap.
2) Remove the four existing 6-32 x 625 standoffs and washers (if installed). Do
not misplace as they will be needed later in this procedure.
3) Install the new standoffs (6-32 x .75”) and washers supplied in the kit into
the four corner mounting holes in the termination board.
Page 26 2104349 rev. AD

4) Center the I/O card over the termination board (green phoenix connectors
facing out). Align the four screw holes at each corner. This should allow the
I/O card to interconnect with I/O Expansion connection on the termination
board. Apply gentle pressure to the I/O card in the two areas located on
either side of the connector until the board is seated.
5) Using the four 6-32 x .625 standoffs removed previously, connect the I/O
card to the termination board. Do not over tighten.
6) Reapply power to the unit. Make the local connection using PCCU32 and
the MMI cable. Once physically connected, open PCCU32, and move into
Entry mode.
7) In the PCCU32 tree-view, select the I/O Interface application. Once
expanded, click on the 6200EX I/O Card sub-menu. If the user is
communicating properly, they will see the setup screens for the daughter
card.
Figure 6–3 I/O Interface screen

8) Disconnect, and remove power externally from the unit.
9) Perform field wiring following the diagrams in Chapter 3. If the internal
PCCU connector is being reinstalled, field wiring must be done prior to
installation.
2104349 rev. AD Page 27

DB-9 Connector to
Termination Board
(Mounted on back)
J2 1
DI1(+)
DI1(-)
DI2(+)
DI2(-)
1 DI3(+)
AI1(+) I/O Daughter Card DI3(-)
AI1(-)
DI4(+)
AI2(+)
DI4(-)
AI2(-)
AI3(+) 8
DO1(+)
DO2(+)
DO3(+)
DO4(+)
DO1(-)
DO2(-)
DO3(-)
DO4(-)
AI3(-)
AOut(+)
AOut(-) 1 8
8 J3
J1
Figure 6–4 I/O daughter card
6.2.8 Internal PCCU connector reassembly (if previously installed)

1) Connect the cable from the PCCU assembly to the termination board.
2) Reinstall the four mounting standoffs. This will secure the termination board
to the device.
6.2.9 Implementation
This drawing does not completely illustrate the installation

methods required for hazardous locations. Prior to any installation
in a Classified Hazardous Location, verify the installation methods
by the Control Drawing referenced on the product’s name tag and
national and local codes.
Page 28 2104349 rev. AD

DB-9 Connector to XFCEX Board I/O
Expansion Connector (J2)
(Mounted on Back) XFCEX Board (Ref)
J3 J6 J5
The DI/PI inputs will accept sensor inputs
which meet the IEC-60947-5-6 electrical
SECURITY characteristics.
+ AI - + DI - + DO - ON
J8
J19
RTD IN I/O EXPANSION
J2 1 COMM1
RTD - 8
6 9 DI1(+)
RTD +
DI1(-)
RTD OUT 1 5 6
DI2(+)
SHIELD 5
J2 DI2(-) To Third Party
RTD 4
1 DI3(+) Digital Input Devices
AI1(+) 3
I/O Daughter Card DI3(-)
4 3 2 1
OFF 2
AI1(-) P/N: 2102458 DI4(+) 1
ON
AI2(+)
To Third Party AI2(-)
DI4(-) SW1
2
Analog Devices J21 AI3(+) 8J16 -
DO1(+)
DO2(+)
DO3(+)
DO4(+)
1
DO1(-)
DO2(-)
DO3(-)
DO4(-)
SEE SHEET 2 MMI
PWR +
AI3(-)
ON OFF
AOut(+) 4
1
AOut(-) 1 3 SW2 8
2
8 J3 1
J1
J20 COMM2
1 2 3 4 5 6 7 8
The Digital Outputs have a maximum “ON”

resistance of 2.5Ω which can switch 48V AC/
DC at up to 100mA. The outputs are isolated
To Third Party (AC voltage for 1 minute at 25°C, RH=60%
Digital Output Devices between input and output) from each other as
well as the control circuit by 1500Vrms.
Figure 6–5 Generic Wiring Diagram
6.2.9.1 Analog Points

Analog Inputs
The input range is 0-10 volts for the three 0-5V analog inputs (AI1, AI2 and AI3).
The inputs have a low pass filter -3 dB point of 100Hz. The sourcing device must
be capable of driving 10K input impedance.
As shown below, an external 250-255 OHM resistor is required (across + and –
input) to convert a 0/4-20 mA signal to a 0/1-5V compatible input.
The analog inputs must be defined in PCCU32.
2104349 rev. AD Page 29

Analog Outputs
The 0-20.48 mA analog output circuit is SINK mode only and requires the use of
an external power supply.
The analog inputs must be defined in PCCU32.
Page 30 2104349 rev. AD

6.2.9.2 Digital/Pulse Points
The DI/PI inputs will accept NAMUR type sensor inputs which meet the IEC-
60947-5-6 electrical characteristics. The digital inputs also function as event
counters.
Digital Outputs
- Optically-isolated type 1A switches
- Have a maximum ON resistance of 2.5Ω which can switch 48V AC/DC at up
to 200 mA at 60°C
- The outputs are isolated (AC voltage for 1 minute at 25°C, RH=60%
between input and output) from each other as well as the control circuit by
1500Vrms
The digital inputs must be defined in PCCU32.
2104349 rev. AD Page 31

Digital or Pulse Inputs
- NAMUR: When in a low impedance, the state must draw more than 2.2 mA;
when in high impedance, the state must draw less than 1.0 mA. It should be
noted that in the NAMUR specification, a low impedance of less than 400
OHMS is considered a short (fault), and a high impedance of greater than
20K OHMS is an open (fault). These two conditions are not monitored.
- Open Collector (O.C.): The output transistor or FET must be capable of
sinking 8.2 mA. Total impedance of the circuit must be less than 1K OHM.
- Dry Contact (i.e., reed-switch): The device must be capable of sinking 8.2
mA. The total impedance, when active, must be less than 1K OHM. Note:
The pulse inputs on the 2102458-001 are designed to accept relatively high-
speed( approximately 20Khz) signals. Therefore, if a reed-switch or other
mechanical device subject to bouncing contacts is used, the application will
require the use of a capacitor across the contact of the switching device ( a
value of 0.1 uF should be a good starting place).
- Active Signal: Must be capable of being connected to a 1K load which is
tied to a 8.2V voltage source. When the output is driven high (above 8.8V),
the load will appear at 215 OHMS connected to a 8.8V. Note: The active
signal type input requires the use of an onboard DAC converter to adjust the
trip threshold of the comparator input. Example: A 0-5V signal will not cause
the input to transition through the NAMUR thresholds. The DAC will be set
to 1.35V (to a value of 69 decimal or 0x45). This will make the apparent
threshold, as seen at the input, to 2.5V.
The digital inputs and pulse inputs must be defined in PCCU32.
Page 32 2104349 rev. AD

2104349 rev. AD Page 33
6.3 4–20 milliamp transmitters
6.3.1 Powering 4–20 Milliamp Transmitters

4-20 milliamp (mA) transmitters are essentially variable constant current sources.
They need to have sufficient voltage applied to them to insure that they will be
able to drive 20 mA onto a 250 OHM load. Different transmitter technologies will
have different powering requirements.
Many 4-20 mA transmitters claim to be operational between 10 and 30 VDC, but
this can be somewhat misleading. If it is a two-wire (line powered) transmitter and
it is sourcing the maximum loop current of 20 mA, 5 VDC is dropped across the
250 OHM resistor. Dropping 5 VDC across the load resistor only leaves 5 to 20
VDC (of the aforementioned 10 to 30 VDC) to operate the transmitter. There is a
good chance that 5 VDC will not be enough to properly operate the transmitter at
its maximum output of 20 mA.
Example: Voltage dropped across the load resistor at the maximum loop current.
E = I x R = 20 mA x 250 OHM = 5 VDC
The figure below shows a 4-20 mA loop being powered by a 12 VDC source. This
could be a solar panel with battery backup. If the battery has been discharged to
12-volts, then only 7-volts would remain to operate the transmitter. This may not
be enough to fully operate the transmitter at higher loop currents.
Assume 20ma 4-20ma

VCC
Transmitter
AI - AI +
- + - +
250Ω
5VDC 7VDC 12VDC

remaining to source
operate Transmitter
The following discussion does not pertain to 1-5 VDC

transmitters.
Totalflow flow meters employ a 250 OHM resistor to convert the 4-20 mA
transmitter current loop to a 1-5 VDC signal. In some meters, this conversion is
made by attaching a 250 OHM resistor across the 4-20 mA input pins (see the
next figure – schematic A). Some meters use a small three-pin jumper to select an
onboard 250 OHM resistor (see the next figure – schematic B). Still, other meters
employ an electronic switch to select the 250 OHM resistor (see the next figure –
schematic C). In the figures , VCC represents the voltage source used to power
the transmitter. In many instances, VCC could be tied to the meter’s VBAT.
With a solar paneled system, such as many Totalflow installations, available
voltage to power the 4-20 transmitter can become an issue. Batteries in a battery
backed solar installation can drop to 12 VDC or less. Some transmitters may not
be able to drive 20 mA into a 250 OHM load with only 12 VDC applied to them.
Fully charged batteries, connected to an operational battery charger, may be
sitting at about 13.5-14 VDC.
Page 34 2104349 rev. AD

External to
Flowmeter
flowmeter VCC
2-wire (line powered)
AI +
4-20ma transmitter
To A/D Converter
User supplies 250Ω

A 250Ω
resistor and wires it
across the AI input
pins
AI -
External to
Flowmeter
flowmeter VCC
AI + 2-wire (line powered)
To A/D Converter
4-20ma transmitter
1 3
Onboard 250Ω
resistor selected
using three-pin
jumper
250Ω B
AI -
To PCCU Control Flowmeter External to VCC

flowmeter
To A/D Converter AI + 3-wire 4-20ma transmitter
Onboard 250Ω resistor is

selected in PCCU setup
250Ω
AI -
C
Again, the 4-20 mA transmitter that was selected by the user must be fully
operational at voltages as low as VCC – 5 VDC. Again, VCC is the source voltage
available at the user’s site, and 5 VDC represents the voltage dropped across the
meter’s 250 OHM resistor at the maximum loop current (20 mA).
Totalflow can provide a 12 to 24 VDC converter. This converter can be powered
from the meter’s VBAT (either comm ports or J16). The converter’s 24 VDC output
can then be used to power the 4-20 mA transmitter loop. In other words, VCC
would now be 24 VDC. Subtracting the 5-volts dropped across the 250 OHM
resister would leave 19 VDC to power the transmitter.
2104349 rev. AD Page 35

Another possible solution would be to reduce the 250 OHM
resistor to a small value, possibly 125 OHMs. An under-
powered transmitter could more easily drive 20 mA into the
lesser resister. Field calibrating the AI would negate any
differences between the 250 OHM and the 125 OHM
resistors. However, as the user reduces the size of the
resistor, they lessen the overall resolution.
6.3.2 Example 1
If the 4-20 mA transmitter can drive full range (20 mA through the 250 OHM
resistor), the user has essentially converted a 4-20 mA current range into a 1-5
VDC voltage range. The analog to digital (A/D) converter used in Totalflow
equipment expects a 1-5 VDC signal. During field calibration, the user might have
the 4 mA of loop current represent 10bbls of fluid per hour and 20 mA represent
100bbls. The conversion to voltage (using the 250 OHM resistor) would be as
follows:
1 VDC = 10bbls/hour
5 VDC = 100bbls/hour
Assuming that the A/D converter is ranged between 0 and 5 VDC and the
converter is resolving 15 bits, the user would expect to resolve about 150μ VDC
(or .0006 mA). These numbers translate to about .003 bbl (3 thousandths of a
barrel or about one half fluid ounce).
6.3.3 Example 2
If the 4-20 mA transmitter cannot drive full range (20 mA through the 250 OHM
resistor), the user may want to reduce the value of the resistor. For this example,
the following will drop it to 125 OHM (or half). A 4-20 mA current would now be
converted to a 5-2.5 VDC voltage range. Again, during field calibration, the user
would have the 4 mA current represent 10bbls per hour and the 20 mA signal
represent 100bbls per hour. The voltage conversion (using the 125 OHM resistor)
would be as follows:
.5 VDC = 10bbls/hour
2.5 VDC = 1000bbls/hour
The A/Ds full range is still 0-5 VDC; however, the user is only using about half of
its range capability. Just like the resistor value, the ability to resolve barrels of fluid
per hour has been cut in half. The overall accuracy remains unchanged, but the
user can only resolve about 0.006bbls (6 thousandths of a barrel or about one
fluid ounce).
6.3.4 Conclusion
If the 4-20 mA transmitter that is being used cannot drive a full 20 mA through the
250 OHM resistor, the user can reduce the resistive value. However, as the
resistive value is reduced, resolution (not overall accuracy) will be reduced
proportionally. If the user drops the resistive value by half (250 OHMs to 125
OHMs), the resolution will be reduced by half.
To reduce the resistive value of an onboard resistor, the user can add an external
resistor across the analog input pins. This places the two resistors in parallel with
one another. The parallel combination produces an equivalent resistance that is
Page 36 2104349 rev. AD

less than either of the two resistors alone. The value of the equivalent resistance
is calculated as shown in the figure below:
External to
Flowmeter
flowmeter VCC
Onboard 250 ohm
resistor selected using 2-wire (line powered)
4-20ma transmitter
three-pin shunt +
1 3
External resistor added
R2 across onboard resistor
R1 250 Ohm
250 Ohm
R1 x R2 250 x 250 62500

Equivalent Resistance = = = = 125 Ohms
R1 + R2 250 + 250 500
2104349 rev. AD Page 37

Contact us:
ABB Inc., Measurement & Analytics
Quotes: totalflow.inquiry@us.abb.com
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www.abb.com/upstream
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Ph: +1 661 833 2030
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We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase
orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third
parties or utilization of its contents - in whole or in parts – is forbidden without prior written consent of ABB.
Copyright© 2018 ABB all rights reserved
©Copyright 2018 ABB, All rights reserved
Document Title
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und.Error! Reference source not found.Error! Reference source not found.Error! Reference source not
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Document No. Rev. Ind. No. of Pages Page

2104349 AD 168 168

NFE 2923 Q MA 001 - A - Manufacturer's Standard O&M Manual

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No.

REV. DATE 2023-06-06

MANUFACTURER'S STANDARD O&M MANUAL

REV. DATE REVISION ISSUED BY CHECKED BY APPROVED BY

REV. DATE 2023-06-06

REV. DATE 2023-06-06

Ultrasonic Flowmeter USM GT400

Manufacturer Our customer service is available for technical queries:

Address RMG Messtechnik GmbH

Original Document The Ultrasonic Flowmeter USM GT400 OPERATING

This document may serve as a reference for translations into

Date created 1/31/2014

Document version Document version Ultrasonic Flowmeter USM GT400

Manual USM GT400 · EN10 · May 2021

2 QUICK GUIDE ....................................................................................... 20

3 DEVICE OVERVIEW ............................................................................ 25

4 FUNCTIONAL PRINCIPLE – ULTRASONIC-FLOW

Manual USM GT400 · EN10 · May 2021

4.1 General description ............................................................................................ 33

6 TRANSPORT AND STORAGE .......................................................... 65

Manual USM GT400 · EN10 · May 2021

6.2 Packing the device for transportation............................................................73

7 CONSTRUCTION AND PLANNING .................................................. 81 III

9 START UP ........................................................................................... 132

Manual USM GT400 · EN10 · May 2021

11 MAINTENANCE .................................................................................. 164

12 ALARM AND WARNING MESSAGES ........................................... 170

Manual USM GT400 · EN10 · May 2021

12.3 Notes ................................................................................................................ 175

13 TECHNICAL SPECIFICATIONS ...................................................... 177

14 SPARE PARTS AND ACCESSORIES ........................................... 199

15 LISTS OF PARAMETERS AND MEASURED VALUES .............. 201

16 USM GT400 APPROVAL .................................................................. 246

17 USM GT400 GLOSSARY .................................................................. 249

18 USM GT400 ATTACHMENT............................................................. 250

Manual USM GT400 · EN10 · May 2021

Manual USM GT400 · EN10 · May 2021

1 About this manual

1.1 Objective of the manual 1

1.1 Objective of the manual

Manual USM GT400 · EN10 · May 2021

1.2 Specialized knowledge required

1.2.1 Specialized knowledge required

Further information can be found under:

Manual USM GT400 · EN10 · May 2021

AGC Automatic Gain Control 3

Manual USM GT400 · EN10 · May 2021

1.2.3 Layout of instructions

Manual USM GT400 · EN10 · May 2021

1.2.4 Working with the device

Manual USM GT400 · EN10 · May 2021

1.2.4.2 Dangers during commissioning

Initial commissioning The initial commissioning must only be carried out

An acceptance test certificate and corresponding test report must be cre-

Manual USM GT400 · EN10 · May 2021

This symbol is used in the manual as a warning of the dan-

With the danger of explosion, the following must be observed, in particular:

Mechanical installation Mechanical installation must only be performed by ap-

Manual USM GT400 · EN10 · May 2021

Manual USM GT400 · EN10 · May 2021

1.2.4.3 Dangers during maintenance and repair

Inadequately qualified persons working on the equipment are unable to

Manual USM GT400 · EN10 · May 2021