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XSeries G4 6200
User manual
ABB XSeries G4 6200 User Manual
Flow computer
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Introduction
Organization & Style
Getting Help
Before You Call
Key Symbols
Safety Practices and Precautions
Safety Guidelines
Safety First
Equipment Markings
Grounding the Product
Operating Voltage
Danger from Loss of Ground
Safe Equipment
Fuse Replacement
Compliance
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE)
1 System Description
Overview
Table 1-1 XFC Family Genealogy
Capabilities
Figure 1-1 Typical G4 EX Installation
Functionality
Flow Computer Calculations
Log Period Records
Display Annunciators
Display Function
Table 1-2 Typical G4 EX Display Options
Figure 1-2 Liquid Crystal Display (LCD) and Indicators
Table 1-3 Default Annunciator Locations
Table 1-4 G4 EX Status and Alarm Description
Computer Hardware
Enclosure
Figure 1-3 G4 EX Enclosure
Figure 1-4 G4 EX Enclosure Left Side
G4 EX Main Processor Board
Figure 1-5 G4 EX Enclosure Right Side
Table 1-5 G4 EX Main Processor Board Specifications
Figure 1–6 G4 EX Main Processor Board
G4 EX Termination Board
Figure 1-7 G4 EX Termination Board
Figure 1-8 Typical DI Point Schematic
Figure 1-9 DI Connection Example
Figure 1-10 DI Connection Example
Figure 1-11 Typical DO Point Schematics
Figure 1-12 DO Connection Example
Explosion Proof Multivariable Transducer (EXIMV)
Figure 1-13 Typical AI Point Schematic
Figure 1-14 AI Example Connections
Figure 1-15 Explosion Proof Multivariable Transducer (EXIMV)
Table 1-6 Explosion Proof EXIMV Specifications
Display Assembly
Resistive Temperature Detector (RTD)
Figure 1-16 Liquid Crystal Display (LCD) Assembly
6270 Optional Equipment Unit (OEU)
Figure 1-17 Explosion Proof RTD
Table 1-7 Standard RTD Probes
Table 1-8 Standard Thermowells
Solar Panel
Figure 1-18 Optional Communication Enclosure
Lithium Battery
G4 EX Application Licensing
Figure 1-19 Solar Panel - Typical Installation
Credit Key (USB)
Laptop Computer Running PCCU32
Local G4 EX Connectors
Serial PCCU Cable (Round Military Cable)
PCCU32 USB Connection
Figure 1-20 RS-232 Local Communication Cable
Bluetooth Connectivity
Network Connectivity (Dynamic IP with Router)
Figure 1-21 USB Local Communication Cable
Figure 1-22 Ethernet Communication Cable
Figure 1-23 Ethernet Connectivity Diagram
2 Installation
Unpacking and Inspection
Unpacking
Inspection
Damaged Components
2" Pole Mount Installation
Type a
Type B
Figure 2-1 Type a Installation Configuration
Type C
Figure 2-2 Type B Installation Configuration
Figure 2-3 Type C Installation Configuration
Manifold Input Lines
Figure 2-4 G4 EX EXIMV Ports
Standard RTD Probe Installation
Figure 2-5 Thermowell Installation into the Meter Run
Explosion Proof RTD Probe Assembly
Figure 2-6 RTD Probe Wiring
Figure 2-7 Explosion Proof RTD Overview
Figure 2-8 Explosion Proof RTD Disassembled
6270 Optional Equipment Unit (OEU) Installation
Figure 2-9 RTD Probe Wiring
Figure 2-10 6270 OEU Pipe Mounting Installation
Battery Pack Installation
Figure 2-11 6270 OEU Wall Mount Installation
Lithium Battery Installation
Figure 2-12 6270 OEU Enclosure
Solar Panel Installation
Figure 2-13 Lithium Battery
Figure 2-14 Solar Panel Installation
AC Charging Unit Installation
Figure 2-15 AC Charger Installed
Figure 2-16 AC Charger Outlet Box Installation
Uninterrupted Power Supply (UPS) to the G4 EX
Figure 2-17 AC Charger Inside the Conduit Enclosure
Figure 2-18 G4 EX to UPS
3 G4 EX Start-Up
PCCU32 Installation and Setup
Step-By-Step Instructions
Establishing Local Communication
Connecting to a Local Port Via a RS-232 Cable
Figure 3-1 System Setup Screen
Connecting to Local USB Port
Figure 3-2 Windows Found New Hardware Wizard
Figure 3-3 Specific Location Selection Window
Figure 3-4 Specify Location for USB Driver (Totalflow.inf)
Setup of the G4 EX for Bluetooth Connectivity
Figure 3-5 System Setup - Bluetooth
Figure 3-6 Select a Bluetooth Device Dialog Box
Setup of the G4 EX for Ethernet Connectivity
Figure 3-7 System Setup Dialog Box - Bluetooth
Figure 3-8 Network Tab
Figure 3-9 Communication Setup
Figure 3-10 System Setup Window
Figure 3-11 Windows Desktop Shortcut Dialog Box
Figure 3-12 Network Tab
Setting up the G4 EX
Date/Time
Figure 3-13 System Setup
Station ID
Location
Security System
Device Legacy Bi-Level Security
Figure 3-14 Station Setup Tab
Winccu32 Software Security
Figure 3-15 Security Setup Dialog Box
Role Based Access Control (RBAC)
Figure 3-16 Winccu32 Edit a Device ID Dialog Box
Figure 3-17 Role Administration Menu Path
Figure 3-18 Security Editor Dialog Box
Figure 3-19 Roles Dialog Box
Figure 3-20 User Name and Password Dialog Box
Figure 3-21 System Setup Dialog Box
Figure 3-22 Send Role Based Access Control File Dialog Box
Figure 3-23 Totalflow-TCP Setup Tab
Figure 3-24 Login Dialog Box
Figure 3-25 System Setup Dialog Box
Figure 3-26 Security Log Tab
Application Licensing Credit Key
Credit Key Driver Installation
Access/View the Credit Key with PCCU32 7.0 (or Later)
Figure 3-27 Credit Key License Utility
Figure 3-28 Credit Key License Utility - Status
Adding Credits to the Credit Key by Telephone
Figure 3-29 Application Credit Key Entry Screen
Transferring Credits to the G4 EX from the Credit Key
Figure 3-30 Application Credit Verification Codes
Transferring Credits to the Credit Key from the G4 EX
Figure 3-31 App Licensing Tab
G4 EX Configuration
Contact Hour
Figure 3-32 Transfer to Credit Key
Log Period
Volume Calculation Period
Calculated Method
Table 3-1 Configurable Calculation Factors
Supercompressibility Calculation (Fpv)
Table 3-2 Fpv Analysis Data
Constants
Table 3-3 Gas Orifice Constants
Alarm Limits
Reset Volume
Table 3-4 Alarm Limits
Start up the G4 EX
Putting the G4 EX on Line
Setting G4 EX Temperature Calculation
G4 EX Standard Displays
Program Display
Table 3-5 G4 EX Displayed Items
4 G4 Ex Maintenance
Overview
Maintenance Support
How to Use this Chapter
Cleanliness
Front Mounted LCD
Returning Parts for Repair
Backing up Configuration Files
Step-By-Step Instructions
Restoring Configuration Files
Step-By-Step Instruction
Performing a Warm Boot
Hardware Warm Boot
Software Warm Boot
Figure 4-1 Reset Button Location
Performing a Cold Boot
Hardware Cold Boot
Software Cold Boot
Figure 4-2 Lithium Battery Connector
Changing the G4 EX Clock
Clock Change Not Crossing an Hour Boundary
Forward Clock Change Crossing an Hourly Boundary
Backward Clock Change Crossing an Hourly Boundary
Replacing the G4 EX Battery Pack
Step-By-Step Instructions
Figure 4-3 6270 OEU Configuration
Replacing the G4 EX Board
Step-By-Step Instructions
Figure 4-4 G4 EX Front End Exploded View
Figure 4-5 Termination Board
Figure 4-6 G4 EX Board
Figure 4-7 G4 EX Board Secondary Component Side
Replacing the G4 EX Termination Board
Step-By-Step Instructions
Figure 4-8 G4 EX Back End Exploded View
Figure 4-9 Termination Board Secondary Component Side
Replacing the Liquid Crystal Display (LCD) Board
Step-By-Step Instructions
Replacing the Lithium Battery
Step-By-Step Instructions
Replacing the Transducer (EXIMV)
Step-By-Step Instructions
Figure 4-10 EXIMV Installation Overview
Figure 4-11 G4 EX with Block Manifold
Calibration
Required Test Equipment
Table 4-1 Calibration Configurable Parameters
Hold Mode
Static Pressure (SP) Calibration Checks
Differential Pressure (DP) Calibration Checks
Figure 4-12 Calibration Diagram
Calibrating Static Pressure (SP)
Calibrating Differential Pressure (DP)
Onboard I/O Calibration Overview
Hold Mode
Calibrating Onboard Analog Inputs
Onboard Pulse and Digital Inputs
Zero Transducer
Static Pressure
Differential Pressure
RTD Calibration and Bias
Step-By-Step Instructions
Figure 4-13 RTD Calibration Screen
Calibrating RTD Temperature Bias
Changing the Orifice Plate
Taking Meter Run out of Service (Simplex Fitting)
Leaving Meter Run In-Service Procedure (Senior Fitting)
5 Troubleshooting
Overview
Troubleshooting Support
Visual Alarm Codes
Sleep Mode
Solar Panel
Communication
Troubleshooting Visual Alarm Codes
Figure 5-1 Troubleshooting Flowchart
Figure 5-2 LCD and Indicators
Table 5-1 Visual Alarm Codes
Figure 5-3 Power Supply - G4 EX Termination Board
Troubleshooting a Blank LCD Screen
Troubleshooting a Low Lithium Alarm (LL)
Troubleshooting an Analog to Digital Failure Alarm (AD)
Resistive Temperature Detector (RTD) Continuity Test
RTD Current Source (Resistive) Test
RTD Impedance Test
Power Troubleshooting
Overview
Power Supply Test
Charger Circuit Test
Figure 5-4 G4 EX Termination Board
Solar Panel Charging System Test
Table 5-2 Specifications for Solar Panels
AC Charging System Unit Test
Figure 5-5 6270 OEU Charger Regulator
Auxiliary Equipment Isolation Test
Figure 5-6 Current Measurement Troubleshooting Cable
Sleep Mode
Reset Procedures
Communications Troubleshooting
Overview
Setting up Communication
Figure 5-7 Communication Troubleshooting Flow Chart
Transceiver Supply Voltage Test
6270 OEU Supply Voltage Test
Transceiver Check
Termination Board Supply Voltage Test
Communication
Termination Board Test
Table 5-3 RS-232 Field Wiring on the G4 EX Termination Board
OEU Termination Strip Test
Communication Test
Termination Board Test
Figure 5-8 OEU Termination Strip
Table 5-4 RS-485 Field Wiring on the G4 EX Termination Board
OEU Termination Strip Test
6 Reference Material
Reference Materials on Abb/Totalflow Website
I/O Daughter Card
Materials Supplied in the Upgrade Kit
I/O Daughter Card Specifications
Installation
Upgrading the Flash
Figure 6-1 Termination Panel with I/O Daughter Card Installed
Figure 6-2 32-Bit Loader Screen
Unit Operating Status Shut down Instructions
Internal PCCU Connector Disassembly (if Installed)
I/O Daughter Card Installation
Figure 6-3 I/O Interface Screen
Internal PCCU Connector Reassembly (if Previously Installed)
Implementation
Figure 6-4 I/O Daughter Card
Figure 6-5 Generic Wiring Diagram
Milliamp Transmitters
Powering 4-20 Milliamp Transmitters
Example 1
Example 2
Conclusion
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XSeries G4 6200/6201EX Flow Computer
2104349 ver. AD
2104349 (AD)
Proprietary information
© Copyright 2018 ABB, All rights reserved.
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Table of Contents
Troubleshooting
Troubleshooting
131
Troubleshooting visual alarm codes
132
Troubleshooting a blank LCD screen
134
Power troubleshooting
138
Auxiliary equipment isolation test
142
Communications troubleshooting
144
Setting up communication
145
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