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 ......................
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 ...................
RS-485 termination board test ................5–20 5.4.12 RS-485 OEU termination strip test ................. 5–22 Reference material ......................... 23 Reference materials on ABB/Totalflow website ................ 23 I/O daughter card ........................24 6.2.1 Materials supplied in the upgrade kit ................24 6.2.2 I/O daughter card specifications .................
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 ..................
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 ........................
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 ..............
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.
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.
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.
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.
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.
1 System description Overview The XFC 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, ®...
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.
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 static pressure Average differential pressure Average flowing temperature...
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).
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. 188.8.131.52 Volume calculation period entries Volume calculation period entries are made every second, by default.
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.
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.
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.
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)
Figure 1–6 G4 EX main processor board 184.108.40.206 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 E PROM.
Figure 1–7 G4 EX termination board 220.127.116.11 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 18.104.22.168 Digital input...
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.
Figure 1–10 DI connection example 22.214.171.124 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.
“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 Typical DO point schematics Figure 1–11 Typical DO point schematics DO connection example Figure 1–12 DO connection example 126.96.36.199 Analog input...
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.
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)
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 -80F to 750F (-62C to 339C) ± 0.35F (± 0.2C)over operating range (as shipped from factory) Accuracy ±...
188.8.131.52 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.
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 1–19 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.
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.
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.
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 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.
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.
2.2.1 Type A 184.108.40.206 Materials supplied G4 EX mounting kit assembly and associated hardware 220.127.116.11 Materials not supplied One 2” x 40” pipe Standard 3 or 5 valve manifold Stainless steel tubing 18.104.22.168 Step-by-step instructions To install the G4 EX, it is recommended that two people perform the installation.
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. 22.214.171.124 Materials supplied G4 EX mounting kit assembly and associated hardware 126.96.36.199 Materials not supplied One 2”...
5) 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.
Stainless steel tubing 188.8.131.52 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.
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).
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.
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.
Certification tag Wiring instructions 184.108.40.206 Materials not supplied ® 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.
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.
220.127.116.11 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 2–11 6270 OEU wall mount installation Step-by-step instructions 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.
Figure 2–12 6270 OEU enclosure 18.104.22.168 Step-by-step instructions 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.
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).
Figure 2–14 Solar panel installation 22.214.171.124 Step-by-step instructions 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.
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.
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.
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”...
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.
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.
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.
® 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.
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.
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.
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.
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.
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.
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 126.96.36.199 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).
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.
Figure 3–13 System setup 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.
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. Description Format Note Station ID XXXXXXXXXX 10-digit alphanumeric 3.3.3 Location The location field can hold up to 24 alphanumeric characters to describe its location.
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.
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).
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.
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).
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 3–20 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.
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 188.8.131.52 Port configuration...
184.108.40.206 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.
Figure 3–25 System Setup dialog box 220.127.116.11 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.
Figure 3–26 Security Log tab 18.104.22.168 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. 22.214.171.124 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.
For collecting analyzer stream data, the user must have Read access to the Analyzer Stream application and the Analyzer Operation application. Application licensing Credit Key 3.5.1 Credit Key driver installation 126.96.36.199 Step-by-step instructions 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.
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.
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.
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.
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...
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.
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.
Default AGA-3 AGA-3 Parameters Units AGA-7 ISO-5167 Value 1985 1992 Flange Tap Type Taps Temperature Base (Tb) 60.0000 Degrees F Viscosity 0.0103 Centipoises Z of Air at Base Condition 0.9996 Fixed Cd Barometric Pressure 14.73 PSIA K Factor (Vol. of Gas Per Pulse) 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.
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.
Description Format Note 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...
4 G4 ex Maintenance 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.
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. 4.2.1 Step-by-step instructions 1) Collect the data from the unit. 2) While in PCCU32, click the Save and Restore Utility icon in the main window toolbar.
COMM1 RESET Figure 4–1 Reset Button Location 2) Upon location, press the Reset button for approximately five seconds. The unit will warm boot. 188.8.131.52 Method 2 1) Open the door to the unit. Ensure that there is voltage on the battery and that the jumper is enabled.
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. 184.108.40.206 Method 2 The user must be in Expert view.
LITHIUM Lithium Battery Connector Figure 4–2 Lithium battery Connector 4.5.2 Software Cold Boot There are two methods for initiating a software cold boot: 220.127.116.11 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.
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.
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.
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.
Figure 4–4 G4 EX Front End Exploded View 4.8.1 Step-by-step instructions 1) Collect data from the unit. 2) Back up the configuration files following the instructions listed previously in this chapter. 3) Verify that the “LL” battery alarm is not being displayed on the G4 EX LCD. Remove power from the device, or insure the area is known to be non-hazardous before removing any enclosure cover.
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. 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.
Potentiometer Processor Card CONTRAST SD CARD SD CARD JTAG LITHIUM Lithium Battery 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.
SENSOR 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.
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)
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) Upon unscrewing the end cap, the user will see the termination board (see Figure 4–5).
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.
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. 4.11.1 Step-by-step instructions 1) Collect data from the unit. 2) Back up the configuration files following the instructions listed previously in this chapter.
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.
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. HIGH SIDE LOW SIDE EQUALIZER VALVE EQUALIZER VALVE VENT TO...
10) 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. 11) After the end cap has been removed, gently pull the display overlay and graphic overlay plate away from the snap on standoffs.
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.
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.
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.
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.
18.104.22.168 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. Step-by-step instructions 1) Enter the Calibration menu’s Calibration screen. This places the G4 EX in Hold.
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.
17) When the current reading stabilizes, accept the target value already 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.
22.214.171.124 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).
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.
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. 4.16.1 Step-by-step instructions 1) Connect the variable resistor or RTD calibration equipment to J7 on the G4 EX board.
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.
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.
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.
Figure 5–1 Troubleshooting flowchart 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.
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 below 2.5 VDC.
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. 126.96.36.199 Step-by-step instructions 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.
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. 188.8.131.52 Step-by-step instructions 1) Begin by collecting data from the unit. 2) View the Event log in PCCU32 for codes (see PCCU32 Help Files for more information).
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. 184.108.40.206 Required equipment Digital Multi-meter (DMM) with alligator clip leads 220.127.116.11 Step-by-step instructions 1) Begin by disconnecting power and communications from the EXIMV. 2) Disconnect the RTD from the EXIMV.
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.
5) If any values are returned out of range, the RTD probe is defective. Replace the RTD. 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.
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. 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.
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.
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).
The following instructions will take the user through the steps for performing this task. 18.104.22.168 Step-by-step instructions 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.
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.
Refer to Chapter 4 for steps on performing both a hardware and software cold start. 22.214.171.124 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.
START Verify unit ID#, Security Code and Protocol are Correct. Verify jumper and terminal & pin wiring are correct. Does Unit Transceiver Transceiver Investigate Supply voltage Respond to Host Supply voltage Transceiver Comm Request? Test within Specs? Issues Investigate Voltage supply Power Supply from unit Issues...
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 ...
126.96.36.199 Step-by-step instructions 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.
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;...
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.
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.
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 188.8.131.52 Step-by-step instructions Voltage on the following steps may be difficult to see using a Digital Multi-meter. If available, an oscilloscope will provide a more accurate reading.
6 Reference material 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.
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.
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.
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 1) Collect data from the unit. 2) Back up all of the configuration and data files.
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.
DB-9 Connector to XFCEX Board I/O Expansion Connector (J2) (Mounted on Back) XFCEX Board (Ref) The DI/PI inputs will accept sensor inputs which meet the IEC-60947-5-6 electrical SECURITY characteristics. + AI - + DI - + DO - RTD IN I/O EXPANSION COMM1 RTD -...
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...
184.108.40.206 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...
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).
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.
External to Flowmeter flowmeter 2-wire (line powered) AI + 4-20ma transmitter To A/D Converter User supplies 250Ω resistor and wires it 250Ω across the AI input pins AI - External to Flowmeter flowmeter 2-wire (line powered) AI + To A/D Converter 4-20ma transmitter Onboard 250Ω...
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.
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 Onboard 250 ohm 2-wire (line powered) resistor selected using 4-20ma transmitter three-pin shunt External resistor added across onboard resistor 250 Ohm 250 Ohm...
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