A6073 FB553

Field Automation Systems
FLOBOSS 553 FLOW MANAGER

Instruction Manual
Form A6073 June 1999 (2nd Edition)
Loose-leaf version: Part Number D301127X012 Bound version: Contact FAS
FloBoss 553 Instruction Manual
Revision Tracking Sheet

June 1999, 2nd Edition This manual may be revised periodically to incorporate new or updated information. The date revision level of each page is indicated at the bottom of the page opposite the page number. A major change in the content of the manual also changes the date of the manual which appears on the front cover. Listed below is the date revision level of each page.
Page 1-20 and 1-21 2-15 2-29 All others
Revision 1/00 1/00 1/00 6/99
Note: This 2nd Edition adds information about changing the default sleep mode activiation values.
Fisher Controls International, Inc. 1999-2000. All rights reserved. Printed in the U.S.A. While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness or any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the products described herein.
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Table of Contents
SECTION 1 GENERAL INFORMATION .......................................................... 1-1
1.1 Manual Overview ........................................................................................................................ 1-1 1.2 Section Contents............................................................................................................ .............. 1-2 1.3 Additional Information ...................................................................................................... .......... 1-2 1.4 Product Overview........................................................................................................................ 1-3 1.5 Installation Requirements ............................................................................................................ 1-8 1.6 Mounting....................................................................................................................................1-13 1.7 Power Consumption Calculation............................................................................................... ..1-15 1.8 Startup and Operation.................................................................................................................1-20
SECTION 2 USING THE FLOBOSS 553 ............................................................ 2-1

2.1 Scope .......................................................................................................................................... 2-1 2.2 Section Contents............................................................................................................ .............. 2-1 2.3 Product Functions........................................................................................................... ............. 2-3 2.4 Product Electronics...................................................................................................................... 2-9 2.5 Connecting the FloBoss to Wiring ............................................................................................ ..2-16 2.6 Calibration .................................................................................................................................2-28 2.7 Troubleshooting and Repair........................................................................................................2-29 2.8 Specifications .............................................................................................................................2-35
SECTION 3 DUAL-VARIABLE SENSOR .......................................................... 3-1

3.1 Scope .......................................................................................................................................... 3-1 3.2 Section Contents............................................................................................................ .............. 3-1 3.3 Description.................................................................................................................................. 3-1 3.4 Process Connections.................................................................................................................... 3-2 3.5 DVS Wiring ................................................................................................................................ 3-2 3.6 Configuration .............................................................................................................................. 3-3 3.7 Calibration .................................................................................................................................. 3-5 3.8 Specifications .............................................................................................................................3-13
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Table of Contents (Continued) SECTION 4 COMMUNICATIONS CARDS....................................................... 4-1

4.1 Scope .......................................................................................................................................... 4-1 4.2 Section Contents............................................................................................................ .............. 4-1 4.3 Product Descriptions ................................................................................................................... 4-1 4.4 Initial Installation and Setup ........................................................................................................ 4-5 4.5 Connecting Communications Cards to Wiring ............................................................................. 4-7 4.6 Troubleshooting and Repair......................................................................................................... 4-8 4.7 Communication Cards Specifications .........................................................................................4-10
APPENDIX A LOOP SCHEMATIC ....................................................................A-1

A.1 Scope ..........................................................................................................................................A-1 A.2 Loop Schematic drawings............................................................................................................A-1
GLOSSARY OF TERMS .......................................................................................... G-1 TOPICAL INDEX .......................................................................................................I-1
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SECTION 1 GENERAL INFORMATION

1.1 MANUAL OVERVIEW
This manual describes the FloBoss 553 Flow Manager, part of the family of FloBoss 500 flow computers manufactured by Fisher Controls. Included in this manual are the following sections: Table of Contents Section 1 Section 2 Section 3 Section 4 Appendix A Glossary Index Table of Contents General Information Using the FloBoss 553 Dual-Variable Sensor Communications Cards IS Loop Schematic Glossary of Terms Topical Index
Table of Contents lists each section and information contained in that section of the document. Section 1 describes this manual and mentions related manuals. This section also provides a summary of the FloBoss hardware, installation requirements, mounting the FloBoss, and power requirements. Section 2 provides information and specifications concerning the use of the FloBoss. Topics covered include the Main Electronics Board, wiring, processes, and troubleshooting. The Main Electronics Board provides the flow sensor input channel, one built-in discrete output channel, a Resistance Temperature Detector (RTD) input, an operator interface port, and a host communications port. Section 3 describes the Dual-Variable Sensor (DVS) included with the FloBoss 553 for sensing static (line) pressure and differential pressure across an orifice. Section 4 provides information and specifications for the optional communications cards. Appendix A shows the intrinsic safety Loop Schematic as approved for the FloBoss 553. Glossary of Terms defines terms used in Fisher Controls documentation. Topical Index alphabetically lists the items contained in this manual, including their page numbers.
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1.2 SECTION CONTENTS

This section contains the following information: Information Manual Overview Section Contents Additional Information Product Overview Options Installation Requirements Environmental Requirements Site Requirements Compliance with Hazardous Area Standards Power Installation Requirements Grounding Installation Requirements I/O Wiring Requirements Mounting Mounting the FloBoss Power Consumption Calculation Determining I/O Channel Power Consumption Totaling Power Requirements Solar Powered Installations Batteries Startup and Operation Startup Operation Section 1.1 1.2 1.3 1.4 1.4.2 1.5 1.5.1 1.5.2 1.5.3 1.5.4 1.5.5 1.5.6 1.6 1.6.1 1.7 1.7.1 1.7.2 1.7.3 1.7.4 1.8 1.8.1 1.8.2 Page Number 1-1 1-2 1-2 1-3 1-7 1-8 1-8 1-9 1-10 1-10 1-11 1-12 1-13 1-13 1-15 1-15 1-16 1-17 1-19 1-20 1-20 1-21
1.3 ADDITIONAL INFORMATION

The following manuals may be used to acquire additional information not found in this manual: & & & Type RL101 ROCLINK Configuration Software User Manual Part Number D301101X012 Function Sequence Table (FST) User Manual Part Number D301058X012 ROC/FloBoss Accessories Instruction Manual Part Number D301061X012
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1.4 PRODUCT OVERVIEW

The FloBoss 553 is a 32-bit microprocessor-based Electronic Flow Measurement (EFM) computer that provides functions required for measuring the differential pressure, static pressure, and the temperature at a single meter run. From these, the FloBoss computes gas flow for both volume and energy. The FloBoss provides on-site functionality and supports remote monitoring, measurement, data archival, communications, and control in Class I, Division 1 locations (which may contain continuous concentrations of flammable gas). The FloBoss design allows you to configure specific applications including those requiring gas flow calculations, data archival, remote communications, and logic and sequencing control using a Function Sequence Table (FST). The FloBoss 553 provides the following standard components and features: Weather-tight, corrosion-resistant enclosure (NEMA 4X). Main Electronic Board. Built-in Liquid Crystal Display (LCD) with two-line alphanumeric viewing. A 32-bit microprocessor, 512K of flash ROM, and 512K of static memory storage. Built-in Discrete Output (DO) for sampler or odorizer control. Built-in Dual-Variable Sensor (DVS) for sensing differential and static pressure. Built-in Resistance Temperature Detector (RTD) input. Operator interface (LOI) port (for non-hazardous areas only). Host communications port for optional communications card. Applications firmware.
Physically, the FloBoss consists of a printed-circuit Main Electronics Board and a display housed in a compact, weather-tight case. The FloBoss is packaged in a NEMA 4X windowed enclosure that can mount on a wall, a pipestand, or directly to the metering pipe. Refer to Figure 1-1. The plastic enclosure protects the electronics from physical damage and corrosive environments. The enclosure has a hinged and gasketed door secured by a lockable hasp. The enclosure has mounting flanges that allow it to be fastened to a wall or panel, or mounted on a pipestand. In addition, it can be direct-mounted, such as on an integral orifice assembly. The internal structural metal is made from a low-copper aluminum alloy. All exposed metal is stainless steel. The enclosure is fabricated from fiberglass-reinforced plastic. Enclosure external dimensions, including mounting flanges and the Dual-Variable Sensor (DVS), are approximately 16.75 inches high by 10.38 inches wide by 6.69 inches deep (425 mm by 264 mm by 170 mm). The DVS is factorymounted to the bottom of the enclosure. Refer to Figure 1-3 on page 1-14 for further dimensional details.
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1-3

Mounting Flange
Display
DVS
DOC0334P
Figure 1-1. FloBoss 553 Flow Manager
The Main Electronics Board, displayed in Figure 1-2, mounts on a backplate under a black-anodized aluminum cover. The dimensions of the board are approximately 5 by 7.5 inches. The majority of the components are surface-mounted, with only the top side of the board used for components. The Main Electronics Board provides built-in I/O capabilities, an LCD display, and provisions for an optional communications card. The main electronics board is factory-mounted inside the housing, which provides protection for the electronics. For more information on the Main Electronics Board, refer to Section 2. The built-in Liquid Crystal Display (LCD) provides the ability to look at data and configuration parameters while on site without using the local operator interface (LOI) and a personal computer. The LCD display is factory-mounted directly to the Main Electronics Board and visible through the window on the enclosure door. Through this display, you can view information (defined by configuration) stored in the FloBoss. Up to 16 items can be defined for display. The display automatically cycles through the configured list of items, displaying a new value approximately every three seconds.
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SCALE IS .5
Operator Interface Port
Coupler
A Motorola 32-bit CMOS microprocessor runs at 14.7 MHz and has low-power operating modes, including inactivity and low battery conditions. The FloBoss comes standard with 512K of built-in, supercapacitor-backed static random access memory (SRAM) for storing data and history. The FloBoss also has 512K of programmable read-only memory (flash ROM) for storing operating system firmware, applications firmware, and configuration parameters. The built-in inputs and outputs (I/O) consist of a port for a Dual-Variable Sensor (DVS), a 4-wire Resistance Temperature Detector (RTD) input interface, and a discrete output (DO). Diagnostic inputs are dedicated to monitoring input voltage and enclosure temperature. Connectors located on the Main Electronics Board provide terminations for input power, an RTD input, a discrete output (DO), DualVariable Sensor (P/DP), and operator interface (LOI) communications. Refer to Figure 1-2. The built-in discrete output (DO) is capable of controlling a sampler or odorizer. The DO may be used as a Timed Duration Output (TDO). The Dual-Variable Sensor (DVS) measures differential pressure and absolute or gauge (static) pressure by converting the applied pressure to electrical signals and making the readings available to the Main Electronics Board. The sensor housing screws into a flanged adapter, which in turn mounts with four bolts to the bottom of the enclosure. The DVS cable plugs directly into the Main Electronics Board at the P/DP connector. For more information on the DVS, refer to Section 3. An RTD temperature probe typically mounts in a thermowell on the metering pipe. RTD wires should be protected either by a metal sheath or conduit connected to a liquid-tight conduit fitting on the bottom of the FloBoss enclosure. The RTD wires connect directly to the four-terminal RTD connector on the Main Electronics Board inside the enclosure. The operator interface (LOI) port, located on the bottom left-hand side of the enclosure (refer to Figure 1-1), provides for a local link between the FloBoss and a personal computer through an Operator Interface Cable. With the personal computer running the ROCLINK Configuration Software, you can configure the functionality of the FloBoss and monitor its operation. User-level security can be enabled or disabled for the LOI port. WARNING Do not use the LOI port in a hazardous location (Class I, Division 1 or 2). For a FloBoss 553 in a C1D1 area, you may use the Laptop Computer connectors wired through an intrinsic safety barrier as shown in the Loop Schematic (Appendix A). The host communications port (located at COM1) is available for use with an optional communications card to permit serial communication protocols. User level security can be enabled or disabled for the host communications port. Refer to Section 4 for details on communication cards. The I/O parameters, DVS inputs, flow calculations, security, and FST programmability are configured and accessed using the ROCLINK Configuration Software. Refer to the ROCLINK Configuration Software User Manual for details concerning software capabilities.
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R1 60 J1
NORM RST P1
Reset Jumper LCD
Super Capacitor "Battery"

C3
U2 P3
Comm Card Mating Connector
P5
U6 U8 U7
U9
Flash Memory Chip
U11
U12
CR6
CR7
PT2 FL1
PT3
PT1 CR9
MV1 MV2
P8
P10
Board Power Connector Integral Sensor Connector
Built-in I/O Wiring

P11
DOC0380A DOC0331A
Figure 1-2. Main Electronics Board
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1.4.1 Firmware
The Version 2.x firmware, contained in flash ROM on the electronics board, determines much of the functionality of the FloBoss, such as: Memory logging of 240 alarms and 240 events. Archival of data for up to 15 history points for up to 35 days. American Gas Association (AGA) flow calculations for a single meter run. Logic and sequencing control by means of a user-defined Function Sequence Table (FST). Communications based on either Modbus protocol or ROC protocol. User-level security.
Refer to Section 2.3 for more information about the functionality provided by the firmware.
1.4.2 Options and Accessories

The FloBoss supports the following options and accessories: Communications Cards for host communications. Local Operator Interface (LOI) cable. Two plug-in communication cards are available for the FloBoss installation. The communication cards provide an interface for the host communications port. These cards permit serial communication protocols. One of the following card types can be accommodated: EIA-232 (RS-232) for asynchronous serial communications. EIA-485 (RS-485) for asynchronous serial communications. Stand-offs on the Main Electronics Board allow the optional communications cards to be added easily. Refer to Section 4 for more information. The local operator interface (LOI) port, which is approved for use in non-hazardous areas only, provides for a direct, local link using an Operator Interface Cable between the FloBoss and a personal computer. With the personal computer running the ROCLINK Configuration Software, you can configure the functionality of the FloBoss and monitor its operation. The Operator Interface Cable is available as an accessory from Fisher. WARNING Do not use the LOI port in a hazardous location (Class I, Division 1 or 2). For a FloBoss 553 in a C1D1 area, you may use the Laptop Computer connectors wired through an intrinsic safety barrier as shown in the Loop Schematic (Appendix A).
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The FloBoss is powered by a 12-volt dc power supply, typically a solar panel and battery combination. Refer to Section 2, Connecting Power Wiring.
1.5 INSTALLATION REQUIREMENTS

This section provides generalized guidelines for successful installation and operation of the FloBoss. Planning helps to ensure a smooth installation. Be sure to consider location, ground conditions, climate, and site accessibility as well as the suitability of the FloBoss application while planning an installation. The versatility of the FloBoss allows it to be used in many types of installations. For additional information concerning a specific installation, contact your Fisher Representative. For detailed wiring information, refer to Section 2. The Installation Requirements section includes: Environmental Requirements Site Requirements Compliance with Hazardous Area Standards Power Installation Requirements Grounding Installation Requirements I/O Wiring Requirements NOTE The FloBoss has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy. If not installed and used in accordance with this instruction manual, the FloBoss may cause harmful interference to radio communications. Operation of the equipment in a residential area is likely to cause harmful interference, in which case you will be required to correct the interference at your own expense.
1.5.1 Environmental Requirements

The FloBoss enclosure is classified as a CSA Type 4X (NEMA 4X equivalent) enclosure. This provides the protection required to keep the units operating under a variety of weather conditions.
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The FloBoss is designed to operate over a -40 to 75 C (-40 to 167 F) temperature range. The LCD temperature range is -25 to 70 C (-13 to 158 F). When mounting the unit, be aware of external devices that could have an effect on the operating temperature. Operation beyond the recommended temperature range can cause errors and erratic performance. Prolonged operation under extreme conditions can result in premature failure of the unit. In extreme climates, it may be necessary to moderate the temperature in which the unit must operate. Check the installation for mechanical vibration. Ensure that the levels of vibration do not exceed those specified (see Specifications in Section 2).
1.5.2 Site Requirements

Careful consideration in locating the FloBoss on the site can help prevent future operational problems. The following items should be considered when choosing a location: Local, state, and federal codes often place restrictions on monitoring locations and may dictate site requirements. Examples of these restrictions are fall distance from a meter run, distance from pipe flanges, and hazardous area classifications. Locate the FloBoss to minimize the length of signal and power wiring. When providing solar power to FloBoss units, orient solar panels to face due South (not magnetic South) in the Northern Hemisphere and due North (not magnetic North) in the Southern Hemisphere. Make sure nothing blocks the sunlight from 9:00 AM to 4:00 PM. Antennas equipped for radio communications must be located with an unobstructed signal path. If possible, locate antennas at the highest point on the site and avoid aiming antennas into storage tanks, buildings, or other tall structures. Allow sufficient overhead clearance to raise the antenna. To minimize interference with radio communications, locate the FloBoss away from electrical noise sources such as engines, electric motors, and utility line transformers. Locate the FloBoss away from heavy traffic areas to reduce the risk of being damaged by vehicles. However, provide adequate vehicle access to aid in monitoring and maintenance.
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1.5.3 Compliance with Hazardous Area Standards

The FloBoss 550 Series typically has hazardous location approval for Class I, Division 1, Groups C and D exposures. The Class, Division, and Group terms are defined as follows: Class defines the general nature of the hazardous material in the surrounding atmosphere. Class I is for locations where flammable gases or vapors may be present in the air in quantities sufficient to produce explosive or ignitable mixtures. Division defines the probability of hazardous material being present in an ignitable concentration in the surrounding atmosphere. Since Division 1 locations are presumed to be hazardous, all electrical devices must be designed as intrinsically safe, explosion proof, etc. Group defines the hazardous material in the surrounding atmosphere. Groups C to D are defined as follows: Group C - Atmosphere containing ethylene, gases or vapors of equivalent hazards. Group D - Atmosphere containing propane, gases or vapors of equivalent hazards. For the FloBoss to be approved for hazardous locations, it must be installed according to the National Electrical Code (NEC) Article 501. WARNING When installing units in a hazardous area, make sure all installation components selected are labeled for use in such areas. Installation and maintenance must be performed only when the area is known to be non-hazardous.
1.5.4 Power Installation Requirements

The typical source of primary power for FloBoss installations is solar power. If line power is used, care must be taken to route it away from hazardous areas, sensitive monitoring devices, and radio equipment. Local and company codes generally provide guidelines for line power installations. Adhere rigorously to all local and National Electrical Code (NEC) requirements for line power installations. CAUTION Power to the FloBoss must be connected only to the terminal block labeled INPUT POWER (the MCU PWR terminals are intended for factory use). For Class I, Division 1 installations, power must be connected through intrinsic safety barriers as specified in the Loop Schematic (Appendix A).
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Refer to Section 1.7, Power Consumption Calculation, on page 1-15 to plan for total power consumption of the FloBoss.
1.5.5 Grounding Installation Requirements

CAUTION Grounding for the FloBoss in Class I, Division 1 installations must be done in accordance with the Loop Schematic (Appendix A). Note that the Intrinsic Safety ground conductors must be connected to a single earth ground. Ground wiring requirements for line-powered equipment are governed by the National Electrical Code (NEC). When the equipment uses line power, the grounding system must terminate at the service disconnect. All equipment grounding conductors must provide an uninterrupted electrical path to the service disconnect. The National Electrical Code Article 250-83 (1993), paragraph c, defines the material and installation requirements for grounding electrodes. The National Electrical Code Article 250-91 (1993), paragraph a, defines the material requirements for grounding electrode conductors. The National Electrical Code Article 250-92 (1993), paragraph a, provides installation requirements for grounding electrode conductors. The National Electrical Code Article 250-95 (1993) defines the size requirements for equipment grounding conductors. Proper grounding of the FloBoss helps to reduce the effects of electrical noise on the units operation and protects against voltage transients, such as induced by nearby lightning. Transient protection is built-in to the FloBoss, providing protection for built-in field wiring inputs and outputs. A surge protection device installed at the service disconnect on line-powered systems offers lightning and power surge protection for the installed equipment. All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less (1 ohm preferred) as measured with a ground system tester for computer equipment. The grounding conductor should have a resistance of 1 ohm or less between the FloBoss case ground lug and the earth ground rod or grid. The grounding installation method for the FloBoss depends on whether the pipeline has cathodic protection. On pipelines with cathodic protection, the FloBoss must be electrically isolated from the pipeline. Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the meter run. In this case, the FloBoss could be flange mounted or saddle-clamp mounted directly on the meter run and grounded with a ground rod or grid system.
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On pipelines without cathodic protection, the pipeline itself may provide an adequate earth ground and the FloBoss could mount directly on the meter run. Using a ground system tester, test to make sure the pipeline to earth impedance is less than 25 ohms. If an adequate ground is provided by the pipeline, do not install a separate ground rod or grid system. All grounding should terminate at a single point. If the pipeline to earth impedance is greater than 25 ohms, the FloBoss installation should be electrically isolated and a ground rod or grid grounding system installed. Shields for I/O signal wiring used in the FloBoss should be grounded. A ground bar is provided inside the FloBoss enclosure for terminating shield wires and other connections that require earth ground. Note that shields should be grounded at one end only to prevent ground loops. A lug on the outside of the FloBoss enclosure is provided to connect the enclosure to earth ground. Note that on the FloBoss 550 series, the ground bar is internally connected to the enclosure ground lug; no further connection between these points is needed.
1.5.6 I/O Wiring Requirements

I/O wiring requirements are site and application dependent. Local, state, or NEC requirements may determine I/O wiring installation methods. Direct burial cable, conduit and cable, or overhead cables are options for I/O wiring installations. Section 2 contains detailed information on connecting I/O wiring to the FloBoss. The recommended cable for I/O signal wiring is an insulated, shielded, twisted-pair. The twisted pair and the shielding minimize signal errors caused by EMI (electromagnetic interference), RFI (radio frequency interference), and transients. A ground bar is provided inside the enclosure for terminating shield wires. Note that cable shields should be grounded at one end only. The I/O wiring for the FloBoss is connected to terminals on the lower edge of the Main Electronics Board. Refer to Figure 1-2. The terminal designations are printed on the electronics cover.
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1.6 MOUNTING
When choosing an installation site, be sure to check all clearances. For dimensions, refer to Figure 1-3. Provide adequate clearance for the enclosure door to be opened for wiring and service. The door is hinged on the left side. The LCD display should be visible and accessible for the on-site operator. When using a solar panel (must not be located in the Class I, Division 1 area with the FloBoss), there should be adequate clearance, and view of the sun should not be obstructed. Allow adequate clearance and an obstructed location for antennas when using radios. The Dual-Variable Sensor (DVS) is factory-mounted directly to the FloBoss enclosure with four bolts. This mounting uses a special coupler to join the threads on the sensor to the four-bolt mounting pattern on the bottom of the FloBoss enclosure. See Section 3 for more information.
1.6.1 Mounting the FloBoss

Mounting of the FloBoss can be accomplished using any of the following methods: Pipe mounted The enclosure provides top and bottom mounting flanges with holes for 2-inch pipe clamps (U-bolts and brackets supplied). The 2-inch pipe can be mounted to another pipe with a pipe saddle, or it can be cemented into the ground deep enough to support the weight and conform to local building codes. Wall or panel mounted Fasten to the wall or panel using the mounting flanges on the enclosure. Use 5/16-inch bolts through all four holes. Hole spacing dimensions are given in Figure 1-3. Integral orifice mounted Fasten to the pipe using integral orifice mounting equipment and techniques. With all mounting methods, the pressure inputs must be piped to the -18 NPT process connections on the sensor. Refer to Section 3 for more information on piping. CAUTION The FloBoss 553 must be mounted vertically with the Dual-Variable Sensor at its base as shown in Figure 1-3.
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10.38 3.25 2.81
2X .44
6.75
12.50
16.88
DOC0334A
Figure 1-3. Outline and Mounting Dimensions
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1.7 POWER CONSUMPTION CALCULATION

A FloBoss systems power consumption determines power supply and battery sizing for both line and solar power. Table 1-1 provides information to assist in determining power requirements. The FloBoss has low power consumption due to a typical duty cycle of 10 to 20% for its microprocessor; the other 80 to 90% of the time the microprocessor is shut off, with external wake-up signals reactivating it. The Power Consumption Calculation section includes: Determining I/O Channel Power Consumption Totaling Power Requirements Solar Powered Installations Batteries
1.7.1 Determining I/O Channel Power Consumption

In estimating total I/O power requirements, the duty cycle of each I/O channel must be estimated. For example, if a discrete output is active for 15 seconds out of every 60 seconds, the duty cycle is: Duty Cycle = Active time/(Active time + Inactive time) = 15 sec/60 sec = 0.25 To calculate the total power consumed by an I/O channel, use Table 1-1 and read the minimum (Pmin) and maximum (Pmax) power consumption value from the table for the desired I/O channel. Use the following equation to calculate the power consumption for a channel with the duty cycle taken into account: Power = (Pmax x Duty Cycle) + [Pmin (1 - Duty Cycle)] Multiply this value by the Quantity of I/O channels with the same Duty Cycle and enter the calculated value in the Subtotal column. Repeat the procedure for all other I/O channels used.
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Table 1-1. Power Consumption of the FloBoss 553 and Powered Devices Device Power Consumption (mW) 12V System
Pmin Main Electronics Board; includes minimum built-in I/O power consumption, RTD, and integral sensor. Built-in Discrete Output (load dependent with a maximum of 5 volts and 25 milliamps). Serial Communications Card 400 Pmax 2000 1 N/A
Quantity
Duty Cycle
Subtotal (mW)
0 30
125
1 N/A
Total
1.7.2 Totaling Power Requirements

To adequately meet the requirements of the FloBoss system, it is important to determine the total power consumption, size of solar panel, and battery backup requirements accordingly. For total FloBoss power consumption, add the device values in Table 1-1. Although Table 1-1 takes into account the power supplied by the FloBoss to its connected devices, be sure to add the power consumption (in mW) of any other devices used with the FloBoss in the same power system, but not accounted for in the table (such as intrinsic safety barriers). Convert the total value (in mW) to Watts by dividing it by 1000. mW / 1000 = Watts For selecting an adequate power supply, use a safety factor (SF) of 1.25 to account for losses and other variables not factored into the power consumption calculations. To incorporate the safety factor, multiply the total power consumption (P) by 1.25. PSF = P x 1.25 = _____ Watts To convert PSF to current consumption in amps (ISF), divide PSF by the system voltage (V), which is 12volts. ISF = PSF / V = _____ Amps
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1.7.3 Solar Powered Installations

Solar power allows installation of the FloBoss in locations where line power is not available. The two important elements in a solar installation are solar panels and the battery. Solar panels and the battery must be properly sized for the application and geographic location to ensure continuous, reliable operation. Note that the solar panel and battery must not be located in a Class I, Division 1 area along with the FloBoss (see Loop Schematic). Fisher Controls does not offer solar panels for FloBoss 500-series units. However, a list of acceptable solar panels is provided below. Refer to the manufacturers literature for installation instructions. The following solar panels are approved by CSA for use in Class I, Division 2 locations. Solarex MSX-5 Solarex MSX-10 UniSolar US-5 UniSolar US-10 5.0 watt 10.0 watt 5.0 watt 10.0 watt
The panel must face due South (not magnetic South) in the Northern Hemisphere and due North (not magnetic North) in the Southern Hemisphere. The panel must also be tilted at an angle from the horizontal dependent on the latitude to maximize the energy output. The angles for different latitudes are normally included in the solar panel documentation. At most latitudes, the performance can be improved by less of an angle during the summer and more of an angle during the winter. As a site may have additional power requirements for radios, repeaters, and other monitoring devices, power supply and converter accessories may be used to minimize the number of separate power sources required for an installation. Solar arrays are used to generate electrical power from solar radiation. The size and number of solar panels required for a particular installation depends on several factors, including the power consumption of all devices connected to the solar array and the geographic location of the installation, as explained below. To determine solar panel output requirements, first determine the solar insolation for your geographic area. The map in Figure 1-4 shows solar insolation (in hours) for the United States during winter months. Your local Fisher Representative can help you find a map detailing your specific geographic area. Insolation (from map) = _____ hours Next, calculate the amount of current required from the solar array per day using the following equation. ISF is the system current requirement. Refer to Section 1.7.2 on page 1-16. Iarray = [ISF (amps) 24 (hrs)]/Insolation (hrs) = _____ amps
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Finally, the number of solar panels can be determined using the following equation: Number of Panels = Iarray amps/(Ipanel amps/panel) = _____ panels
Figure 1-4. Solar Insolation in Hours for the United States
For example, if Iarray equals 0.54 amps, and Ipanel equals 0.29 amps for a 5-watt panel, then the number of panels required equals 1.86, which would be rounded up to 2 (panels connected in parallel). Alternatively, the next larger solar panel can be used, which in this case would be a 10-watt panel. Table 1-2 gives Ipanel values for solar panels recommended by Fisher Controls. NOTE The I panel value varies depending on the type of solar panel installed. Refer to the vendors specifications for the solar panel being used.
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Table 1-2. Solar Panel Sizing Panel 5 watt 10 watt 11 watt I panel 0.29 amps 0.58 amps 0.7 amps
1.7.4 Batteries
When used in solar installations, the battery provides power for the FloBoss when the solar panels are not generating sufficient output. Note that the solar panel and battery must not be located in a Class I, Division 1 area along with the FloBoss (see Loop Schematic). Typical battery configurations use a 12-volt, sealed (non-venting), rechargeable, gel-cell, lead-acid battery. The amount of battery capacity required for a particular installation depends upon the power requirements of the equipment and days of reserve (autonomy) desired.
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1.8 STARTUP AND OPERATION

Before starting the FloBoss, perform the following checks to ensure the unit is properly installed. Make sure the enclosure has a good earth ground connected to the earth ground bus inside the enclosure. Check the field wiring for proper installation. Refer to Section 2. Make sure the Input Power has the correct polarity. Make sure the Input Power is fused at the power source. WARNING To ensure safe operation, installation and wiring connections must be made as shown in the Loop Schematic of Appendix A. Only the options listed there may be used. CAUTION Bonding between conduit connections is not automatic and must be provided as part of the installation. CAUTION Power to the FloBoss 550 Series must only be connected to the INPUT POWER connector, not to the MCU PWR connector. Ensure that the voltage does not exceed 16 Vdc, or damage to the FloBoss electronics may result. CAUTION It is important to check the input power polarity before turning on the power. Incorrect polarity can damage the FloBoss electronics.
1.8.1 Startup
After observing the above cautions, apply power to the FloBoss. After the FloBoss completes start-up diagnostics (RAM and other internal checks), the LCD displays the date and time to indicate that the FloBoss completed a valid reset sequence. If the LCD does not come on, refer to the Troubleshooting and Repair paragraphs in Section 2 for possible causes. IMPORTANT NOTICE For the FloBoss 553 to operate properly on a 12-volt system with intrinsic safety barriers in place, you must change the activation values for the sleep mode to lower
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values as instructed in Section 1.8.2. If you do not change these values, the FloBoss will readily go into a sleep mode and fail to operate normally.
1.8.2 Operation
Once startup is successful, it is necessary to configure the FloBoss to meet the requirements of the notice above and of the application. The ROCLINK Configuration Software User Manual (Form A6051) details the procedure for configuring the FloBoss and calibrating the I/O. Once the FloBoss is configured and calibrated, it can be placed into operation. WARNING Local configuration or monitoring of the FloBoss through the LOI port on the bottom of the enclosure must be performed only in an area known to be nonhazardous. To set the proper sleep mode activation values (see NOTICE above), connect a computer to the LOI port and run the ROCLINK Configuration Software. In the I/O menu, select AI and page (use F3 key) to the screen for Point E1. In this screen make sure alarming is Enabled, and use the Alarms pushbutton to bring up the Alarms dialog box. In this dialog box, change the Low Alarm value to 5.6 volts, change the LoLo Alarm value to 5.2 volts, and click OK. These values will allow the FloBoss to operate with intrinsic safety barriers without unnecessarily going into sleep mode. Save the new values in the E1 screen (use F8 key). Also save the new values to permanent memory (in case of a cold restart) by selecting Flags in the System menu, turning Write to Internal Config Memory to Yes, and saving (F8 key). During operation, the FloBoss can be monitored (to view or retrieve current and historical data) either locally or remotely. Local monitoring is accomplished either by viewing the LCD panel detailed in Section 2, or by using ROCLINK on a PC connected through the LOI port. Remote monitoring is performed through the host port (COM1) of the FloBoss, using either ROCLINK or host software. Refer to the ROCLINK User Manual for more information on monitoring.
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SECTION 2 USING THE FLOBOSS 553

2.1 SCOPE
This section describes the FloBoss 553 Flow Manager, focusing on how it works and how to connect its wiring. Topics include: Product Functions Product Electronics Connecting the FloBoss to Wiring Troubleshooting and Repair Specifications

This section contains the following information: Information Scope Section Contents Product Functions Flow Measurement 1985 Flow Calculations 1992 Flow Calculations History Points Minute Historical Log Hourly Historical Log Daily Historical Log Alarm Log Event Log Security Function Sequence Tables (FST) Modbus Product Electronics Main Electronics Board Overview Microprocessor and Memory Liquid Crystal Display Communications Ports Operator Interface Port Host Port Section Page Number 2.1 2-1 2.2 2-1 2.3 2-3 2.3.1 2-3 2.3.1.1 2-3 2.3.1.2 2-4 2.3.2 2-6 2.3.2.1 2-6 2.3.2.2 2-6 2.3.2.3 2-7 2.3.2.4 2-7 2.3.2.5 2-7 2.3.3 2-8 2.3.4 2-8 2.3.5 2-8 2.4 2-9 2.4.1 2-9 2.4.2 2-9 2.4.3 2-11 2.4.4 2-11 2.4.4.1 2-11 2.4.4.2 2-12
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Information Built-In Discrete Output RTD Input Diagnostic Inputs Real-Time Clock Automatic Self-Tests Connecting the FloBoss to Wiring Making Wiring Connections Connecting Ground Wiring Connecting Power Wiring RTD Wiring Discrete Output Wiring Connecting Communications Wiring Operator Interface Port Wiring Host Port Wiring Dual-Variable Sensor Wiring Calibration Troubleshooting and Repair Backup Procedure Before Removing Power Resetting the FloBoss Warm Start Cold Start Jumper Reset After Installing Components Specifications
Section Page Number 2.4.5 2-12 2.4.6 2-13 2.4.7 2-13 2.4.8 2-13 2.4.9 2-14 2.5 2-16 2.5.1 2-17 2.5.2 2-19 2.5.3 2-20 2.5.4 2-22 2.5.5 2-24 2.5.6 2-25 2.5.6.1 2-26 2.5.6.2 2-27 2.5.7 2-27 2.6 2-28 2.7 2-29 2.7.1 2-29 2.7.2 2-30 2.7.2.1 2-30 2.7.2.2 2-31 2.7.2.3 2-32 2.7.3 2-33 2.8 2-35
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2.3 PRODUCT FUNCTIONS

This section describes the functions of the FloBoss 553, most of which is determined by its firmware. The features and applications provided by the firmware, which is configured by using the ROCLINK Configuration Software, are: 1985 or 1992 AGA flow calculations for an orifice meter. Archival of data for up to 15 history points. Memory logging of 240 alarms and 240 events. Security with local and remote password protection. Logic and sequencing control using a user-defined FST program. Modbus Protocol Emulation Program.
2.3.1 Flow Measurement

The primary function of the FloBoss 553 is to measure and calculate the flow of natural gas in accordance with the 1985 or 1992 American Petroleum Institute (API) and American Gas Association (AGA) standards. The FloBoss performs either 1985 or 1992 AGA calculations, depending on which was ordered. The primary inputs used for the orifice metering flow measurement function are differential pressure, static (line) pressure, and temperature. The differential and static pressure inputs come from the DualVariable Sensor. The temperature input comes from an RTD probe. In the FloBoss 553: Differential pressure is sampled once per second. Static pressure is sampled once per second. Temperature is sampled and linearized once per second. The RTD is internally re-calibrated for every 5 C temperature change as sensed by enclosure temperature (diagnostic input E5).
2.3.1.1 1985 Flow Calculations for Orifice Metering

The 1985 flow calculation is in accordance with ANSI/API 2530-85 (AGA Report No. 3 1985), API Chapter 14.2 (AGA Report No. 8 1985), and API Chapter 21.1. The 1985 flow calculation may be configured for either Metric or English units.
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Flow Time
The differential pressure stored for each second is compared to the configured low flow cutoff. If the differential pressure is less than or equal to the low flow cutoff or the converted static pressure is less than or equal to zero, flow is considered to be zero for that second. Flow time for a recalculation period is defined to be the number of seconds for which the differential pressure exceeded the low flow cutoff.
Input and Extension Calculation

Every second the FloBoss 553 stores the measured input for differential pressure, static pressure, and temperature and calculates the flow extension (defined as the square root of the absolute upstream static pressure times the differential pressure). Flow time averages of the inputs and the flow extension over the configured recalculation period (Integral Multiplier Period) are calculated unless there is no flow for an entire recalculation period. If there is no flow, averages of the inputs are recorded to allow monitoring during no flow periods.
Instantaneous Rate Calculations

The instantaneous value of the flow extension is used with the previous recalculation periods C (C Prime) to compute the instantaneous flow rate. The instantaneous flow rate is used with the volumetric heating value to compute the instantaneous energy rate.
Flow and Energy Accumulation

The averages of the differential and static pressure, temperature, and flow extension are used with the flow time to compute the flow and energy over the recalculation period. The flow and energy are then accumulated and stored at the top of every hour. At the configured Contract Hour, the flow and energy are then stored to the Daily Historical Log and zeroed for the start of a new day.
2.3.1.2 1992 Flow Calculations for Orifice Metering

The 1992 flow calculation is in accordance with ANSI/API 2530-92 (AGA Report No. 3 1992), API Chapter 14.2 (AGA Report No. 8 1992 2nd printing 1994), and API Chapter 21.1. The 1992 flow calculation may be configured for either Metric or English units.
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Flow Time
The differential pressure stored for each second is compared to the configured low flow cutoff. If the differential pressure is less than or equal to the low flow cutoff or the converted static pressure is less than or equal to zero, flow is considered to be zero for that second. Flow time for a recalculation period is defined to be the number of seconds for which the differential pressure exceeded the low flow cutoff.
Input and Extension Calculation

Every second the FloBoss 553 stores the measured input for differential pressure, static pressure, and temperature and calculates the flow extension (defined as the square root of the absolute upstream static pressure times the differential pressure). Flow time averages of the inputs and the flow extension over the configured recalculation period are calculated unless there is no flow for an entire recalculation period. If there is no flow, averages of the inputs are recorded to allow monitoring during no flow periods.
Instantaneous Rate Calculations

The instantaneous value of the flow extension is used with the previous recalculation periods Integral Multiplier Value (IMV) to compute the instantaneous flow rate. The IMV is defined as the value resulting from the calculation of all other factors of the flow rate equation not included in the Integral Value (IV). The IV is defined as the flow extension. The instantaneous flow rate is used with the volumetric heating value to compute the instantaneous energy rate.
Flow and Energy Accumulation

The averages of the differential and static pressure, temperature, and flow extension are used with the flow time to compute the flow and energy over the recalculation period. The flow and energy are then accumulated and stored at the top of every hour. At the configured Contract Hour, the flow and energy are then stored to the Daily Historical Log and zeroed for the start of a new day.
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2.3.2 History Points

A total of fifteen history points may be accessed in the FloBoss 553. The first eight are pre-configured for flow metering history and cannot be changed. For orifice metering, they are as follows: 1. 2. 3. 4. 5. 6. 7. 8. Accumulated Flowing Minutes. Averaged Differential Pressure. Averaged Static Pressure. Averaged Temperature. Averaged C or Integral Multiplier Value (IMV). Averaged Pressure Extension or Integral Value (IV). Accumulated Instantaneous Flow. Accumulated Instantaneous Energy.
History points 2, 3, 4, and 6 are set up as an Average Archive Type, using one of the following techniques: Flow dependent time-weighted linear averaging. Flow dependent time-weighted formulaic averaging. Flow-weighted linear averaging. Flow-weighted formulaic averaging.
The remaining seven history points may be configured as desired.
2.3.2.1 Minute Historical Log

The FloBoss has a 60-minute Historical Log for every history point. The Minute Historical Log stores the last 60 minutes of data from the current minute. Each history point has Minute Historical Log entries unless the history point is configured for FST-controlled logging.
2.3.2.2 Hourly Historical Log

The FloBoss has a total of 840 Hourly Historical Logs available for every history point. The Hourly Historical Log is also called the Periodic Log. Normally, the Hourly Log is recorded every hour at the top of the hour. The exceptions are FST Minute and FST Second logging. The time stamp for periodic logging consists of the month, day, hour, and minute. The exception is for FST Second logging, in which the time stamp consists of the day, hour, minute, and second.
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2.3.2.3 Daily Historical Log

The FloBoss has a total of 35 Daily Historical Logs for every history point. The Daily Log is recorded at the configured Contract Hour every day with a time stamp that is the same as the Hourly Log. Each history point has Daily Historical Log entries unless the history point is configured for FST-controlled logging.
2.3.2.4 Alarm Log

The Alarm Log contains the change in the state of any alarm signal that has been enabled for alarms. The system Alarm Log has the capacity to maintain and store up to 240 alarms in a circular log. The Alarm Log has information fields which include time and date stamp, alarm clear or set indicator, and either the Tag name of the point which was alarmed with the current value or a 14-character ASCII description. In addition to providing functionality for appending new alarms to the log, it allows host packages to request the index of the most recently logged alarm entry. Alarm Logging is available internally to the system, to external host packages, to the FST, and to User C programs. Alarm Logs are not stored to the flash ROM during the ROCLINK Save Configuration function. The Alarm Log operates in a circular fashion with new entries overwriting the oldest entry when the buffer is full. The Alarm Log provides an audit history trail of past operation and changes. The Alarm Log is stored separately to prevent recurring alarms from overwriting configuration audit data.
2.3.2.5 Event Log

The Event Log contains changes to any parameter within the FloBoss made through the protocol. This Event Log also contains other FloBoss events such as power cycles, cold starts, and disk configuration downloads. The system Event Log has the capacity to maintain and store up to 240 events in a circular log. The Event Log has information fields which include point type, parameter number, time and date stamp, point number if applicable, the operator identification, and either the previous and current parameter values or a 14-byte detail string in ASCII format. In addition to providing functionality for appending new events to the log, it allows host packages to request the index of the most recently logged event entry. Event Logging is available internally to the system, to external host packages, and to the FST.
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Event Logs are not stored to flash ROM when the Save Configuration function is issued in the ROCLINK Configuration Software. The Event Log operates in a circular fashion with new entries overwriting the oldest entry when the buffer is full. The Event Log provides an audit trail history of past operation and changes. The Event Log is stored separately to prevent recurring alarms from overwriting configuration audit data.
2.3.3 Security
The FloBoss provides for security within the unit. A maximum of 16 log-on identifiers (IDs) may be stored. In order for the unit to communicate, the log-on ID supplied to the ROCLINK Configuration Software must match one of the IDs stored in the FloBoss. The Operator Interface port (Security on LOI) has security Enabled by default. The host port (Security on COM1) can likewise be configured to have security protection, but is disabled by default. Refer to the ROCLINK Configuration Software User Manual concerning security.
2.3.4 Function Sequence Tables (FST)

The FloBoss supports FST user programmability. The FST program can be from 200 to 300 lines of code depending upon the FST. The FST code resides in static RAM and is backed up to flash memory when the Save Configuration function is issued through the ROCLINK Configuration Software. See the ROCLINK Configuration Software User Manual and the Function Sequence Table (FST) User Manual (Form A4625).
2.3.5 Modbus
The Modbus Protocol Emulation Program is contained within the FloBoss firmware. The Modbus application is designed to allow the FloBoss to emulate the communications protocol used by Modbus devices. The Modbus communications protocol is fully described in the reference guide entitled Modicon Modbus Protocol publication PI-MBUS-300. Although the Modbus protocol can be either a Master or a Slave device, the FloBoss 553 is the Slave device. The Modbus protocol supports two modes of transmission, ASCII and RTU. Both modes of transmission are supported by the FloBoss 553.
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2.4 PRODUCT ELECTRONICS

This section describes the FloBoss Main Electronics Board, which is also called the MCU board.
2.4.1 Main Electronics Board Overview

The Main Electronics Board components support the functionality of the FloBoss. Refer to Figure 2-1. The board provides: 32-bit microprocessor Built-in static RAM Flash ROM Liquid Crystal Display (LCD) display Communications card host port (P3) Operator interface port (LOI) Built-in Discrete Output (DO) Built-in RTD Input (RTD) Board temperature and voltage monitor/diagnostic inputs Real-time clock and backup power Automatic self-tests
2.4.2 Microprocessor and Memory

The FloBoss derives processing power from a 32-bit microprocessor. The 32-bit CMOS microprocessor features dual 32-bit internal data buses and a single 8-bit external data bus. The unit can address up to four megabytes of memory including high-speed direct memory access. The Main Electronics Board has 512 Kbytes of static random access memory (SRAM) for storing interrupt vectors, Function Sequence Tables (FST), alarms, events, and history data. The Main Electronics Board also has a 512 Kbyte flash memory chip for storing the operating system factory code and configuration parameters. Two of the 64 Kbyte blocks are reserved for internal usage.
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R1 60 J1
Factory Test Jack
NORM RST P1
Reset Jumper
Supercapacitor
C3
U2 P3
P5
U6 U8 U7
U9
U11
Transorbs
U12
CR6
CR7
LOI RS232 Driver Positive Temperature Coefficient Resistor

PT1 CR9 MV1 MV2
EMI Filter
FL1 P8
PT2
PT3
MOVs Transorb
P10
Positive Temperature Coefficient Resistor
P11
DOC0331A
Figure 2-1. Main Electronics Board
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2.4.3 Liquid Crystal Display

A two-line Liquid Crystal Display (LCD) panel is mounted on the Main Electronics Board. The panel has automatic contrast adjustment due to temperature sensing and bias adjustment circuitry on the Main Electronics Board. The LCD panel remains on at all times when the power applied is within the valid operating range. The panel cycles its display through a configured list of up to 16 parameter values. The first two displays, which you cannot configure, show values for time and date, operating voltages, and battery condition. The next five displays are configured by the factory to show certain flow parameters, but you may change their configuration. Refer to the ROCLINK User Manual for details on how to configure the list of values for the LCD panel.
2.4.4 Communications Ports

The FloBoss provides for two communication ports: Operator interface port LOI. Host port for communication to a remote host COM1.
2.4.4.1 Operator Interface Port LOI

The Operator Interface port, also called the Local Operator Interface (LOI) port, provides direct communications between the FloBoss and the serial port of an operator interface device such as an IBM compatible computer. The interface allows you to access the FloBoss (using the ROCLINK Configuration Software) for configuration and transfer of stored data. The LOI terminal on the Main Electronics Board provides wiring access to a built-in EIA-232 serial interface and is capable of up to 19.2k baud rate. The operator interface port supports only ROC protocol communications. The LOI also supports the log-on security feature of the FloBoss if the Security on LOI is Enabled in ROCLINK. A cannon-type waterproof connector on the bottom of the enclosure provides connection through a prefabricated cable (available from Fisher) for an operator interface device, typically an IBMcompatible personal computer (PC) running the ROCLINK Configuration Software. Inside the FloBoss enclosure, the cannon-type connector is wired to three terminals (LOI) on the Main Electronics Board. WARNING Do not use the LOI port on the bottom of the FloBoss enclosure in a hazardous location (Class I, Division 1 or 2). Instead, use the Laptop Computer connectors that are wired through an intrinsic safety barrier as shown in the Loop Schematic (Appendix A).
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2.4.4.2 Host Port COM1

The host port (also called the COM1 port) is activated by the installation of the optional communications card. The host port is used to monitor or alter the FloBoss from a remote site using a host or the ROCLINK Configuration Software. The host port automatically configures itself based upon the specific communications card installed. The host port supports baud rates up to 19.2K. COM1 also supports the log-on security feature of the FloBoss if the Security on COM1 is Enabled in ROCLINK. The host port can receive messages in either ROC or Modbus protocol and will respond with the same type of protocol. The host port is capable of initiating a message in support of spontaneous Report by Exception (RBX) and Store and Forward when using ROC protocol. Refer to the ROCLINK Configuration Software User Manual. The communications connectors on the Main Electronics Board provide the FloBoss with electrical access and mounting provisions for the optional communications cards. The communications cards mount directly on the connectors at P3 on the Main Electronics Board and are held in place with three compression stand-offs. The stand-offs on the Main Electronics Board poke through the communications card. The communications cards available for the FloBoss allow for RS-232 or RS-485 serial data communications. Refer to Section 4 for further information on the communication cards.
2.4.5 Built-In Discrete Output

The FloBoss provides a Discrete Output (DO) to provide control capabilities for a sampler or odorizer. The Discrete Output is rated for switching applications as indicated in Table 2-1. This built-in Discrete Output can perform sampler functions, but may also be used as a standard DO. This includes toggle mode, latched mode, and timed DO mode. The built-in Discrete Output is configured as DO Point A4.
Table 2-1. Discrete Output Output voltage - ON Output voltage - OFF Output Current 5 volts 0 volts 25 milliamps
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When the Sampler function is Enabled, the FloBoss provides a Time Duration Output (TDO) based on the volume. A control volume and a pulse duration must be specified with the Sampler function. After each flow calculation, an internal volume accumulator is compared to the control volume. If the accumulator exceeds the control volume, a pulse is produced and the accumulator is reduced by the control volume. This output may be used to drive an external totalizer, odorizer, gas sampler, or similar device. Refer to Section 2.5.5, Discrete Output Wiring, on page 2-24.
2.4.6 RTD Input

The FloBoss supports a direct input from a Resistance Temperature Detector (RTD) sensor. The terminals for the RTD wires are located at the bottom right of the Main Electronics Board and labeled RTD. Refer to Figure 2-1. The RTD input is converted through a 16-bit RTD converter chip. During operation, the RTD is read once per second. The value from the RTD is linearized, and then it is sent to processing as Analog Input (AI) Point A3. The AI routine converts this value to engineering units, performs calibration corrections, and checks alarming. The board temperature (diagnostic point E5) is monitored by the RTD routine; if the board temperature has changed by roughly 9 F (5 C), the RTD circuitry is sent a command to recalibrate its reference. Refer to Section 2.5.4, RTD Wiring, on page 2-22.
2.4.7 Diagnostic Inputs

There are two functional diagnostic inputs built into the Main Electronics Board of the FloBoss 550series unit: one for input (battery) voltage, and one for temperature. Although these points cannot be calibrated, they can be used to monitor input voltage and temperature and generate alarms. The input voltage is accessed by the configuration software as Analog Input (AI) Point E1, while the board temperature is accessed as point E5.
2.4.8 Real-Time Clock

The real-time clock provides the FloBoss with the time of day, month, year, and day of the week. The time chip automatically switches to backup power when the Main Electronics Board loses primary input power. Backup power for the real-time clock, provided by a supercapacitor, is adequate for at least three weeks.
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2.4.9 Automatic Self-Tests

The FloBoss performs the following self-tests on a periodic basis: Battery low and battery high. Software and hardware watchdog. RTD automatic temperature compensation. Dual-Variable Sensor (DVS) operation. Charging voltage for the supercapacitor. Memory validity.
The FloBoss operates with 6 to 16 volts of dc power. The LCD becomes active when an input voltage with the proper polarity and startup voltage is applied to the INPUT POWER connector (provided the power input fusing/protection is operational). The battery low and high tests ensure that the FloBoss has the correct voltage to operate in a safe mode. The software watchdog is controlled by the Main Electronics Board. This watchdog checks the software for validity every 1.2 seconds. If necessary, the software is automatically reset. The hardware watchdog is controlled by the Main Electronics Board and monitors the power to the hardware. If this voltage drops below 4.75 volts, the FloBoss is automatically shut down. RTD automatic temperature compensation is tested at approximately every 5 degrees Celsius temperature change of the board temperature. The FloBoss 553 monitors the Dual-Variable Sensor for accurate and continuous operation. Voltage for charging the supercapacitor is checked to ensure that it is continuously applied when the FloBoss is powered. A memory validity self-test is performed to ensure the integrity of memory.
2.4.9.1 Low Power Modes

The processor used in the FloBoss is capable of low power operation under predetermined conditions. These features are available because of the Phase Lock Loop (PLL) used to control the speed of the system clock. The base crystal frequency is 3.6863 MHz and is raised by the PLL to 14.7 MHz for normal system operation. During the low power modes, the PLL and oscillator are in various states of shutdown. Two low power modes are supported: Standby and Sleep (also called Doze). Standby This mode is used during periods of inactivity. When the operating system cannot find a task to run, the FloBoss enters Standby mode. Processor loading is calculated by using the amount of time spent in Standby mode. This mode keeps the clocks running and communications active with baud clocks running. A Periodic Interrupt Timer wakes up the FloBoss and starts the normal operating mode.
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Wake-up from Standby occurs when the FloBoss receives a: Timed / Alarmed interrupt from the Real-Time Clock. Signal from the Operator Interface port LOI. Signal from built-in I/O. Sleep This mode is activated if a low input voltage is detected. The FloBoss input voltage is compared to the low-low alarm (LoLo Alarm) limit in the diagnostic Analog Input (point E1) for the battery/input voltage. This value defaults to 10.6 volts. The Low Alarm for point E1 defaults to 11 volts. For the FloBoss 553 to operate properly on a 12-volt system with intrinsic safety barriers in place, you must change these alarm limits to lower values (typically 5.2 and 5.6 volts, but not lower than 5.2 volts) by using the ROCLINK Configuration Software. Wake-up from Sleep occurs when the FloBoss receives a: Timed / Alarmed interrupt from the Real-Time Clock. Signal from the Operator Interface port LOI. If the battery voltage is less than the low-low alarm limit configured for Analog Input E1, the unit: 1. 2. 3. 4. 5. 6. Writes an alarm message to the Alarm Log. Sets the Real-Time Clock alarm for 55 minutes. Writes the message Low Battery, Sleep Mode to the LCD. Enters the Sleep mode. Shuts down communications. Wakes up by the Real-Time Clock alarm (set in step 2) and rechecks the voltage to see if operation is possible. If the voltage is greater than the LoLo Alarm limit for Analog Input Point Number E1, a normal restart sequence begins.
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2.5 CONNECTING THE FLOBOSS TO WIRING

The following paragraphs describe how to connect the FloBoss to power, ground, I/O devices, and communications devices. Use the recommendations and procedures described in the following paragraphs to ensure safety for personnel and to avoid damage to equipment. The field I/O wiring terminations are accessed by opening the front door. The terminals and connectors are arranged on the lower edge of the Main Electronics Board. The terminal designations are printed on the circuit board cover. Refer to Figure 2-2. This section includes: Making Wiring Connections Connecting Ground Wiring Connecting Power Wiring RTD Wiring Discrete Output Wiring Connecting Communications Wiring Dual-Variable Sensor Wiring WARNING To ensure safe operation, installation and wiring connections must be made as shown in the Loop Schematic of Appendix A. Only the options listed there may be used. CAUTION When installing equipment in a hazardous area, ensure that all components are approved for use in such areas. Check the product labels. CAUTION Bonding between conduit connections is not automatic and must be provided as part of the installation. CAUTION Power to the FloBoss must only be connected to the INPUT POWER connector. Ensure that the voltage applied (normally limited by the intrinsic safety barriers) is no more than 16 Vdc at the FloBoss connector, or damage to the circuits may result.
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CAUTION Always turn the power to the FloBoss off before you attempt any type of wiring.
CAUTION To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap. CAUTION It is important to check the input power polarity before turning on the power. Incorrect polarity can damage the FloBoss.
2.5.1 Making Wiring Connections

The FloBoss Main Electronics Board I/O connectors use removable compression terminals that accommodate wiring up to #14 AWG (American Wire Gauge) in size. The Input Power termination also uses a removable connector and can accommodate wiring up to #14 AWG. In all cases, connections are made by baring the end ( inch maximum) of the wire, inserting the bared end into the clamp beneath the termination screw, and then tightening the screw. The inserted wires should have a minimum of bare wire exposed to prevent short circuits. Allow some slack in the length of the wire when making connections to prevent strain on the circuit board. For Class I Division 1 installations, be sure to use rigid metal conduit with seals when passing out of the Class I Division 1 area. All installation wiring must follow code to meet the respective Class and Division ratings. Refer to the Loop Schematic in Appendix A for detailed wiring instructions and required intrinsic safety barriers. NOTE Only the options listed in the Loop Schematic can be used in a Class I Division 1 location.
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The following connectors are provided on the Main Electronics Board: Board power MCU PWR (wired by factory). Dual-Variable Sensor P/DP. Operator Interface port LOI. Discrete Output DO. Resistance Temperature Detector RTD. Communications card connector P3 (underneath cover).
The following connector is provided in the upper right corner of the case: Power Input INPUT POWER. The I/O terminals and connectors are arranged on the lower edge of the Main Electronics Board. The terminal designations are printed above on the circuit board cover as shown in Figure 2-2. The recommended cable for I/O signal wiring is an insulated, shielded, twisted pair of 24 AWG. (minimum) copper wire. The twisted pair and the shielding minimize signal errors caused by EMI (electromagnetic interference), RFI (radio frequency interference), and transients. The shield should be grounded on one end only. If the cable passes between different area classifications, it should be grounded on the end in the area with the less hazardous rating. Cable with multiple twisted pairs is acceptable for analog signal wiring, provided there is a shield around all pairs inside the jacket. Discrete signal pairs should be individually shielded. If the cabling is exposed to sunlight, it should have a UV-resistant jacket.
Figure 2-2. I/O Terminals and Connectors
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2.5.2 Connecting Ground Wiring

The FloBoss and related components must be connected to an I.S. earth ground, as indicated in the Loop Schematic (Appendix A). There is a ground bar located inside the enclosure along the bottom. This ground bus bar is electrically bonded to the enclosures strengthening structure and provides screw compression terminals to connect shields from I/O wiring, etc. An external lug on the bottom outside of the enclosure (refer to Figure 2-3) provides a place to connect an earth ground to the enclosure. This ground lug is electrically bonded to the ground bar through the enclosure structure. It is recommended that 14 AWG wire be used for the ground wiring. Make sure the installation has only one ground point to prevent creation of a ground loop circuit. A ground loop circuit could cause erratic operation of the system. The Main Electronics Board is electrically isolated from the enclosure ground. To ensure proper operation, it should not be grounded at any terminal. NOTE Do not connect the earth ground to any terminal on the Main Electronics Board.
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I.S. Ground
Figure 2-3. Earth Ground Connection
2.5.3 Connecting Power Wiring

It is important that good wiring practice be used when sizing, routing, and connecting power wiring. All wiring must conform to state, local, and NEC codes. The INPUT POWER terminal block located on the power pass-through card (called the Power Regulation Card on the Loop Schematic) can accommodate up to 14 AWG wire. Refer to Figure 2-4. WARNING To ensure safe operation, wiring connections must be made as shown in the Loop Schematic of Appendix A. WARNING Although the circuits in the FloBoss 550-Series unit are classified as Intrinsically Safe, other sources of ignition may exist. Therefore, ensure that the area is in a nonhazardous state before working in it. For the power wiring, it is recommended to use a jacketed, 2-conductor cable. Each conductor should be insulated, stranded, 14 AWG copper wire. If the cable is exposed to sunlight, the jacket material needs to be UV-resistant. Within 18 inches of the point where the cable passes out of the Class I Division 1 area, a conduit seal must be used to prevent gas migration.
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The terminals on the INPUT POWER terminal block are designated, top to bottom, as follows: + signal positive input ground (pre-wired by factory) signal negative input
Input Power Connector
Figure 2-4. Location of Input Power Connector
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To make power connections: 1. Unplug the INPUT POWER connector from its socket. 2. Insert each bared wire end into the clamp beneath its termination screw on the connector. The middle terminator is ground and is wired by the factory to the ground bus. Make sure the polarity (+/-) is correct. 3. Secure the screw. 4. Plug the connector back into the INPUT POWER socket.
2.5.4 RTD Wiring

WARNING To ensure safe operation, installation and wiring connections must be made as shown in the Loop Schematic of Appendix A. Only the options listed there may be used. The temperature is input through the Resistance Temperature Detector (RTD) probe and circuitry. An RTD temperature probe mounts directly to the piping using a thermowell, outside the FloBoss enclosure. RTD wires should be protected either by a continuous metal sheath or conduit (armored cable is not acceptable for explosion-proof installation) connected to a liquid-tight fitting on the bottom of the enclosure. The RTD wires connect to the four screw terminals designated RTD on the Main Electronics Board. Refer to Figure 2-5. The RTD input is associated with Analog Input Point A3. The FloBoss provides terminations for a four-wire 100-ohm platinum RTD with a DIN 43760 curve. The RTD has an alpha equal to 0.00385. A three-wire or two-wire RTD probe can be used instead of a four-wire probe; however, the longer the signal wiring, the less accurate the measurement by three-wire and two-wire RTDs. Wiring between the RTD probe and the FloBoss must be shielded wire, with the shield grounded only at one end to prevent ground loops. Ground loops can cause RTD input signal errors. The RTD terminals on the Main Electronics Board are designated and defined as follows: REF + RET source reference signal positive input signal negative input return reference
As shown in Figure 2-5, the connections at the RTD terminals for the various RTD probes are as follows (typical colors of red and white are used):
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Terminal REF + RET
4-Wire RTD Red Red White White
3-Wire RTD Jumper to + Red, Jumper to REF White White
2-Wire RTD Jumper to + Red, Jumper to REF White, Jumper to RET Jumper to
Red Red Red Red
Red Red
RTD Probe (4-wire
Note: If the RTD is located outside the Class I Division 1 area, it must be connected through intrinsic safety barriers as detailed in the Loop Schematic.
Figure 2-5. RTD Wiring Terminal Connections
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2.5.5 Discrete Output Wiring

WARNING To ensure safe operation, installation and wiring connections must be made as shown in the Loop Schematic of Appendix A. Only the options listed there may be used. A Discrete Output is provided on the FloBoss Main Electronics Board, as shown in Figure 2-6. The typical application for this output is a sampler or odorizer control, although it may be used for other purposes. The Discrete Output is associated with Discrete Output Point A4. The DO uses a P-channel MOSFET to switch current-limited power to the positive terminal. The negative terminal is internally connected to battery negative. A voltage-limiting diode and a back-EMF diode are included to help protect the FloBoss electronics. Because the output is not isolated, care must be used to ensure that the operation of the load does not affect the operation of the FloBoss. The load should be connected as follows: DO + DO Positive load Negative load
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Note: Refer to Loop Schematic for device parameters, as well as to connect DO to a device located outside the Class I Division 1 area.
Discrete Device
Figure 2-6. Discrete Output Terminal Wiring
2.5.6 Connecting Communications Wiring

The FloBoss has the flexibility to communicate to external devices using different protocols. Communications take place either through the operator interface port (LOI) or the host port (COM1). Wiring connections for the LOI port are made using screw terminals on the electronics board (the special 3-pin connector on the bottom of the case is intended for use only in non-hazardous areas). Wiring connections for the host port are made using screw terminals on the optional communications card.
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2.5.6.1 Operator Interface Port Wiring

Figure 2-7 displays the operator interface (LOI) port. The LOI port provides connections for a built-in EIA-232 communications interface to a configuration and monitoring device. The configuration and monitoring device typically is an IBM-compatible personal computer. The LOI port is intended primarily for use with the ROCLINK Configuration Software. The LOI port is compatible with RS232-type signals. The signals originate on the Main Electronics Board terminations and are factory-wired to the three-terminal, cannon-style connector located on the bottom of the enclosure. A prefabricated operator interface cable is available as an accessory from Fisher. WARNING Do not use the LOI port on the bottom of the FloBoss enclosure in a hazardous location (Class I, Division 1 or 2). Instead, use the Laptop Computer connectors that are wired through an intrinsic safety barrier as shown in the Loop Schematic (Appendix A). An RTS terminal for the LOI port is provided on the Main Electronics Board; however, it is not intended for use in Class I Division 1 areas. The following table shows the signal routing of the Main Electronics Board terminations and the cannon-style connector: Main Board BLK WHT RED Cannon Connector 1 2 3 Signal Common RXD TXD
If a 9-pin connector is used to connect to the communications ports on the PC, then pin 2 should connect to RXD, pin 3 to TXD, and pin 5 to common.
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COM
RXD TXD
Note: Refer to Loop Schematic to connect LOI signals to a device located outside the Class I Division 1 area.
Figure 2-7. Operator Interface Wiring
2.5.6.2 Host Port Wiring

The host port (COM1) provides communications access to the FloBoss through an optional communications card. Section 4 describes the types of communications cards available for the FloBoss 553 and how to make wiring connections to them.
2.5.7 Dual-Variable Sensor Wiring

For information on DVS wiring, refer to Section 3.
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2.6 CALIBRATION
The calibration routines support 5-point calibration, with the three mid-points calibrated in any order. The low-end or zero (Set Zero) reading is calibrated first, followed by the high-end or full-scale (Set Span) reading. The three mid-points can be calibrated next if desired. The diagnostic Analog Inputs input voltage and board temperature are not designed to be calibrated. The inputs that are supported with the 5-point calibration are: Differential pressure located at Analog Input Point A1. Static (line) pressure located at Analog Input Point A2. Temperature (RTD) located at Analog Input Point A3. The calibration procedure for these inputs is described in Section 3.
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2.7 TROUBLESHOOTING AND REPAIR

This troubleshooting and repair information is designed to help you identify problems and take initial measures to correct them. Return faulty FloBoss units to your Fisher Representative for repair or replacement. To troubleshoot communications cards, refer to Section 4. NOTE If the FloBoss 553 is entering the Sleep Mode for no apparent reason, ensure that the activation values have been set as instructed in Section 1.8.2. The following tools are typically required for troubleshooting: IBM-compatible personal computer. ROCLINK Configuration Software (runs on the personal computer). Digital multi-meter, Fluke 8060A or equivalent. The ROCLINK Configuration Software is required for most of the troubleshooting. Refer to the ROCLINK Configuration Software User Manual for additional information.
2.7.1 Backup Procedure Before Removing Power

Use the following backup procedure when removing or adding FloBoss components. This procedure preserves the current FloBoss configuration and data held in RAM. Before removing power to the FloBoss for repairs, troubleshooting, or enhancements, perform this backup procedure. The procedure assumes you are using Revision 2.0 or later of the standard ROCLINK Configuration Software. WARNING When working on units in a hazardous area, make sure components selected are listed for use in such areas. Installation and maintenance must be performed only when the area is known to be non-hazardous. CAUTION To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap. CAUTION There is a possibility of losing the configuration and historical data while performing the following procedure. As a precaution, save the current configuration and historical data to permanent memory as follows.
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1. Launch the ROCLINK Configuration Software. 2. Connect to ROCLINK. 3. Select Collect ROC Data from the File menu. 4. Select All in the Collect ROC Data dialog box. 5. Enter a File Name and click OK.
2.7.2 Resetting the FloBoss

If you are experiencing problems with the FloBoss that appear to be software related, try resetting the FloBoss. As described in the following paragraphs, there are three ways to reset the FloBoss: Warm Start. Cold Start. Jumper Reset. For example, if security was enabled on both communication ports of the FloBoss, the settings were saved to permanent memory, and then the ID and/or Passwords were lost, communications with the FloBoss will be locked out on both ports until a Jumper Reset is performed; then the host port could be used, since its security is disabled by default. If none of these reset methods seem to help, the FloBoss may need to be returned to the factory for repair.
2.7.2.1 Warm Start

This re-initialization is performed by setting a parameter in the System Flags. The re-initialization includes the Tasks, Database, Communication Ports, DVS, and I/O. It does not change the current configuration of any parameters. Refer to Figure 2-8. 1. Launch the ROCLINK Configuration Software. 2. Perform the Backup Procedure in Section 2.7.1, on page 2-29. 3. Select Flags from the System menu option. 4. Set the Warm Start flag to Yes. 5. Press (F8)Save.
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Figure 2-8. ROC System Flags
Alternately, you can perform a warm start by removing power from the FloBoss and then restoring it. Make sure that jumper P1 on the Main Electronics Board is in the NORM position for a warm start to take place.
2.7.2.2 Cold Start

This reinitialization is performed by setting a parameter in the System Flags, called Cold Start Options. The reinitialization includes the Tasks, Database, Communication Ports, DVS, I/O, and restoring the saved configuration if there is one. A Cold Start also includes the following based upon the value entered in Figure 2-9.
Figure 2-9. Cold Start Options
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1. Launch the ROCLINK Configuration Software. 2. Perform the Backup Procedure in Section 2.7.1, on page 2-29. 3. Select Flags from the System menu option. 4. Click the Cold Start flag Options. Refer to Figure 2-8. 5. Select the type of Cold Start you desire. Select Restore config and clear all of above to reset all options. 6. Click OK. 7. Press (F8)Save.
2.7.2.3 Jumper Reset

The FloBoss Main Electronics Board has a jumper located at P1 in the upper right-hand corner of the board that can be used to perform a special type of cold start. Refer to Figure 2-10. This jumper permits a power-up reset to re-establish a known operating point. The reset includes reinitializing the Tasks, Database, Communication Ports, DVS, and I/O and restoring the factory default configuration. This cold start does not include any of the clearing options available in a Cold Start performed by using ROCLINK (see Section 2.7.2.2).
P1 NORM RST
DOC0277U
Figure 2-10. Reset Jumper Shown in Normal Position
WARNING Power should be removed from outside a hazardous area before working in it. If this is not possible, ensure that steps have been taken (such as ventilation) to make the area non-hazardous before applying or removing power in the classified area.
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CAUTION This type of reset restores the factory configuration defaults. Any user-entered configuration data will be lost; therefore, try to back up any required data before performing this reset. To reset the FloBoss and load the factory default values into all configurable parameters: 1. Perform the Backup Procedure in Section 2.7.1, on page 2-29. 2. Disconnect the INPUT POWER terminal block to remove power. 3. Remove the four phillips-head screws securing the cover over the electronics board. Lift off the cover and move the P1 jumper to the reset (RST) position. To enact a reset, power up the unit with the jumper installed. 4. Apply power by plugging in the INPUT POWER terminal block. 5. Remove the P1 jumper on the Main Electronics Board and install it in the normal (NORM) position. Replace the cover and secure it with the four screws. 6. Refer to Section 2.7.3 and perform the After Installing Components.
2.7.3 After Installing Components

After removing power to the FloBoss and installing components as needed, perform the following steps to start your FloBoss and reconfigure your data. The procedure assumes you are using Version 2.0 or later of the standard ROCLINK Configuration Software. WARNING When working on units in a hazardous area, make sure components selected are listed for use in such areas. Installation and maintenance must be performed only when the area is known to be non-hazardous. CAUTION Ensure all input devices, output devices, and processes remain in a safe state upon restoring power.
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CAUTION To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap.
1. Reconnect power to the FloBoss by inserting the INPUT POWER terminal block back into its socket. 2. Launch the ROCLINK Configuration Software, log in, and connect to the FloBoss. 3. Verify that the configuration is correct. If it is not, continue by configuring the needed items. If major portions or the entire configuration needs to be reloaded, perform the remaining steps. 4. Select Download from the File menu, and in the resultant sub-menu. 5. Select Disk Config. to ROC. 6. In the dialog box that appears (see Figure 2-11), select the File Name you entered in step 4 of Section 2.7.1, Backup Procedure Before Removing Power, on page 2-29 and click OK. 7. Select the portions (see Figure 2-12) of the configuration you want to load or restore. 8. Press (F8)Download to restore the FloBoss configuration.
Figure 2-11. Open Configuration File
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Figure 2-12. Download Configuration
2.8 SPECIFICATIONS
Refer to the following pages for specifications of the main electronics board.
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Main Specifications
PROCESSOR MEMORY Motorola 32 bit, running at 14.7 MHz. Program: 512 Kbyte flash ROM (electrically programmable) for firmware and configuration. Data: 512 Kbyte SRAM, super capacitor-backed for up to 4 weeks. Memory Reset: A reset jumper enables a cold start initialization when used during power-up. TIME FUNCTIONS Clock Type: 32 kHz crystal oscillator with regulated supply, super capacitor-backed. Year/Month/Day and Hour/Minute/Second, with Daylight Savings Time control. Clock Accuracy: 0.01%. Watchdog Timer: Hardware monitor expires after 1 second and resets the processor. DIAGNOSTICS These conditions are monitored and alarmed: SRAM validity/operation, DVS and RTD point fail, input voltages, and enclosure internal temperature. COMMUNICATIONS PORTS Local Operator Interface: EIA-232 (RS-232D) format. Software configured; 1200 to 19.2K baud selectable. Screw-cap protected connector. Host Interface: Depends on the optional communications card installed (see Spec. Sheet 3:COM). USER INTERFACE 2 line by 16 character LCD. Continually updates approximately every 3 seconds. See Environmental specification for operating temperature. POWER 6.2 to 16 Vdc at 0.2 amp maximum. DVS (BUILT-IN) Interface: High-speed digital interface with power for DVS. Inputs and Physical Characteristics: See DVS Specifications table. WEIGHT 18.0 lb. (8.2 kg) nominal, including DVS and coupler. 2-36 Rev 6/99 RTD INPUT (BUILT-IN) Quantity/Type: Single input for a 2, 3, or 4-wire RTD element. Terminals: Ref current source, + positive signal input, - negative signal input, and Ret return. Sensing Range: -50 to 100 C (-58 to 212 F). Accuracy (includes linearity, hysteresis, repeatability): 0.56 C (1.0 F) over sensing range. Ambient Temperature Effects per 28 C (50 F): 0.50 C (0.90 F) for process temperatures from -40 to 100 C (-40 to 212 F). Filter: Band-pass hardware filter. Resolution: 16 bits. Conversion Time: 100 sec. Sample Period: 1 sec minimum. DISCRETE OUTPUT (BUILT-IN) Quantity/Type: 1 sourced, high-side switched output. Terminals: + positive output, - negative (common). Voltage: Nominal 5 volts. Frequency: 1.5 Hz maximum. Sample Period: 200 ms minimum. Typical Source Current: 25 mA, with auto reset. ENVIRONMENTAL Operating Temperature: -40 to 75 C (-40 to 167 F), excluding LCD display, which is -25 to 70 C (-13 to 158 F). Storage Temperature: -50 to 85 C (-58 to 185 F). Operating Humidity: 5 to 95%, non-condensing. Vibration: Meets SAMA PMC 31.1, Section 5.3, Condition 3. ESD Immunity: Meets IEC 801-2 and EN 50082-2. RFI Immunity: Meets IEC 801-3 and EN 50082-2. EFT Immunity: Designed to meet IEC 801-4 and EN 50082-2. Voltage Surge Immunity: Designed to meet IEC 801-5 and EN 61000-4-5.
Main Specifications
DIMENSIONS Overall: 16.75 in. H by 10.38 in. W by 6.69 in. D (425 mm by 264 mm by 170 mm). Height includes top mounting flange and DVS. Wall Mounting: 2.81 in. W by 12.50 in. H (71 mm by 318 mm) between mounting hole (0.38 in. diameter) centers. Pipestand Mounting: Mounts on 2-inch pipe with U-bolt mounting kit (supplied). Process Connections: See DVS Specifications. CLASSIFICATION FCC Class A and CISPR 22 computing device. ENCLOSURE Construction: Fiberglass-reinforced plastic with lockable hasp and gasketed door. Internal structural metal is low-copper aluminum alloy. All exposed metal is stainless steel. Meets CSA Type 4X rating (NEMA 4X equivalent). Wiring access: Three 0.88 in. pre-punched holes: one in right side, two in bottom. APPROVALS Approved as Model W40076 by CSA for hazardous locations Class I, Division 1, Groups C and D, intrinsically safe.
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SECTION 3 DUAL-VARIABLE SENSOR

3.1 SCOPE
This section describes the Dual-Variable Sensor (DVS), which provides differential pressure and static pressure inputs to the FloBoss 553 Flow Manager for orifice flow calculation. Note the DVS is quite similar to the Multi-Variable Sensor (MVS) used with the FloBoss 407; however, the MVS can provide a temperature input to the FloBoss, while a DVS does not.

This section contains the following information: Information Scope Section Contents Description Process Connections DVS Wiring Configuration Calibration Verifying Calibration Calibrating the FloBoss Zero Shift Specifications Section 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.7.1 3.7.2 3.7.3 3.8 Page Number 3-1 3-1 3-1 3-2 3-2 3-3 3-5 3-5 3-6 3-12 3-13
3.3 DESCRIPTION
The DVS, which uses Rosemount sensor technology, measures differential pressure and absolute or gauge (static) pressure by converting the applied pressure to electrical signals and making the readings available to the Main Electronics Board. The sensor housing screws into an adapter, which in turn mounts with four bolts to the bottom of the FloBoss enclosure. The DVS cable plugs directly into the Main Electronics Board at the P/DP connector. The readings from the Dual-Variable Sensor are stored in analog inputs on the FloBoss 553. The differential pressure value uses the Analog Input (AI) Point A1 and the static (line) pressure value uses the AI Point A2. If the alarm for either point is Enabled and the sensor fails to communicate, either during initialization or operation, an alarm is entered in the Alarm Log.
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The DVS uses an interrupt to inform the Main Electronics Board that it is ready for an update. This must occur at least once per second. The FloBoss 553 then converts this value and stores it in the proper analog input for access by other functions within the unit. If an update does not occur in the one second interval, the sensor is re-initialized. A point fail alarm is set if the sensor does not respond to the initialization.
3.4 PROCESS CONNECTIONS

Piping from the meter run must be connected to the Dual-Variable Sensor (DVS) of the FloBoss 553. Both the static and differential pressures are piped to female -18 NPT connections on the bottom of the DVS. The FloBoss 553 is an upstream device, meaning that the static pressure line normally must be connected to the high-pressure side (labeled H on the sensor body). If you need to use the FloBoss 553 as a downstream device: 1. Connect the H side of the sensor to downstream pressure, so that flow in relation to the sensor is reversed from its normal direction. 2. Use ROCLINK to configure the meter run for Downstream operation (this automatically adjusts the static pressure by adding in the differential pressure). 3. Calibrate the differential pressure as described in Section 3.6.
3.5 DVS WIRING

The FloBoss 553 and the Dual-Variable Sensor are shipped from the factory with the wiring connected as shown in Figure 3-1. The DVS cable connection is made at the P/DP (pressure/differential pressure) terminal connector and plugs directly into the Main Electronics Board at P11. WARNING Power should be removed from outside a hazardous area before working in it. If this is not possible, ensure that steps have been taken (such as ventilation) to make the area non-hazardous before applying or removing power in the classified area. CAUTION Always turn power off to the FloBoss 553 before you connect or disconnect signal wiring.
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P/DP Connector
DVS Ribbon Cable
Figure 3-1. DVS Wiring
The top part of Figure 3-1 displays the FloBoss 553 wiring terminals. The rest of the figure showns how the DVS ribbon cable connects from the P/PD connector to the DVS unit. The ribbon cable is keyed to fit into the P/PD connector in only one direction. The DVS comes installed by the factory.
3.6 CONFIGURATION
Use the ROCLINK Configuration Software, Version 2.1 or later, to configure the DVS for a FloBoss 553 with Version 2.0 or later firmware. Refer to Section 2.3.2 concerning History Points. The differential pressure is configured at Analog Input Point Number A1. The static pressure (gauge or absolute) is configured at Analog Input Point Number A2. The Resistance Temperature Detector (RTD) is configured at Analog Input Point Number A3. The initial pressures are read from the defaults contained within the DVS. The initial range of the differential pressure is 0 to 250 inches of water and the static pressure is either 0 to 800 psi (55.15 bar) or 0 to 3600 psi (250 bar) depending upon the sensor installed. The ranges can be changed through the calibration routines. It is recommended that the turndown on the ranges not be greater than five.
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The Dual-Variable Sensor also supports the conversion of values to Metric units. In Metric mode, both the differential pressure and the static pressure are in kPa. To enter the Metric mode, using ROCLINK Configuration Software: 1. Select the System menu. 2. From the pull-down menu, select Information. 3. On the system information display (see Figure 3-2) under Units, enable the Metric field. 4. Press (F8)Save.
Figure 3-2. System Information
The FloBoss automatically adjusts the units, ranges, alarm limits, and calibration factors of the differential pressure, static pressure, RTD, and enclosure/battery temperature, to the Metric mode. To return to US units, enable the US field and save this change to the FloBoss. The FloBoss adjusts the values to US units for the entire meter run.
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3.7 CALIBRATION
Calibration is performed using the ROCLINK Configuration Software. The procedure allows you to perform a 5-point (minimum, maximum, and up to three intermediate points) calibration of the DVS.
3.7.1 Verifying Calibration

The ROCLINK Configuration Software can be used to verify the calibration. This is normally done as a check to see if a re-calibration is needed. To verify, perform the following steps: CAUTION To protect the differential cell of the Dual-Variable Sensor, open the by-pass valve on the valve manifold prior to isolating the sensor from the process. This will keep one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied. This should be done whether you are calibrating differential or static pressure. Refer to Figure 3-7 on page 3-8 for the recommended sequence. 1. Launch the ROCLINK Configuration Software and logon to the FloBoss 553. 2. Select the Calibration pushbutton either from the Quick Setup menu or from the Meter menu. 3. Press the Freeze pushbutton. This displays the Meter Calibration window. Refer to Figure 3-3. The current reading is shown under each meter input as the Freeze Value. These values will be used in the flow calculations while the points are being verified.
Figure 3-3. Meter Calibration Window
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4. Select the Verify function that is listed under the input to calibrate. This displays the Verify Calibration window as in Figure 3-4.
Figure 3-4. Verify Calibration
5. Apply the desired pressure value to the input. 6. If the Tester Value and the Live Reading are to be logged to the Event log as a record of the verification, select the Log Verify pushbutton. 7. Continue this for all pressures/values that need to be verified. 8. When complete, select the Cancel pushbutton to return to the Meter Calibration window. 9. When the verification for a selected point is complete, you have the choice to verify or calibrate another input or to complete the verification or calibration. When complete, connect the DualVariable Sensor back to the process. CAUTION To protect the differential cell of the Dual-Variable Sensor, do not close the by-pass valve on the valve manifold until after process pressure has been reapplied. This will keep one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied. Refer to Figure 3-12 on page 3-11. 10. Select the Done pushbutton to close the calibration window, to cancel the freeze values, and to begin using live readings for the flow calculations.
3.7.2 Calibrating the FloBoss

The ROCLINK Configuration Software is used to perform initial calibration or re-calibration, such as after an orifice plate is changed in the meter run handled by the FloBoss. Perform the following steps: 1. Launch the ROCLINK Configuration Software and logon to the FloBoss 553.
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2. Select the Calibration function from either the Quick Setup menu or the Meter menu. 3. Press the Freeze pushbutton. This displays the Meter Calibration window as in Figure 3-5. The current reading is shown under each meter input as the Freeze Value. These values will be used in the flow calculations while the points are being calibrated.
Figure 3-5. Meter Calibration
4. Select the Calibrate pushbutton under the desired input to calibrate Diff Press, Stat Press, or Temperature. This displays the Set Zero calibration window as in Figure 3-6.
Figure 3-6. Set Zero Calibration for Differential Pressure
5. If you are calibrating a pressure input, read the following Caution, and then isolate the Dual-Variable Sensor from the process. If you are calibrating a temperature input, proceed to Step 7.
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CAUTION To protect the differential cell of the Dual-Variable Sensor, open the by-pass valve on the valve manifold prior to isolating the sensor from the process. This will keep one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied. This should be done whether you are calibrating differential or static pressure. Refer to Figure 3-7 for the recommended sequence.
Bleed
Bleed
High Pressure Remains

Close
Open
Close
Operating
Shutdn2
Shutdown Sequence
Figure 3-7. Removing the DVS from Service
6. If you are calibrating a pressure input, set up the pressure calibrator and make the necessary connections to the DVS. 7. If you are calibrating a temperature input, disconnect the RTD sensor and connect a decade box (or comparable equipment) to the RTD terminals of the FloBoss 553. 8. Apply the low (zero) value. For a pressure input, this would typically be open to atmosphere. 9. Enter the applied value in the Dead Weight / Tester Value field of the Set Zero dialog. Refer to Figure 3-6. For static pressure on an absolute-pressure device, remember to enter the actual atmospheric pressure, such as 14.73 psi. 10. When the displayed Live Reading is stable, select the Set Zero pushbutton to calibrate the zero reading. The Set Span window then appears as in Figure 3-8.
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Figure 3-8. Set Span
11. Apply the desired high value to the input (the top end of the expected operating range). If you are calibrating the Diff Press input, and the DVS is configured for Downstream operation, be sure to apply the calibrator pressure to the low (labeled L) side of the sensor; the Live Reading will appear as a negative value. Static pressure for Downstream is calibrated the same as for Upstream. 12. Enter the applied value in the Dead Weight / Tester Value field of the Set Span dialog. For static pressure on an absolute-pressure device, remember to add in the actual atmospheric pressure, such as 300 + 14.73. If you are calibrating the Diff Press input, and the DVS is configured for Downstream operation, enter the value as positive, even though the Live Reading is a negative value. The software will automatically compensate. 13. When the Live Reading is stable, select the Set Span pushbutton to calibrate the high reading. The window advances to the Set Midpoint 1 window as in Figure 3-9.
Figure 3-9. Set Midpoint 1
14. If a two-point calibration is to be performed, refer to step 23. 15. If midpoints are to be calibrated, apply the desired pressure or temperature and enter the applied value in the Dead Weight / Tester Value field. Note that the midpoints can be calibrated in any order.
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16. When the Live Reading is stable, select the Set Mid 1 pushbutton to calibrate this reading. The display advances to the Set Midpoint 2 window as in Figure 3-10.
17. If a three-point calibration is being performed, refer to step 23. 18. If additional midpoints are to be calibrated, apply the desired pressure or temperature and enter the applied value in the Dead Weight / Tester Value field. 19. When the Live Reading is stable, select the Set Mid 2 pushbutton to calibrate this reading. The display advances to the Set Midpoint 3 window as in Figure 3-11.
20. If a four-point calibration is being performed, refer to step 23. 21. If a third midpoint is to be calibrated, apply the desired pressure or temperature and enter the applied value in the Dead Weight / Tester Value field. 22. When the Live Reading is stable, select the Set Mid 3 pushbutton to calibrate this reading. The display returns to the Meter Calibration window.
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23. When the calibration for a selected point is complete, you have the choice to calibrate another input or to complete the calibration. If calibration is complete, and you calibrated pressure inputs, read the following Caution and then return the Dual-Variable Sensor to service. CAUTION To protect the differential cell of the Dual-Variable Sensor, do not close the by-pass valve on the valve manifold until after process pressure has been reapplied. This will keep one side of the differential sensor from being subjected to high pressure while the other side has no pressure applied. Refer to Figure 3-12.
1a Close
1b Close
Close
Open
Open
Pre-Startup
start2
Startup Sequence
Figure 3-12. Returning the DVS to Service
NOTE If you calibrated the Differential Pressure input, refer to Section 3.7.3, Zero Shift, before completing the last step. 24. Finally, select the Done pushbutton to cause the calibration window to close, freeze values to be canceled (unfrozen), and live readings to resume being used for the flow calculations. All calibration settings that were changed are automatically recorded into the Event Log of the FloBoss.
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3.7.3 Zero Shift

If desired, the Zero Shift procedure can be used after calibrating the pressure inputs. The reason for performing Zero Shift is because the Differential Pressure is calibrated without line pressure being applied to the sensor. When the sensor is connected back to the process after calibration, a shift in the differential pressure can occur due to the influence of the line pressure. This effect can be canceled out with a Zero Shift adjustment. To check or adjust for Zero Shift, leave the sensor by-pass valve open (to simulate a no-flow condition), with either line pressure or a normal operating static pressure from the calibrator applied to the sensor. This applies the same pressure to both sides of the differential pressure diaphragm to give a zero differential pressure reading. Perform the following steps: 1. Ensure the ROCLINK Configuration Software is connect to the FloBoss 553 and running the calibration procedure. 2. If the meter inputs were already released from the freeze condition, use the Freeze pushbutton. This returns the Meter Calibration window as shown in Figure 3-3. 3. Under the Diff Press input, select the Zero Shift pushbutton to open the Set Zero Shift window shown in Figure 3-13.
Figure 3-13. Set Zero Shift
4. Check the Reading to determine if a Zero Shift correction needs to be performed. 5. If the reading is not zero, use the Set Zero Shift pushbutton to adjust the Zero Shift. If adjustment is not required, use the Cancel pushbutton. You are returned to the Meter Calibration window, where you can select Done to close the calibration window, cancel the freeze values, and cause the FloBoss to begin using live readings for the flow calculations.
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3.8 SPECIFICATIONS
DVS Specifications
DIFFERENTIAL PRESSURE INPUT Range: 0 - 250 in. H2O (0 - 62.2 kPa). Reference Accuracy: 0.075% of span (includes linearity, hysteresis, and repeatability effects). STATIC PRESSURE INPUT Range*: Either Absolute or Gauge: 0 - 800 psia/psig (0 - 5516 kPa) 0 - 3626 psia/psig (0 - 25,000 kPa) Reference Accuracy: 0.075% of span (includes linearity, hysteresis, and repeatability effects). Stability: 0.1% of upper range limit for 12 months. PROCESS CONNECTIONS 1/4-18 NPT on 2-1/8 in. centers, located on bottom of Coplanar flange. CONSTRUCTION 316 SST*. Wetted O-rings are glass-filled TFE. Coupler is stainless steel (CF8M).
*Consult factory for special ranges and materials that may be available. Note: For other specifications, see the Main Specifications in Section 2.
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SECTION 4 COMMUNICATIONS CARDS

4.1 SCOPE
This section describes the communications cards used with the FloBoss 550-Series Flow Manager.

This section contains the following information: Information Scope Section Contents Product Descriptions EIA-232 Serial Communications Card EIA-485 Serial Communications Card Initial Installation and Setup Installing Communications Cards Connecting Communications Cards to Wiring EIA-232 Communications Card Wiring EIA-485 Communications Card Wiring Troubleshooting and Repair Replacing a Communications Card Communication Cards Specifications Serial Card Specifications Section 4.1 4.2 4.3 4.3.1 4.3.2 4.4 4.4.1 4.5 4.5.1 4.5.2 4.6 4.6.1 4.7 4.7.1 Page Number 4-1 4-1 4-1 4-2 4-4 4-5 4-5 4-7 4-7 4-7 4-8 4-8 4-10 4-10
4.3 PRODUCT DESCRIPTIONS

The communications cards provide communications between the FloBoss and a host system or external devices. The communications cards install directly onto the Main Electronics Board at P3 and activate the host port (COM1) when installed. COM1 is configured using ROCLINK. The following cards are available: EIA-232 Serial Communications Card. EIA-485 Serial Communications Card.
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4.3.1 EIA-232 Serial Communications Card

The EIA-232 communications card meets all EIA-232 specifications for single-ended, RS-232 asynchronous data transmission over distances of up to 50 feet. Refer to Figure 4-1. The EIA-232 communications card provides transmit, receive, and modem control signals. Normally, not all of the control signals are used for any single application. This is one of the optional interface cards for the host port of the FloBoss 500-series products. The EIA-232 card P1 connector plugs into the Main Electronics Board at P3 and activates COM1. RTS, DCD, and DTR signal/control lines are supported; however, only the RTS signal is approved for used with FloBoss 550-Series units (see Loop Schematic). The EIA-232 communications card defaults are: 9600 baud rate, 8 data bits, 1 stop bit, no parity, 10 millisecond Key On Delay, and 10 millisecond Key Off Delay. The maximum baud rate is 19.2k. The EIA-232 communications card includes LED indicators that display the status of the RXD, TXD, DTR, DCD, and RTS signal/control lines. LED indicators are detailed in Table 4-1.
P1 C1
Mating Connector
FB1 C2
U1 CR1 DCD R1
C3 C4
CR2 RXD R2 CR3 TXD R3 R5 R6 CR4 RTS F2 CR5 DTR

DCD
R4 Q1 R9 Q2
U2
LEDs
R7
R8
C5 C6 FB2 C7
GND
RXD
DTR
TXD
IN
Radio Power Control Terminals (not used on FB550-Series)
RTS
TB2
TB3
Host Port Terminals
DOC0274A
Figure 4-1. EIA-232 Serial Communications Card

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Table 4-1. Communications Cards LED Indicators
LEDs DCD DTR
STATUS AND ACTIVITY The DCD data carrier detect LED lights when a valid carrier tone is detected. The DTR data terminal ready LED lights when a signal from the processor specifies the modem is ready to answer an incoming call. When the DTR goes off, a connected modem disconnects. The RTS ready to send LED lights when a signal from the processor specifies the modem is ready to transmit. The RXD receive data LED blinks when a data signal is being received by the communications card. The LED is on for a space and off for a mark. The TXD transmit data LED blinks when a data signal data is being sent from the processor. The LED is on for a space and off for a mark.
RTS RXD TXD
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4.3.2 EIA-485 Serial Communications Card

The EIA-485 communications cards meet EIA-485 specifications for differential, RS-485 asynchronous transmission of data over distances of up to 4000 feet. Refer to Figure 4-2. The EIA-485 drivers are designed for true multi-point applications with multiple devices on a single bus. This is an optional interface communications card for the host port, which activates COM1. The P1 connector on the EIA-485 communication card plugs into the Main Electronics Board at P3. RTS is supported to control transmission. RTS must be active during TXD. The default values for the EIA-485 communications card are: 9600 Baud Rate, 8 Data Bits, 1 Stop Bit, No Parity, 10 millisecond Key On Delay, and 10 millisecond Key Off Delay. The maximum baud rate is 19.2k. The EIA-485 communications card includes LED indicators that display the status of the RXD, TXD, and RTS signal/control lines. LED indicators are detailed in Table 4-1.
Mating Connector
LEDs
Host Terminals COM1
Figure 4-2. EIA-485 Serial Communications Card
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4.4 INITIAL INSTALLATION AND SETUP

Communications card installation is normally performed at the factory when the FloBoss is ordered. However, the modular design of the FloBoss 500-series makes it easy to change hardware configurations in the field. The following procedures assume that this is a first-time installation of a communications card in a FloBoss and that the unit is currently not in service. For units currently in service, refer to the procedures in Section 4.6, Troubleshooting and Repair. CAUTION When installing units in a hazardous area, ensure that the components selected are listed for use in such areas. Work only in an area known to be non-hazardous. CAUTION Be sure to use proper electrostatic handling, such as wearing a grounded wrist strap, or components on the circuit cards may be damaged.
4.4.1 Installing Communications Cards

All communications cards install into the FloBoss in the same manner. 1. Ensure power is removed, such as by unplugging the INPUT POWER connector from its socket. For a FloBoss 550-Series unit, remove the cover from over the Main Electronics Board by removing the four Phillips-head screws securing it. 2. Plug the communications card connector into connector P3 on the Main Electronics Board. Figure 4-3 shows the card location. Gently press the connectors together until the card contacts a stand-off. 3. Ensuring that the three stand-off holes in the communications card line up with the compression stand-offs on the Main Electronics Board, firmly press the communications card onto the stand-offs. 4. Connect the wiring to the communications card (see Section 4.5). For a FloBoss 550-Series unit, route this wiring through the slot on the left-hand side of the cover, reattaching the cover with the four screws. 5. Using the ROCLINK Configuration Software, configure communication parameters as needed by the application. Be sure to save the configuration to permanent memory.
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Mating Connector Stand-off Hole Communications Card
Stand-off Hole
Stand-off Hole
Figure 4-3. Communications Card Location
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4.5 CONNECTING COMMUNICATIONS CARDS TO WIRING

Signal wiring connections to the communications cards are made using the terminal block located on the serial communications cards.
4.5.1 EIA-232 Communications Card Wiring

The EIA-232 communications card provides for RS232 signals on the host port. This communications card also provides a means to switch power to external devices (In and Out terminals); however, this feature should not be used on the FloBoss 550-Series due to the energy restrictions of Intrinsic Safety requirements. LEDs are provided for diagnostic functions. The screw terminals and their functions are as follows: Terminal RXD TXD DTR* RTS DCD* GND IN* Out* Function Receive data Transmit data Data Terminal Ready Ready to Send Data Carrier Detect Ground Power input Switched power output
*Do not use for FloBoss 550-Series, due to requirements of Loop Schematic. For the FloBoss 550-Series, refer to the Loop Schematic in Appendix A for details of using IS barriers with the approved signal lines.
4.5.2 EIA-485 Communications Card Wiring

The EIA-485 communications card provides for RS-485 signals on the host port located at COM1. Wiring should be twisted-pair cable. This card also provides additional protection for the external wiring and the board circuitry. LEDs are provided for diagnostic functions. The terminals and their functions are as follows: Terminal A B GND Function RS485 positive RS485 negative Ground
For the FloBoss 550-Series unit, refer to the Loop Schematic in Appendix A for details of using IS barriers with these signal lines.
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4.6 TROUBLESHOOTING AND REPAIR

There are no user serviceable parts on the communications cards. If a card appears to be operating improperly, verify that the card is set up according to the information contained in Section 4.4, Initial Installation and Setup. If it still fails to operate properly, the recommended repair procedure is to remove and replace the card. The faulty card should be returned to your Fisher Representative for repair or replacement. Follow the procedures below to help ensure data is not lost and equipment is not damaged during replacement of a communications card.
4.6.1 Replacing a Communications Card

If you are installing a communications card for the first time, refer to Section 4.4. To remove and replace a communications card on an in-service FloBoss, perform the following procedure. Be sure to observe the cautions to avoid losing data and damaging equipment. WARNING Before working in a hazardous area, ensure that appropriate precautions have been taken, such as ventilating the area to make it non-hazardous. CAUTION When repairing units in a hazardous area, ensure that the components selected are listed for use in such areas. Change components only in an area known to be nonhazardous. CAUTION There is a possibility of losing the FloBoss 500-series configuration and historical data while performing the following procedure. As a precaution, save the current configuration and historical data to permanent memory as instructed in Section 2.7.1, Backup Procedure. CAUTION Be sure to use proper electrostatic handling, such as wearing a grounded wrist strap, or components on the circuit cards may be damaged.
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CAUTION During this procedure, all power will be removed from the FloBoss and devices powered by the FloBoss. Ensure that all connected input devices, output devices, and processes will remain in a safe state when power is removed from the FloBoss and also when power is restored to the FloBoss. 1. Refer to Section 2.7.1 and perform the RAM Backup Procedure. 2. Remove the INPUT POWER connector from its socket. For a FloBoss 550-Series unit, also remove the four Phillips-head screws securing the MCU cover and lift the cover out. 3. Disconnect existing wiring to the communications card, labeling or marking wires as needed. 4. Using a rocking motion, gently disengage the two stand-off connectors located at the bottom of the communications card. 5. Using a rocking motion, gently disengage the stand-off connector located at the top, middle of the communications card. 6. Using a rocking motion, disengage the connectors at P1, pull the card free from the Main Electronics Board at P3. 7. To reinstall a communications card, orient the card with the P1 connectors on the communications card mating with the connectors at P3 on the Main Electronics Board. Plug the card into its mating connectors and gently press until the connectors firmly seat. 8. Using a rocking motion, gently engage the three stand-off connectors. 9. Connect the wiring to the communications card (see Section 4.5). For a FloBoss 550-Series unit, route the wiring through the slot on the left-hand side of the cover, reattaching the cover with the four screws. 10. Reconnect power by plugging in the INPUT POWER connector. 11. Check the configuration data and FSTs, and load or modify them as required. 12. Verify that the FloBoss 500-series performs as required. 13. Perform the After Installing Components detailed in Section 2.7.3. If you changed the configuration, save the configuration data to Flash ROM. If you changed the configuration, history database, or FSTs, save them to disk. See Section 2.7.1 for more information.
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4.7 COMMUNICATION CARDS SPECIFICATIONS

The following subsection lists the specifications for the serial communications cards.
4.7.1 Serial Card Specifications

EIA-232D CARD Meets EIA-232 standard for singleended data transmission over distances of up to 50 feet (15 m). Data Rate: Selectable from 1200 to 19.2k baud. Format: Asynchronous, 7 or 8-bit (software selectable) with full handshaking. Parity: None, odd, or even (software selectable). EIA-485 CARD Meets EIA-485 standard for differential data transmission over distances of up to 4000 feet (1220 meters) for multiple devices. Data Rate: Selectable from 1200 to 19.2k baud. Format: Asynchronous, 7 or 8-bit (software selectable). Parity: None, odd, or even (software selectable). LED INDICATORS POWER REQUIREMENTS ENVIRONMENTAL Individual LEDs for RXD, TXD, and RTS signals. EIA-232D card also has LEDs for DTR and DCD. 4.75 to 5.25 Vdc, 0.03 W maximum, supplied by processor board. Operating Temperature: -40 to 75 C (-40 to 167 F). Storage Temperature: -50 to 85 C (-58 to 185 F). Operating Humidity: To 95% relative, non-condensing. WEIGHT DIMENSIONS APPROVALS 0.8 oz. (23 g) nominal. 0.7 in. H by 2.0 in. W by 2.75 in. L (18 by 51 by 70 mm). See Loop Schematic.
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APPENDIX A LOOP SCHEMATIC

A.1 SCOPE
This appendix provides the Loop Schematic (drawing W20268) for Model W40076, which covers the approved intrinsic safety installation/wiring for the FloBoss 553 Flow Manager. Although the Loop Schematic specifies the requirements for safety barriers, the following intrinsically safe barriers are specifically recommended: Input Power Barrier: LOI or RS-232/RS-485 Barrier: Discrete Output: RTD Input: Stahl 9001/01-158-390-10 Stahl 9002/22-240-160-00 Stahl 9001/01-086-390-10 Stahl 9002/22-032-300-11
A.2 LOOP SCHEMATIC DRAWINGS

The Loop Schematic consists of three sheets, as shown on the following pages.
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A-2
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A-4
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GLOSSARY OF TERMS
A
A/D Analog to Digital. AGA American Gas Association. AWG American Wire Gauge. AI Analog Input. AO Analog Output. Analog Analog data is represented by a continuous variable, such as an electrical current signal. AP Absolute Pressure. API American Petroleum Institute. Area A user defined grouping of database entities. ASCII American Standard Code for Information Interchange. Attribute A parameter that provides information about an aspect of a database point. For example, the alarm attribute is an attribute that uniquely identifies the configured value of an alarm.
B
BTU British Thermal Unit, a measure of heat energy. Built-in I/O Input/Output channels that are fabricated into the ROC or FloBoss and do not require a separate module. Also called on-board I/O.
C
C1D1 Shorthand for Class I, Division 1 hazardous area. C1D2 Shorthand for Class I, Division 2 hazardous area. Coil Digital output, a bit to be cleared or set. COM1 Communications port on the ROC364 that may be used for host communications. On the FloBoss 407, this Comm port is built-in for RS-232 serial communications. For the FloBoss 500-series, this is the Host port. COM2 Communications port on the ROC364 or FloBoss 407 that may be used for host communications. COMM Communications port on the ROC306 or ROC312 that may be used for host communications. Configuration Refers either to the process of setting up the software for a given system or the result of performing this process. The configuration activity includes editing the database, building schematic displays and reports, and defining user calculations. Typically, the software setup of a device that can often be defined and changed. Can also mean the hardware assembly scheme. CPU Central Processing Unit. CRC Cyclical Redundancy Check.
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CSA Canadian Standards Association. CTS Clear to Send modem communications signal.
D
D/A Digital to Analog. DB Database. dB Decibel. A unit for expressing the ratio of the magnitudes of two electric signals on a logarithmic scale. DCD Data Carrier Detect modem communications signal. Also, Discrete Control Device A discrete control device energizes a set of discrete outputs for a given setpoint and matches the desired result against a set of discrete inputs. Deadband A value that is an inactive zone above the low limits and below the high limits. The purpose of the deadband is to prevent a value such as an alarm from being set and cleared continuously when the input value is oscillating around the specified limit. This also prevents the logs or data storage location from being over-filled with data. DI Discrete Input. Discrete Input or output that is non-continuous, typically representing two levels such as on/off. DO Discrete Output. DMM Digital multimeter. DP Differential Pressure. DSR Data Set Ready modem communications signal. DTR Data Terminal Ready modem communications signal. Duty Cycle Proportion of time during a cycle that a device is activated. A short duty cycle conserves power for I/O channels, radios, an such. DVM Digital voltmeter. DVS Dual-Variable Sensor. Provides static and differential pressure inputs to certain FloBoss 500-series Flow Managers.
E
EEPROM Electrically Erasable Programmable Read-Only Memory, a form of permanent memory. EDS Electronic Static Discharge. EFM Electronic Flow Metering or Measurement. EIA-232 Serial Communications Protocol using three or more signal lines, intended for short distances. EIA-422 Serial Communications Protocol using four signal lines. EIA-485 Serial Communications Protocol requiring only two signal lines. Can allow up to 32 devices to be connected together in a daisy-chained fashion. EMF Electro-motive force.
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EMI Electro-magnetic interference. ESD Electro-static discharge. EU Engineering Units. Units of measure, such as MCF/DAY.
F
Firmware Internal software that is factory-loaded into a form of ROM. In the ROC or FloBoss, the firmware supplies the software used for gathering input data, converting raw input data calculated values, storing values, and providing control signals. FlashPAC Module ROM and RAM module that contains the operating system, applications firmware, and communications protocol in a ROC300-series unit. Flash ROM A type of read-only memory that can be electrically re-programmed. It is a form of permanent memory (needs no backup power). Also called Flash memory. FloBoss A specialized Remote Operations Controller (ROC), Fisher Controls microprocessorbased unit that provides remote monitoring and control. Force Write an ON/OFF, True/False, or 1/0 value to a coil. FM Factory Mutual. FPV Supercompressibility Factor. FSK Frequency Shift Keyed. FST Function Sequence Table, a type of program that can be written by the user in a high-level language designed by Fisher Controls.
G
GFA Ground Fault Analysis. GND Electrical ground, such as used by the ROC power supply. GP Gauge Pressure. GV101 Configuration software used to configure ROC units to gather data, as well as most other functions. GV110 A host computer system software with one or more DOS-based personal computers that run the GV110 operations software and are linked to the field with a communications system. The host computer system software runs as a real-time operating system, and can monitor and control operations in the field as they actually happen.
H
HART Highway Addressable Remote Transducer. Holding Register Analog output number value to be read. hw Differential pressure.
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I, J
ID Identification. IEC Industrial Electrical Code. IEEE Institute of Electrical and Electronic Engineers. The Open System Interconnection (OSI) reference model and an international standard for the organization of local area networks (LANs) established by the International Standards Organization (ISO) and the IEEE. IMV Integral Multiplier Value. Input Digital input, a bit to be read. Input Register Input numeric value to be read. I/O Input/Output. I/O Module Module that plugs into an I/O slot on a ROC to provide an I/O channel. IRQ Interrupt Request. Hardware address oriented. IS Intrinsic Safety or Intrinsically Safe. IV Integral Value.
K
Kbytes Kilobytes. kHz Kilohertz.
L
LCD Liquid Crystal Display. Display-only device used for reading data. LDP Local Display Panel. A display-only device that plugs into a ROC300-series unit via a parallel interface cable. The LDP consists of a 4-line by 20-character alphanumeric display and four pushbuttons used to access information stored by the ROC. LED Light-emitting diode. LOI Local Operator Interface. Refers to the serial (RS-232) port on the ROC or FloBoss through which local communications are established, typically for configuration software running on a PC. LPM Lighting Protection Module. Use this module to provide lightning and power surge protection for ROCs and FloBoss units. LRC Longitudinal Redundancy Checking error checking.
M
mA Milliamps. MCU Master Controller Unit. Modular I/O I/O channels provided on a ROC using I/O modules. See I/O Module. MMBTU Million British Thermal Units. MPU Microprocessor Unit.
G-4
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MVS Multi-Variable Sensor. The MVS provides differential pressure, static pressure, and temperature inputs to the FloBoss 407 for orifice flow calculation. mV Millivolts or 0.001 volt. mW Milliwatts or 0.001 watt.
N
NEC National Electrical Code. NEMA National Electrical Manufacturers Association.
O
OH Off-Hook modem communications signal. Off-line Accomplished while the target device is not connected (by a communications link). For example, off-line configuration is configuring a ROC in a electronic file that is later loaded into the ROC. Ohms Units of electrical resistance. On-line Accomplished while connected (by a communications link) to the target device. For example, on-line configuration is configuring a ROC while connected to it, so that current parameter values are viewed and new values can be loaded immediately. Opcode Type of message protocol used by the ROC to communicate with the configuration software, as well as host computers with ROC driver software.
P, Q
Parameter A property of a point that typically can be configured or set. For example, the Point Tag ID is a parameter of an Analog Input point. Parameters are normally edited by using configuration software running on a PC. PC Personal Computer Pf Flowing pressure. P/DP Pressure/Differential Pressure. PI Pulse Input. PID Proportional, Integral, and Derivative control feedback action. PIT Periodic Timer Interrupt. Point Software-oriented term for an I/O channel or some other function, such as a flow calculation. Points are defined by a collection of parameters. Point Number The rack and number of an I/O point as installed in the ROC system. Point Type The point type attribute defines the database point to be one of the possible types of points available to the system. The point type determines the basic functions of a point. Preset Number value previously determined for an register. PRI Primary PID control loop. PSTN Public switched telephone network.
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PT Process Temperature. PTT Push-to-talk signal. Pulse Transient variation of a signal whose value is normally constant. PV Process variable or process value.
R
Rack For a ROC, a rack is a row of slots into which I/O modules may be plugged. The rack is given a letter to physically identify an I/O channel location, such as A for the first rack. Builtin I/O channels are assigned a rack identifier of A, while diagnostic I/O channels are considered to be in rack E. RAM Random Access Memory. In a ROC or FloBoss, it is used to store history, data, most user programs, and additional configuration data. RBX Report-by-exception. In a ROC or FloBoss, it always refers to spontaneous RBX in which the ROC contacts the host to report an alarm condition. RFI Radio frequency interference. RI Ring Indicator modem communications signal. ROC Remote Operations Controller, Fisher Controls microprocessor-based unit that provides remote monitoring and control. ROCLINK Configuration software used to configure ROC or FloBoss units to gather data, as well as most other functions. ROCPAC Module ROM and RAM module that contains the operating system, applications firmware, and communications protocol in a ROC300-series unit. ROM Read-only memory. Typically used to store firmware. Flash memory. RTC Real-time clock. RTD Resistance Temperature Detector. RTS Ready-to-Send modem communications signal. RTU Remote Terminal Unit. RTV Room Temperature Vulcanizing, typically a sealant or caulk like silicone rubber. RXD Received data communications signal.
S
SAMA Scientific Apparatus Makers Association. Script The program instructions (script) embedded within an object. Soft Points A type of ROC point with generic parameters that can be configured to hold data as desired by the user. SP Setpoint or Static Pressure. SPI Slow Pulse Input. SPK Speaker.
G-6
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SRAM Static Random Access Memory. Stores data as long as power is applied; typically backed up by a lithium battery or supercapacitor. SRBX Spontaneous Report-By-Exception. Refer to RBX. SVA Signal Value Analog. SVD Signal Value Discrete.
T-Z
TDI Timed Discrete Input or Time Duration Input. TDO Timed Discrete Output or Time Duration Output. Tf Flowing temperature. TLP Type (of point), Logical (or point) number, and Parameter number. TXD Transmitted data communications signal.
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G-7
G-8
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INDEX
Numerical
1985 AGA Flow Calculations..................................................2-3 1992 AGA Flow Calculation ...................................................2-4 32-bit CMOS Microprocessor ....................................1-5 Class I..................................................................... 1-10 Clock Real-Time........................................................... 2-13 Coil...........................................................................G-1 Cold Start................................................................ 2-31 COM1..............................................................2-12, G-1 COM2.......................................................................G-1 COMM .....................................................................G-1 Comm Port Host.................................................................... 2-12 Operator Interface ............................................... 2-11 Communication Ports .............................................. 2-11 Communications Connectors ......................................................... 2-12 Wiring ................................................................ 2-25 Communications Cards.............................................. 4-1 Descriptions.......................................................... 4-1 EIA-232 ............................................................... 4-2 EIA-485 ............................................................... 4-4 Installation............................................................ 4-5 LED Indicators ..................................................... 4-3 Location ............................................................... 4-6 Replacing ............................................................. 4-8 Specifications ..................................................... 4-10 Troubleshooting.................................................... 4-8 Wiring .................................................................. 4-7 Configuration ............................................................G-1 Dual-Variable Sensor............................................ 3-3 Verify................................................................... 3-5 Contents............................................................. 3-1, 4-1 CPU ..........................................................................G-1 CRC..........................................................................G-1 CSA ..........................................................................G-2 CTS ..........................................................................G-2
A
A/D .......................................................................... G-1 Accessories................................................................1-7 Additional Information...............................................1-2 After Installing Components.....................................2-33 AGA.................................................................. 2-3, G-1 AI See Analog Inputs ................................................ G-1 Alarm Log .................................................................2-7 Analog...................................................................... G-1 Analog Inputs ............................................................3-1 RTD.................................................................... 2-13 Antennas....................................................................1-9 AO See Analog Outputs.............................................. G-1 AP ............................................................................ G-1 API.................................................................... 2-3, G-1 Approvals ................................................................ 1-10 Area.......................................................................... G-1 ASCII ....................................................................... G-1 Attribute.................................................................... G-1 Automatic Self Tests................................................2-14 AWG........................................................................ G-1
B
Backup Procedures .................................................. 2-29 After Installing Components ................................ 2-33 BTU ......................................................................... G-1 Built-in I/O ............................................................... G-1
D
D/A...........................................................................G-2 Daily Historical Logs ................................................ 2-7 dB.............................................................................G-2 DB ............................................................................G-2 DCD .........................................................................G-2 Deadband..................................................................G-2 DI See Discrete Inputs ...............................................G-2 Diagnostic ................................................................. 1-5 Diagnostic Inputs .................................................... 2-13 Differential Pressure.............2-3, 2-6, 2-28, 3-2, 3-3, G-5 Dimensions ...................................................... 1-3, 1-14 Discrete.....................................................................G-2 Discrete Outputs............................................... 1-5, 2-12 I-1
C
C Prime .....................................................................2-6 Calculations 1985 AGA.............................................................2-3 1992 Flow .............................................................2-4 Input and Extension........................................2-4, 2-5 Instantaneous Rate..........................................2-4, 2-5 Calibration............................................................... 2-28 Dual-Variable Sensor ............................................3-5 I/O Channels ....................................................... 1-21 Cathodic Protection................................................... 1-12 Rev 6/99
Wiring................................................................. 2-24 Division 2................................................................ 1-10 DMM ....................................................................... G-2 DO .......................................................... 1-5, 2-12, 2-18 See Discrete Outputs ............................................ G-2 Downstream Usage of DVS .......................................3-2 DP ............................................................................ G-2 DSR.......................................................................... G-2 DTR .................................................................. 4-3, G-2 Dual-Variable Sensor Calibration ............................................................3-5 Configuration ........................................................3-3 Description............................................................3-1 DVS......................................................................3-1 Specifications...................................................... 3-13 Wiring...................................................................3-2 Duty Cycle ...................................................... 1-15, G-2 DVM ........................................................................ G-2 DVS .................................................................. 1-5, G-2 Downstream Usage................................................3-2 Upstream Usage ....................................................3-2
E
EDS.......................................................................... G-2 EEPROM ................................................................. G-2 EFM ..........................................................................1-3 EIA-232.................................................................... G-2 EIA-232 Communications Cards ................................4-2 EIA-422.................................................................... G-2 EIA-485.................................................................... G-2 EIA-485 Communication Cards .................................4-4 Electrical Isolation .................................................... 1-11 Electromagnetic Interference....................................1-12 Electronics Board.......................................................2-9 EMF ......................................................................... G-2 EMI........................................................ 1-12, 2-18, G-3 Enclosure Dimensions ...........................................................1-3 Energy Accumulation .........................................2-4, 2-5 Energy, Instantaneous ................................................2-6 Environmental Requirements ........................................................1-8 ESD.......................................................................... G-3 EU............................................................................ G-3 Event Log..................................................................2-7 Extension Calculation ................................................2-5
F
Figure 1-1. FloBoss 553 Flow Manager.....................1-4 Figure 1-2. Main Electronics Board...........................1-6 Figure 1-3. Outline and Mounting Dimensions ........1-14 Figure 1-4. Solar Insolation in Hours for the United States ..................................................................... 1-18
Figure 2-1. Main Electronics Board ........................ 2-10 Figure 2-2. I/O Terminal......................................... 2-18 Figure 2-3. Earth Ground Connection ..................... 2-20 Figure 2-4. Location of Input Power Connector....... 2-21 Figure 2-5. RTD Wiring Terminal Connections . 2-23 Figure 2-6. Discrete Output Terminal Wiring.......... 2-25 Figure 2-7. Operator Interface Wiring ..................... 2-27 Figure 2-8. ROC System Flags................................ 2-31 Figure 2-9. Cold Start Options ................................ 2-31 Figure 2-10. Reset Jumper Shown in Normal Position ................................................................. 2-32 Figure 2-11. Open Configuration File ..................... 2-34 Figure 2-12. Download Configuration..................... 2-35 Figure 3-1. DVS Wiring ........................................... 3-3 Figure 3-2. System Information ................................ 3-4 Figure 3-3. Meter Calibration Window...................... 3-5 Figure 3-4. Verify Calibration................................... 3-6 Figure 3-5. Meter Calibration.................................... 3-7 Figure 3-6. Set Zero Calibration for Differential Pressure................................................................... 3-7 Figure 3-7. Removing the DVS from Service ............ 3-8 Figure 3-8. Set Span ................................................. 3-9 Figure 3-9. Set Midpoint 1........................................ 3-9 Figure 3-10. Set Midpoint 2.................................... 3-10 Figure 3-11. Set Midpoint 3.................................... 3-10 Figure 3-12. Returning the DVS to Service ............. 3-11 Figure 3-13. Set Zero Shift ..................................... 3-12 Figure 4-1 ................................................................. 4-2 Figure 4-1. EIA-232 Serial Communications Card .... 4-2 Figure 4-2. EIA-485 Serial Communications Card .... 4-4 Figure 4-3. Communications Card Location.............. 4-6 Firmware.....................................................1-7, 2-3, G-3 Flash Memory ........................................................... 2-9 Flash ROM.........................................................1-5, G-3 FlashPAC..................................................................G-3 FloBoss.....................................................................G-3 FloBoss Flow Manager.............................................. 1-1 Flow and Energy Accumulation.......................... 2-4, 2-5 Flow Calculations 1985 AGA ............................................................ 2-3 Flow Measurement.................................................... 2-3 Flow Time.......................................................... 2-4, 2-5 Flow, Instantaneous................................................... 2-6 Flowing Minutes ....................................................... 2-6 FM............................................................................G-3 Force.........................................................................G-3 FPV ..........................................................................G-3 FSK ..........................................................................G-3 FST....................................................................2-8, G-3 Function Sequence Table (FST) User Manual ............ 1-2 Functions .................................................................. 2-3
G
GFA..........................................................................G-3 Rev 6/99
I-2
GND......................................................................... G-3 GP ............................................................................ G-3 Grid Impedance ........................................................ 1-11 Ground Rod.............................................................. 1-11 Grounding Earth Ground ....................................................... 1-11 Wiring Requirements........................................... 1-11 Groups C, and D ...................................................... 1-10 GV101...................................................................... G-3 GV110...................................................................... G-3
Isolation....................................................................1-11 IV .............................................................................G-4
J
Jumper .................................................................... 2-32
K
Kbytes.......................................................................G-4 kHz ...........................................................................G-4
H
Hardware Watchdog ................................................ 2-14 HART....................................................................... G-3 Hazardous Locations................................................ 1-10 History Log ...............................................................2-6 History Points ............................................................2-6 Holding Register....................................................... G-3 Host Port ........................................................ 2-11, 2-12 Wiring................................................................. 2-27 Hourly Historical Log ................................................2-6 hw ............................................................................ G-3
L
LAN..........................................................................G-4 LCD.................................................................2-11, G-4 LDP ..........................................................................G-4 LED..........................................................................G-4 LEDs Communications Cards ......................................... 4-3 Liquid Crystal Display...................................... 1-4, 2-11 Local Operator Interface LOI .......................................................1-5, 1-7, 2-11 LOI Wiring......................................................... 2-26 LOI ..................................................................2-18, G-4 Loop Schematic.........................................................A-1 Low Battery ............................................................ 2-15 Low Power Modes .................................................. 2-14 LPM..........................................................................G-4 LRC..........................................................................G-4
I
I/O............................................................................ G-4 Built-in .................................................................1-5 I/O Channel Power Consumed ................................................ 1-15 I/O Module ............................................................... G-4 I/O Power Requirements .......................................... 1-15 I/O Terminals .......................................................... 2-18 I/O Wiring Requirements ......................................... 1-12 ID............................................................................. G-4 IEC........................................................................... G-4 IEEE......................................................................... G-4 Impedance Grid .................................................................... 1-11 IMV.......................................................................... G-4 Information Additional .............................................................1-2 Input......................................................................... G-4 Input and Extension Calculation..........................2-4, 2-5 INPUT POWER ...................................................... 2-18 Input Register ........................................................... G-4 Installation Communications Cards..........................................4-5 Guidelines.............................................................1-8 Instantaneous Rate Calculations ..........................2-4, 2-5 Integral Multiplier Value............................................2-6 IMV ......................................................................2-5 Integral Value ............................................................2-6 IV .........................................................................2-5 IRQ .......................................................................... G-4 ISO........................................................................... G-4 Rev 6/99
M
mA............................................................................G-4 Main Electronics Board .......................1-4, 1-6, 2-9, 2-10 Specifications ..................................................... 2-35 MCU.........................................................................G-4 MCU Board .............................................................. 2-9 MCU PWR ............................................................. 2-18 Memory .................................................................... 2-9 Metric ....................................................................... 3-4 Microprocessor................................................... 1-5, 2-9 Minute Historical Log ............................................... 2-6 Modbus.................................................................... 2-8 Modular I/O ..............................................................G-4 MOSFET ................................................................ 2-24 Mounting ........................................................1-13, 1-14 MPU .........................................................................G-4 mV............................................................................G-5 MVS ..................................................................3-1, G-5 mW...........................................................................G-5
N
National Electrical Code NEC ................................................................... 1-10 I-3
NEC ......................................................................... G-5 NEMA...................................................................... G-5 NORM..................................................................... 2-33
O
Off-line..................................................................... G-5 OH ........................................................................... G-5 Ohms........................................................................ G-5 On-line ..................................................................... G-5 Opcode ..................................................................... G-5 Operation................................................................. 1-21 Operator Interface Port.................................... 2-11, 2-26 LOI ................................................................1-5, 1-7 Wiring................................................................. 2-26 Options......................................................................1-7 OSI........................................................................... G-4 Outline ......................................................................1-4 Overview...................................................................1-3
Surge Protection ...................................................1-11 Totaling Requirements........................................ 1-16 Wiring ........................................................2-16, 2-20 Power Consumption, Total ...................................... 1-15 Preset ........................................................................G-5 Pressure .............................................................3-2, G-5 Pressure Connections................................................. 3-2 PRI ...........................................................................G-5 Process Connections......................................... 1-13, 3-2 Processor................................................................... 1-5 Product Overview...................................................... 1-3 PSTN ........................................................................G-5 PT.............................................................................G-6 PTT...........................................................................G-6 Pulse .........................................................................G-6 PV.............................................................................G-6
R
Rack .........................................................................G-6 Radio Frequency Interference .................................. 1-12 RAM..................................................................1-5, G-6 Backup Procedure............................................... 2-29 RBX..........................................................................G-6 Real-Time Clock .............................................2-13, 2-15 Rebooting See Resetting the FloBoss ................................... 2-30 Repair ..................................................................... 2-29 Replacing Communications Cards ......................................... 4-8 Report by Exception................................................ 2-12 Reset Jumper........................................................... 2-32 Resetting the FloBoss .............................................. 2-30 RFI .........................................................1-12, 2-18, G-6 RI..............................................................................G-6 ROC..........................................................................G-6 ROC/FloBoss Accessories Instruction Manual ........... 1-2 ROCLINK ................................................................G-6 ROCPAC Module .....................................................G-6 ROM.........................................................................G-6 Flash..................................................................... 1-5 RS232 Communication Card Wiring .................................................................. 4-7 RTC..........................................................................G-6 RTD........................ 1-5, 2-3, 2-13, 2-14, 2-18, 2-28, G-6 Wiring ................................................................ 2-22 RTS ..........................................................2-26, 4-3, G-6 RTU..........................................................................G-6 RXD ..................................................................4-3, G-6
P
P/DP......................................................... 2-18, 3-2, G-5 P1............................................................................ 2-33 P3............................................................................ 2-18 Parameter ................................................................. G-5 PC ............................................................................ G-5 Periodic Timer Interrupt.................................................... 2-14 Periodic Log ..............................................................2-6 Periodic Timer Interrupt............................................ G-5 Pf.............................................................................. G-5 Phase Lock Loop .....................................................2-14 PI See Pulse Inputs ................................................... G-5 PID........................................................................... G-5 Piping...............................................................1-13, 3-2 PIT ........................................................................... G-5 Pmax .......................................................................1-15 Pmin........................................................................1-15 Point......................................................................... G-5 Point Number ........................................................... G-5 Point Type ................................................................ G-5 Polarity .................................................. 1-20, 2-14, 2-17 Power Before Removing ................................................2-29 Consumption....................................................... 1-15 Consumption Table ............................................. 1-16 I/O Requirements ................................................ 1-15 Low Modes ......................................................... 2-14 Operating ............................................................ 2-14 Requirements ...................................................... 1-10 Sleep (Doze) Mode.............................................. 2-15 Solar Power......................................................... 1-17 Standby Mode ..................................................... 2-14
S
SAMA ......................................................................G-6 Sampler................................................................... 2-13 Script ........................................................................G-6
I-4
Rev 6/99
Section Contents .................................................3-1, 4-1 Security ................................... 1-5, 2-8, 2-11, 2-12, 2-30 Site Requirements ......................................................1-9 Sleep Mode.............................................................. 2-15 Soft Points ................................................................ G-6 Software Watchdog.................................................. 2-14 Solar Arrays Refer to Solar Panels ........................................... 1-17 Solar Panels ...............................................................1-9 Power.................................................................. 1-17 Sizing.................................................................. 1-17 SP............................................................................. G-6 Specifications Communications Cards........................................ 4-10 Serial Communications Cards.............................. 4-10 SPI ........................................................................... G-6 SPK .......................................................................... G-6 SRAM ...................................................................... G-7 SRBX ....................................................................... G-7 See RBX .............................................................. G-6 Standby Mode.......................................................... 2-14 Startup.............................................................. 1-20, 3-8 Startup and Operation .............................................. 1-20 Static Pressure .................................... 2-3, 2-6, 2-28, 3-3 Static Random Access Memory SRAM...................................................................2-9 Surge Protection........................................................ 1-11 SVA ......................................................................... G-7 SVD ......................................................................... G-7 System Voltage........................................................ 1-16
Tf..............................................................................G-7 Timer Interrupt.................................................2-14, G-5 TLP...........................................................................G-7 Totaling Power Requirements.................................. 1-16 Troubleshooting ...................................................... 2-29 Communications Cards ......................................... 4-8 Reset .................................................................. 2-30 TXD...................................................................4-3, G-7 Type RL101 ROCLINK Configuration Software User Manual .................................................................... 1-2
U
Units ......................................................................... 3-4
V
Vibration................................................................... 1-9 Voltage ................................................................... 1-16
W
Warm Start.............................................................. 2-30 Watchdog Software and Hardware....................................... 2-14 Wiring Communications................................................. 2-25 Communications Cards ......................................... 4-7 Discrete Outputs ................................................. 2-24 Dual-Variable Sensor............................................ 3-2 EIA-485 Communications Cards........................... 4-7 General............................................................... 2-17 Grounding Requirements .................................... 1-11 I/O Terminals ..................................................... 2-18 I/O Wiring .......................................................... 1-12 LOI .................................................................... 2-26 Power ................................................................. 2-20 RS232 Communications Card ............................... 4-7 RTD ................................................................... 2-22 Wire Gauge ........................................................ 2-20
T
Table 1-1. Power Consumption of the FloBoss 553 and Powered Devices.................................................... 1-16 Table 1-2. Solar Panel Sizing ..................................1-19 Table 2-1. Discrete Output ......................................2-12 Table 4-1. Communications Cards LED Indicators ....4-3 TDI........................................................................... G-7 TDO ................................................................ 2-13, G-7 Temperature .............................. 1-9, 2-3, 2-6, 2-14, 2-28 Terminal Connections ..............................................2-17 Tests Automatic ........................................................... 2-14
Z
Zero Shift................................................................ 3-12
Rev 6/99
I-5
If you have comments or questions regarding this manual, please direct them to your Fisher Representative or contact:
FAS Technical Documentation Fisher Controls International, Inc. 1612 South 17th Avenue Marshalltown, Iowa 50158 FAX: 515-754-3630 I-6 Rev 6/99

A6073 FB553

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Field Automation Systems

FLOBOSS 553 FLOW MANAGER

Loose-leaf version: Part Number D301127X012 Bound version: Contact FAS

FloBoss 553 Instruction Manual

Revision Tracking Sheet

Page 1-20 and 1-21 2-15 2-29 All others

Revision 1/00 1/00 1/00 6/99

FloBoss 553 Instruction Manual

SECTION 2 USING THE FLOBOSS 553 ............................................................ 2-1

SECTION 3 DUAL-VARIABLE SENSOR .......................................................... 3-1

FloBoss 553 Instruction Manual

Table of Contents (Continued) SECTION 4 COMMUNICATIONS CARDS....................................................... 4-1

APPENDIX A LOOP SCHEMATIC ....................................................................A-1

GLOSSARY OF TERMS .......................................................................................... G-1 TOPICAL INDEX .......................................................................................................I-1

FloBoss 553 Instruction Manual

SECTION 1 GENERAL INFORMATION

FloBoss 553 Instruction Manual

1.2 SECTION CONTENTS

1.3 ADDITIONAL INFORMATION

FloBoss 553 Instruction Manual

1.4 PRODUCT OVERVIEW

FloBoss 553 Instruction Manual

Figure 1-1. FloBoss 553 Flow Manager

Operator Interface Port

FloBoss 553 Instruction Manual

FloBoss 553 Instruction Manual

Reset Jumper LCD

Super Capacitor "Battery"

Comm Card Mating Connector

Flash Memory Chip

Board Power Connector Integral Sensor Connector

Built-in I/O Wiring

Figure 1-2. Main Electronics Board

FloBoss 553 Instruction Manual

1.4.2 Options and Accessories

FloBoss 553 Instruction Manual

1.5 INSTALLATION REQUIREMENTS

1.5.1 Environmental Requirements

FloBoss 553 Instruction Manual

1.5.2 Site Requirements

FloBoss 553 Instruction Manual

1.5.3 Compliance with Hazardous Area Standards

1.5.4 Power Installation Requirements

FloBoss 553 Instruction Manual

1.5.5 Grounding Installation Requirements

FloBoss 553 Instruction Manual

1.5.6 I/O Wiring Requirements

FloBoss 553 Instruction Manual

1.6.1 Mounting the FloBoss

FloBoss 553 Instruction Manual

10.38 3.25 2.81

Figure 1-3. Outline and Mounting Dimensions

FloBoss 553 Instruction Manual

1.7 POWER CONSUMPTION CALCULATION

1.7.1 Determining I/O Channel Power Consumption

FloBoss 553 Instruction Manual

1.7.2 Totaling Power Requirements

FloBoss 553 Instruction Manual

1.7.3 Solar Powered Installations

FloBoss 553 Instruction Manual

Figure 1-4. Solar Insolation in Hours for the United States

FloBoss 553 Instruction Manual