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ABB XSeries G4 6200 User Manual Download Page 99

 

2104349 rev. AD 

Page 4

–1 

 

4  G4 ex Maintenance 

4.1 

Overview 

The following chapter will provide the user with standard maintenance information 
and instructions on how to remove and install G4 EX components. 

4.1.1  Maintenance Support 

If installation, calibration and maintenance assistance is required, the user can 
contact the Totalflow Service Department. 

USA: (800) 442-3097 

 

 

International: 001-918-338-4888 

4.1.2  How to Use This Chapter 

It is recommended that the user develop a regularly scheduled maintenance 
program. By establishing a maintenance program, the G4 EX downtime can be 
minimized. 

Record all items within this chapter in the maintenance practice procedures. 
Practical experience permits updating this schedule over a period of time. This 
results in many maintenance items being handled on a routine basis before 
potential problems result in a failure. 

4.1.3  Cleanliness 

Because a G4 EX installation is primarily exposed to external environmental 
conditions, it is important that it be regularly inspected for cleanliness, both 
externally and internally. Foreign contaminants can cause damage to interior 
mounted components that can render the G4 EX inoperable. 

4.1.4  Front Mounted LCD 

The user is informed of operational problems and operational limit violations by 
observing the alarm codes on the LCD display. Troubleshooting techniques for 
dealing with these alarm codes is presented later in the manual. 

4.1.5  Returning Parts for Repair 

If a Totalflow component is to be returned to Totalflow for repair, securely wrap it 
in protective anti-static packaging. Before returning a component, call Totalflow for 
a Return for Authorization (RA) number. Affix this number to the outside of the 
return package. 

Part shipments must be prepaid by the customer. Any part that is not covered by 
the original system warranty will be shipped to the customer, F.O.B. 

4.2 

Backing Up Configuration Files 

Before beginning any maintenance on the G4 EX, the user should collect the data, 
and back up all co

nfiguration files to the laptop’s hard drive or disk. This upload 

safeguards data and allows the user to restart the unit without the obstacles 
associated with reconfiguring the G4 EX should any problem arise. 

Although there are Save buttons within the Entry mode screens in PCCU32 that 
allow the user to back up Entry model data items, a complete system backup is 
only accomplished by using the Save and Restore Utility or the 32-Bit Loader. 

Summary of Contents for XSeries G4 6200

Page 1: ...Totalflow product line Proprietary information Copyright 2018 ABB All rights reserved 2104349 AD User manual XSeries G4 6200 6201EX Flow Computer 2104349 ver AD ...

Page 2: ...ained as accurately as possible Should any discrepancies exist the US English version will be considered final Notice This publication is for information only The contents are subject to change without notice and should not be construed as a commitment representation warranty or guarantee of any method product or device by Owner Inquiries regarding this manual should be addressed to ABB Inc Totalf...

Page 3: ...1 2 1 Enclosure 1 8 1 2 2 G4 EX main processor board 1 10 1 2 3 G4 EX termination board 1 12 1 2 4 Explosion proof multivariable transducer EXIMV 1 17 1 2 5 Display assembly 1 19 1 2 6 Resistive temperature detector RTD 1 19 1 2 7 6270 Optional Equipment Unit OEU 1 20 1 2 8 Solar panel 1 21 1 2 9 Lithium battery 1 22 1 3 G4 EX application licensing 1 22 1 3 1 Credit Key USB 1 24 1 4 Laptop compute...

Page 4: ... software security 3 16 3 4 3 Role Based Access Control RBAC 3 17 3 5 Application licensing Credit Key 3 25 3 5 1 Credit Key driver installation 3 25 3 5 2 Access view the Credit Key with PCCU32 7 0 or later 3 25 3 5 3 Adding credits to the Credit Key by telephone 3 27 3 5 4 Transferring credits to the G4 EX from the Credit Key 3 28 3 5 5 Transferring Credits to the Credit Key from the G4 EX 3 29 ...

Page 5: ...Replacing the transducer EXIMV 4 17 4 12 1 Step by step instructions 4 17 4 13 Calibration 4 19 4 13 1 Required test equipment 4 19 4 13 2 Hold mode 4 20 4 13 3 Static pressure SP calibration checks 4 20 4 13 4 Differential pressure DP calibration checks 4 22 4 13 5 Calibrating static pressure SP 4 23 4 13 6 Calibrating differential pressure DP 4 25 4 14 Onboard I O calibration overview 4 26 4 14 ...

Page 6: ...y voltage test 5 16 5 4 5 Transceiver check 5 17 5 4 6 Termination board supply voltage test 5 17 5 4 7 RS 232 communication 5 18 5 4 8 RS 232 termination board test 5 18 5 4 9 RS 232 OEU termination strip test 5 19 5 4 10 RS 485 communication test 5 20 5 4 11 RS 485 termination board test 5 20 5 4 12 RS 485 OEU termination strip test 5 22 6 Reference material 23 6 1 Reference materials on ABB Tot...

Page 7: ...ation 1 22 Figure 1 20 RS 232 local communication cable 1 25 Figure 1 21 USB local communication cable 1 26 Figure 1 22 Ethernet communication cable 1 27 Figure 1 23 Ethernet connectivity diagram 1 27 Figure 2 1 Type A Installation Configuration 2 3 Figure 2 2 Type B Installation Configuration 2 4 Figure 2 3 Type C installation configuration 2 5 Figure 2 4 G4 EX EXIMV ports 2 6 Figure 2 5 Thermowe...

Page 8: ...e Based Access Control File dialog box 3 21 Figure 3 23 Totalflow TCP Setup tab 3 21 Figure 3 24 Login dialog box 3 22 Figure 3 25 System Setup dialog box 3 23 Figure 3 26 Security Log tab 3 24 Figure 3 27 Credit Key License Utility 3 26 Figure 3 28 Credit Key License Utility Status 3 26 Figure 3 29 Application Credit Key entry screen 3 27 Figure 3 30 Application Credit verification codes 3 28 Fig...

Page 9: ...mily genealogy 1 1 Table 1 2 Typical G4 EX display options 1 5 Table 1 3 Default annunciator locations 1 6 Table 1 4 G4 EX status and alarm description 1 6 Table 1 5 G4 EX main processor board specifications 1 11 Table 1 6 Explosion proof EXIMV specifications 1 18 Table 1 7 Standard RTD probes 1 20 Table 1 8 Standard Thermowells 1 20 Table 3 1 Configurable calculation factors 3 31 Table 3 2 Fpv an...

Page 10: ...ride in the ongoing support we provide our customers When you purchase a product you receive documentation which should answer your questions however Totalflow Technical Support provides you an 800 number as an added source of information If you require assistance call USA 800 442 3097 International 001 918 338 4888 Before you call Know your Totalflow s model and serial number Serial numbers can b...

Page 11: ...to draw attention to information that may require further investigation or consideration prior to continuing Safety practices and precautions This manual contains information and warnings which have to be followed by the user to ensure safe operation and to retain the product in a safe condition Installation maintenance and repairs should only be performed by a trained and qualified technician Ple...

Page 12: ...and authorized specialist should attempt these tasks A specialist would be one who is experienced in either assembly electrical connection installation or maintenance of a given device and holds the necessary qualifications for the task When opening covers or removing parts exercise extreme care live parts or connections can be exposed Installation and maintenance must be performed by person s qua...

Page 13: ...ectric components must follow guidelines stipulated in the Certification Drawings shipped with this unit DANGER indicates a personal injury hazard immediately accessible as one reads the markings CAUTION indicates a personal injury hazard not immediately accessible as one reads the markings or a hazard to property including the equipment itself Equipment markings Protective ground earth terminal G...

Page 14: ...mmitted to actively protecting the environment Do not dispose of WEEE as unsorted municipal waste Collect WEEE separately Participation in the management of WEEE is critical to the success of WEEE collection Electrical and electronic equipment marked using the crossed out wheeled bin symbol shall not be mixed with general household waste Correct disposal at a recycling facility will help save valu...

Page 15: ...tion systems The G4 EX is an accurate and reliable gas flow computer with the capability to measure and monitor gas flow in compliance with AGA API and ISO standards The G4 EX is a low power microprocessor based unit designed to meet a wide range of measurement control monitor and alarming applications for remote gas systems located in DIV 1 hazardous areas See Table 1 1 for the XFC family genealo...

Page 16: ...evice The G4 EX may be used in conjunction with a laptop that is running PCCU32 software PCCU32 is required for initial setup and setup of the advanced features The G4 EX maintains a history of alarms as well as average differential pressure DP average static pressure SP average flowing temperature Tf accumulated volume energy and an average extension The G4 EX can be programmed to calculate flow ...

Page 17: ... for SP DP Tf and flow rate 1 1 3 Flow computer calculations The records and statistics generated are based on the following calculation methods of the G4 EX Calculation of flow rates and volumes in accordance with AGA 3 85 AGA 3 92 AGA 7 or ISO 5167 Calculation of flow rates and volumes in accordance with AGA 8 92 Gross or Detail or NX 19 Supercompressibility Standards Calculation of flow extensi...

Page 18: ...etermined by geographic location of the unit and total power consumption of the system Totalflow project engineers can select the appropriate battery and solar requirements for the user s specific application Larger capacity batteries are available to increase autonomy if required Three available power sources External solar panel standard External AC or AC to DC power External 24 12 VDC power Liq...

Page 19: ...zero seconds will set any item to Off See the Program Display section and the PCCU32 Help Files for additional information Table 1 2 Typical G4 EX display options Display Description DATE TIME MM DD YY HH MM SS Current date and time 24 hour clock YEST DP LOW NN PERCENT Yesterday s time below DP Low Set Point YEST DP HIGH NN PERCENT Yesterday s time below DP High Set Point FLOW RATE NNNNNN N SCF HR...

Page 20: ...1 3 Default annunciator locations Annunciator Application A1 Measurement Tube 1 A2 CIM 0 A3 Valve Control A4 COM2 A5 Plunger A6 Local COM0 A7 System A8 TF Remote COM1 Table 1 4 G4 EX status and alarm description Indicator Description System LL Low Lithium Battery Alarm When LL low lithium is displayed lithium battery voltage is not sufficient to maintain SRAM data A new lithium battery measures ap...

Page 21: ...ication BF Back Flow Condition Visible only when DP variable displayed Z Zero Flow Condition Visible only when Flow Rate displayed H Hold Displayed when PCCU32 has entered Calibration mode on a Measurement Application A Alarm Condition Need to view alarm The user may need to compare application limits to current values to determine where the alarm condition is present AD A to D Failure Displayed i...

Page 22: ...orrosion resistant and NEMA 4X rated Unauthorized removal of the end caps are protected with a 1 16 countersunk hex head set screw on each end cap Remove power from the device or insure the area is known to be non hazardous before removing any enclosure cover For further information refer to the certification drawing indicated on the device s nametag and national and local electrical codes Do not ...

Page 23: ...1 9 Figure 1 3 G4 EX enclosure Figure 1 4 G4 EX enclosure left side 3 76 7 87 9 50 NPT CONDUIT ENTRIES NPT CONDUIT ENTRIES 01 53 30º 01 84 OPTIONAL EXTERNAL PCCU FLAMEPROOF HOUSING 2101416 001 NPT CONDUIT ENTRIES XFCG4 EX ...

Page 24: ...display connector J2 Lithium battery connector J5 Engine card connector XA1 Sensor interface connector J6 Termination board connector J1 The G4 EX transducer assembly utilizes a small electronic board that contains the factory characterization data This allows the main electronics on the sensor assembly to be individually field replaceable in the event of failures Installation and or maintenance o...

Page 25: ...s a general purpose motherboard for the 6200 6201EX devices Table 1 5 G4 EX main processor board specifications Component Description Power 9 to 30 VDC External Power SWVBAT 1 fused with 2 5 amp PTC VBAT 1 fused with 2 5 amp PTC Charger No Charger Memory Application Totalflow exe runs out of 16M SRAM RAM memory has lithium backup battery Application and configuration files permanently stored in 32...

Page 26: ... termination board the user will find connectors for two 2 communication ports RS 232 RS 422 or RS 485 software selectable The user should also note that there is a dedicated port for RS 232 local communications This is a plug type port and will connect to an internal PCCU connector or an explosion proof external PCCU connector For more information on the explosion proof PCCU connector see the cor...

Page 27: ... wires to the G4 EX boards the user should remove all power sources and insure that they are grounded properly The digital input reads an external contact This is primarily used as a status input to read external equipment The contact must be closed to be considered ON The ON condition is recorded in the log period alarms and can trigger the action of the G4 EX s digital voltage output OFF is defi...

Page 28: ...bounce disabled Input specifications Dry contact form A open collector or active voltage Minimum contact resistance to activate input 1000Ω Voltage threshold to deactivate the input 3 1V referenced to GND terminal Voltage threshold to activate the input 0 5V referenced to GND terminal Conductor pairs must be shielded to prevent spurious signals Figure 1 8 Typical DI point schematic Figure 1 9 DI c...

Page 29: ...owing measurement parameters or conditions Differential pressure over high limit Volume set point Differential pressure under low limit Flow temperature low Static pressure over high limit Flow temperature high Static pressure under low limit Flow rate low Low charger voltage Flow rate high Remote sense is on Trip on digital input Custom programmable by Totalflow or user programmable with IEC 1131...

Page 30: ... 1 11 Typical DO point schematics DO connection example Figure 1 12 DO connection example 1 2 3 4 Analog input The G4 EX provides one analog input as a means of receiving data represented by continuously varying voltage current Open circuit voltage 0 VDC Short circuit leakage current 0 uA typical Input impedance 103 5KΩ typical 0 to 10V Measurable input voltage range 0 to 10 34 VDC Maximum voltage...

Page 31: ... the factory calibrated smart integral multivariable transducer The EXIMV is characterized over temperature so that any changes occurring in the EXIMV or in the electronics can be compensated Providing the primary measurement capability for the G4 EX see Figure 1 15 the circuitry and characterization information are stored in the raw sensor board EXIMV specifications are discussed in Table 1 6 ...

Page 32: ...12 FS 0 0012 FS effective signal resolution Mounting spec Change from perpendicular front to back around X axis 0 5 URL Static pressure Accuracy Linearity Hysteresis and repeatability combined 0 075 of user calibrated spans from 20 to 100 of URL Ambient temperature effect within the operational temperature limit 0 075 of URL 0 06 of Reading Stability 0 1 of URL for 12 months Differential pressure ...

Page 33: ...lizes four lines by 16 characters The user can then customize the annunciators based on their own specific needs The alarm codes and annunciators communicate a basic message s to the user and indicate a need for further attention These codes are location dependent and may mean different things based upon which character space the code appears in These are also user configurable Figure 1 16 Liquid ...

Page 34: ...1691 070 3 00 2101691 030 8 00 2101691 080 4 00 2101691 040 9 00 2101691 090 5 00 2101691 050 10 00 2101691 095 Table 1 8 Standard Thermowells Thread Diameter U Length Base Part Number 2 through 10 1622305 1 2 through 10 1622302 3 4 2 through 10 1622300 1 2 7 6270 Optional Equipment Unit OEU The G4 EX unit is designed to be located in DIV 1 Hazardous areas therefore many features and requirements ...

Page 35: ...ations Figure 1 18 Optional communication enclosure 1 2 8 Solar panel A solar panel can be configured in the system to provide a charging source for the battery DIV 1 installations would require that the solar panel and battery pack be installed in a General Purpose or DIV 2 area Typically the solar panel would be connected through a charger regulator that is located in the 6270 OEU Depending upon...

Page 36: ...acity 2 mA to 2V 2 1 Ah Rated voltage 3 6 V Wires AWG 24 Enclosure UL 94V2 Mounting Hook and loop fastner Operating temperature range 55 C to 85 C 67 F to 185 F 1 3 G4 EX application licensing The G4 fourth generation EX offers the user unrivaled power and flexibility The G4 EX units can support far more applications than the G3 third generation devices Various applications require that Totalflow ...

Page 37: ...pplications include System Application Communications I O Subsystem Therms Master Therms Slave Analysis Trend System LevelMaster Pulse Accumulator NGC Client PID Controller Operations XMV Interface Holding Registers Units Conversion Host Interface Displays General applications typically provide some type of measurement control logging and or archival function General applications include AGA 3 Mea...

Page 38: ...og at the top of each contract day Unlicensed applications cause the meter to connect more slowly 1 4 Laptop computer running PCCU32 PCCU32 software running in a laptop Windows environment offers the user the most capabilities for programming the G4 EX The Windows environment features user friendly help files and easy to follow menus If configured with the USB option the laptop computer connects v...

Page 39: ...meter s round military connector see Figure 1 20 Connecting the PCCU cable to the meter will cause the annunciator in the LCD to display an upper case letter L for local connect The G4 EX meter must be ordered to include serial communication capability A change over kit may be purchased to adapt the G4 to USB capability Figure 1 20 RS 232 local communication cable 1 5 2 PCCU32 USB connection The l...

Page 40: ...g using Bluetooth functionality This option can be accessed through PCCU32 1 5 4 Network connectivity dynamic IP with router When the user elects to operate the G4 EX in a network environment using an Ethernet is a practical solution PCCU32 communication with the meter over an Ethernet connection TCP IP requires the use of a hub switch or router along with the appropriate cabling see Figure 1 23 E...

Page 41: ...2104349 rev AD Page 1 27 Figure 1 22 Ethernet communication cable Figure 1 23 Ethernet connectivity diagram ...

Page 42: ......

Page 43: ...he shipping carton is damaged keep it until the contents have been inspected for damage Inspect the unit s exterior for dents chipped paint etc Inspect the LCD window for breakage Visually inspect the electronic boards cables and EXIMV for damage 2 1 3 Damaged components If any components have been damaged or if there are noticeable defects notify the Totalflow representative Keep all shipping mat...

Page 44: ...top of the 2 pipe with the U bolts Use the provided hex nuts flat washers and spring lock washers to tighten the pole mount bracket to the 2 pipe Position the mounting bracket high enough on the pipe to allow slope from the externally mounted manifold to the tap valves 2 Position the provided back clamp on the pole mount bracket and align the mounting holes between the two pieces 3 Upon alignment ...

Page 45: ...ing kit assembly and associated hardware 2 2 2 2 Materials not supplied One 2 x 40 pipe Standard 3 or 5 valve manifold Stainless steel tubing 2 2 2 3 Step by step instructions To install the G4 EX it is recommended that two people perform the installation One to hold the unit in position and the other to install and tighten the mounting brackets The method of installation must be consistent with t...

Page 46: ...ansducer s bottom mounting holes with those on the pole mount bracket 8 Upon alignment replace the hex screws hex nuts flat washers and spring lock washers through their respective mounting holes on the mounting brackets and into the pole mount bracket Upon completion tighten see Figure 2 2 Figure 2 2 Type B Installation Configuration It should be noted that if this is the type of installation con...

Page 47: ...t bracket to the 2 pipe Position the mounting bracket high enough on the pipe to allow slope from the externally mounted manifold to the tap valves 2 Position the provided back clamp on the pole mount bracket and align the mounting holes between the two pieces 3 Upon alignment take the G4 EX and its attached transducer and set it within the recessed groove on the back clamp 4 Once the G4 EX and it...

Page 48: ...s steel tubing Tubing fittings A backup wrench should always be used when working with stainless steel tubing and valves This prevents the fitting from turning and or putting tension on stainless steel tubing Figure 2 4 G4 EX EXIMV ports 2 2 4 2 Step by step instructions 1 Install the isolation valves on the meter run 2 Install the tubing between the meter run and the XFC It should be noted that t...

Page 49: ...Nylon tie wraps 2 2 5 2 Materials not supplied Customer must specify Thermowell U length Teflon tape 2 2 5 3 Step by step instructions 1 Install the Thermowell into the meter run see Figure 2 5 The power should be removed from the G4 EX before performing any field wiring 2 Using snap ring pliers adjust the probe length so that it is spring loaded against the bottom of the Thermowell 3 Screw the pr...

Page 50: ...able to the meter run pipe with plastic tie wraps Do not wrap cable around the meter run pipe 2 2 6 Explosion proof RTD probe assembly If the G4 EX is installed in a DIV 1 area the explosion proof RTD must be used see Figure 2 7 The following procedures assume that the explosion proof RTD kit was purchased as an option For additional information refer to the Wiring Interconnect and Application Ins...

Page 51: ...itting Be aware that the union nut is on the union bottom Tighten Figure 2 8 Explosion proof RTD disassembled 4 Screw the union top into the bottom of the connection head and tighten 5 Unscrew and remove the cap from the explosion proof Connection Head 6 Insert the RTD probe through the opening in the head Holding the probe from underneath screw the spring clockwise down into the center of the wir...

Page 52: ...he unit 2 2 7 6270 Optional Equipment Unit OEU installation If the 6270 OEU enclosure is used it may be configured to include other options including but not limited to a battery pack to provide power to the G4 EX communication equipment and solar panel charger Following local codes for installation this unit would normally be located in a DIV 2 or General Purpose area The unit may be mounted on a...

Page 53: ...ep by step instructions Instructions assume that the user has completed the installation of the 2 pipe 1 Using the instructions supplied with the mounting kit attach the bracket to the back of the enclosure unit 2 Position the unit on the 2 mounting pipe and secure in place with two U bolts flat washers lock washers and two bolts see Figure 2 10 2 2 7 2 Wall mount Before beginning review the proce...

Page 54: ...the following procedures The battery is packed and shipped separately from the 6270 OEU Before installation inspect the power cables that are located inside the 6270 OEU where they terminate on the battery pack and the connector for breakage Before beginning review the procedures and the materials required for installation To extend the life of the battery pack fully charge the battery prior to in...

Page 55: ...lling and verifying the connection on the lithium battery The lithium battery is disabled when shipped from the factory The user will need to connect the battery before continuing 2 2 9 1 Step by step instructions 1 To connect the battery remove the front cover of the G4 EX Look for the battery connector behind and to the lower right side of the display see Figure 2 13 2 On the G4 EX board the lit...

Page 56: ...r to the Battery Pack Installation section Exercise caution when installing the solar panel so as not to damage it For solar panel installations where the panel is mounted on the top or to the side of a meter house please insure that the panel receives full sun all day When mounted the solar panel will face up from the horizon at a 50 angle and face in a southern direction The 6270 OEU system with...

Page 57: ... the 2 extension pipe with U bolts and associated mounting hardware Do not tighten the U bolts until the solar panel has been correctly oriented 6 For northern hemispheres position the solar panel facing south for southern hemispheres position the solar panel facing north For optimum charging the solar panel should not be in shadows for any portion of the day The panel should be kept clean for max...

Page 58: ...ead to the terminal and the wire to the terminal 15 Following the connection of the solar panel power cable secure the cable to the 2 extension and mounting pipe cable with the provided plastic tie wraps 2 2 11 AC charging unit installation The AC power charging unit maintains a constant voltage charge on the installed battery pack see Figure 2 15 2 2 11 1 Materials supplied AC charging unit Pipe ...

Page 59: ...e outside of the lock nut from the nipple Leave the sealing ring and inside lock nut Figure 2 15 AC charger installed Figure 2 16 AC charger outlet box installation 4 Feed the AC charger s DC power lines into the enclosure see Figure 2 16 ...

Page 60: ...bottom of the enclosure 9 Pipe the conduit and associated AC wiring into the AC charger conduit box The AC charger is rated at either 120 VAC 60 Hz or 240 VAC 50 Hz Connect the 120 V hot and neutral or the two hot wires for 240 V to the terminals of the AC charger Connect the ground wire to the green screw 10 Verify that the DC power wires are terminated properly inside the 6270 OEU cabinet and th...

Page 61: ...2104349 rev AD Page 2 19 Figure 2 18 G4 EX to UPS ...

Page 62: ......

Page 63: ...tion has not been turned off If the Install Program does not automatically load click on Start and then Run Type the CD DVD drive letter plus setup For example E setup Click the OK button 2 The Install Program will load followed by a Welcome message Click the Next button 3 A screen will display that asks for user information Complete entering in the relevant information and enter the serial number...

Page 64: ...al port located on the unit 2 The user needs to open PCCU32 Upon selection PCCU32 will open 3 With the MMI cable connected click the Connect icon on the PCCU32 main toolbar The Local Connect screen will display If the invalid security code screen displays enter four zeroes 0000 for the new code and click the OK button The G4 EX should have defaulted to 0000 on start up If the meter has been given ...

Page 65: ...river Totalflow inf 3 2 2 1 Step by step instructions 1 If the G4 EX and laptop are powered up when the connection is made the user will receive the Found New Hardware Wizard screen see Figure 3 2 When this screen displays the user needs to select the No not this time radio button Click Next Figure 3 2 Windows found new hardware wizard 2 To install Totalflow inf select the Install from a list or s...

Page 66: ...Page 3 4 2104349 rev AD Figure 3 3 Specific location selection window Figure 3 4 Specify location for USB driver Totalflow inf ...

Page 67: ...etooth adapter into the computer Ensure that all the relevant drivers are installed and the device is working properly 2 Open PCCU32 From the PCCU32 main toolbar select the System Setup icon This will take the user to the System Setup dialog box 3 The user will need to click the Bluetooth radio button to establish that this is the method by which they are connecting 4 Once this has been accomplish...

Page 68: ...oth Figure 3 6 Select a Bluetooth device dialog box 8 The user can close out of the System Setup dialog box and press the Connect button PCCU32 will attempt to pair with the selected Bluetooth supported Totalflow device and establish communication with it ...

Page 69: ...t After this is accomplished the user can set the com port in the drop down list provided on the System Setup dialog box 11 The user will then need to close the System Setup screen and connect to PCCU32 to communicate with the device 3 2 4 Setup of the G4 EX for Ethernet connectivity To set up the G4 EX for an Ethernet connection the user must first connect locally using either the RS 232 or USB c...

Page 70: ...and set the Enable DHCP parameter field value to Yes The other fields within the tab will auto populate Click the Send button 4 Next the user will need to locate the Totalflow TCP selection under Communications in the PCCU32 tree view see Figure 3 9 Once selected the user is taken to the Setup tab In this tab the user needs to set the Protocol parameter value to Totalflow TCP When done click the S...

Page 71: ...op down menu select Setup From the fly out menu select System Setup 6 Within the System Setup dialog box see Figure 3 10 click the TCP IP radio button Next enter the network ID or IP address for the meter in the corresponding parameter field The network ID is the same ID that the user entered earlier within the meter setup 7 Upon finishing click the Close button ...

Page 72: ... meter For instructions on how to accomplish this task follow steps 10 12 otherwise the user may continue on to the next section 10 Create a desktop shortcut and assign a name to it For the sake of the example the following will use the meter s ID for the shortcut name 11 The user will now need to point to the version of PCCU32 that they want to use the user may have multiple versions of PCCU32 on...

Page 73: ... Two 1 Connect locally using either the RS 232 instructions or the USB instructions covered in the previous section s 2 In PCCU32 Entry mode select Communications from the tree view see Figure 3 12 Upon selection click on the Network tab 3 In the Network tab set the Enable DHCP parameter field value to No Click the Send button The remaining parameter fields within the Network tab will auto populat...

Page 74: ...IP address on the board 7 The user will need to reopen PCCU32 but do not connect 8 From the PCCU32 toolbar click the Setup icon This will take the user to the System Setup dialog box see Figure 3 13 9 Within the System Setup dialog box the user needs to select the TCP IP radio button 10 Move to the Network ID or IP parameter field and type in the IP address that was established in step 4 11 Click ...

Page 75: ...ered and programmed for the most widely used configuration Depending on the programming device that is being used the following are minimum required entries Specific information required to complete each step is discussed in the PCCU32 Help Files 3 3 1 Date time The G4 EX date and time should be set before other tube parameters are entered This insures that events are properly dated and time tagge...

Page 76: ...read across three elements the flow meter PCCU32 and WinCCU32 Currently there are three types of security that are possible Device enforced legacy level 1 2 security WinCCU enforced legacy security Device and PCCU32 enforced Role Based Access Control RBAC security The following sections will cover these security options 3 4 1 Device legacy bi level security The G4 EX has a security switch S2 on th...

Page 77: ...for a WinCCU32 operator Modbus access to the meters is not protected by the security codes 3 4 1 2 PCCU32 software security PCCU32 will require the appropriate security code to be entered 1 To enter the security code the user will need to move to System Setup in PCCU32 2 Enter the appropriate security code and select Close In the provided example see Figure 3 15 the operator has been provided with...

Page 78: ...has to be entered to access the operating parameters even if there is one programmed into the device 3 4 2 WinCCU32 software security WinCCU32 also requires the appropriate security codes be entered in the Device ID see Figure 3 16 1 Highlight the appropriate meter in WinCCU and click Edit ID 2 Enter either the level 1 or level 2 security code 3 Click OK ...

Page 79: ...list of access roles that are relevant to the user s company hierarchy From this role list it is then possible to create user accounts with various assigned roles The user is also given the ability to take the newly created configuration and save it in the form of a security file to their PC The security file can then be sent to a G4 device where it is then implemented RBAC is enforced by both the...

Page 80: ...en selected the Security Editor dialog box displays see Figure 3 18 Figure 3 18 Security Editor dialog box RBAC security files are supported by G4 and NGC devices The user is given the ability to select the device type that the security file is specifically intended for For each role it is possible to set the access level for each function that is listed The Entry View function sets the highest se...

Page 81: ...ty files to and from G4 devices 3 4 3 3 Role creation The following instructions will walk the user through the steps for creating a new role 1 Select the row that has the corresponding access level that the user wants Upon location click the Copy button 2 A dialog box displays and asks for the name of the new role Assign a name to the role The new role is then available in the Roles dialog box 3 ...

Page 82: ...as a default file name suggested for saving The Open button opens a security file from the PC for editing see Figure 3 18 The New button clears all users and starts editing a new security configuration with default roles and no users RBAC security files are saved with a unique extension rba by default There is also a default directory that hosts these files The directory is configurable by selecti...

Page 83: ...urity file Under each port which has a protocol specified is a parameter field called Authentication This parameter can be set to Disabled Enabled or Enable by Security Switch See Figure 3 23 Disabled Does not perform any RBAC functions on the port Enabled If the administrator name and or password are lost or forgotten it will be necessary to use TfLoader to delete TfCold and TfData and then cold ...

Page 84: ...isable the default RBAC credentials select the menu item Operate Setup System Setup see Figure 3 25 After a security file is sent to a Totalflow G4 device the user is disconnected from the device and asked to re login under the following circumstances RBAC security was not enabled on the connected port before the security file is downloaded The user is not defined in the new security file The user...

Page 85: ...when a user logs in the user name the port where the access was made and the actions taken before logout Log entries are also generated when a security file is downloaded and or processed Additionally the results of applying the configurations will also be logged every time a new security file is downloaded This tab is available in Advanced and Expert view modes see Figure 3 26 ...

Page 86: ...bration access rights a user must also have read write access to the following applications System Flow measurement I O subsystem Display application For calibrating wireless I Os the user must have Read Write access to the Wireless I O application and the Communication Ports application For calibrating the XMV the user must also have Read Write access to the XMV Interface application and the Comm...

Page 87: ...utton If the user inserts the credit key in a different USB port on the computer it will need to be installed for that new USB port In other words the credit key must be installed on each available port if the user does not intend to use the same USB port each time they use the credit key 3 5 2 Access view the Credit Key with PCCU32 7 0 or later To access and view the credit key the user must use ...

Page 88: ... rev AD Figure 3 27 Credit Key License Utility 5 The number of credits will display This is the same dialog box that the user would use to add more credits to the credit key Figure 3 28 Credit Key License Utility Status ...

Page 89: ... plugged in 6 Upon connection with a Totalflow Order Entry representative click the OK button 7 The representative will ask the user to read the five 5 encrypted codes that appear directly beneath the Do Phone Update button Read them from top to bottom see Figure 3 29 Figure 3 29 Application Credit Key entry screen 8 The representative will give the user four codes to enter in the provided fields ...

Page 90: ...e Figure 3 31 2 Install the credit key in an available USB port 3 Click the Load button to view the available credits This screen enables the user to see the licensing status of the G4 EX as well as the available credits on the credit key The left pane shows the type and amount of the available credits on the credit key The upper right pane is for information purposes only It shows the various ava...

Page 91: ...4 devices Credits can be transferred from the G4 EX The user selects the type of credit and the amount of those credits to be transferred If the G4 EX has a surplus of credits these credits can be transferred to the credit key to be used on other meters If the G4 EX requires additional credits these credits can be transferred from the credit key See the previous section for the steps on how to acc...

Page 92: ... what credits are in the machine what credits are being used and any surplus or deficit of credits A surplus of credits is highlighted in green A deficit of credits is highlighted in red 4 Select the Transfer to Credit Key button see Figure 3 32 5 In the Type drop down field select the credit type from the available selections 6 In the Amount field set the number of credits to transfer 7 Upon comp...

Page 93: ...c 2 sec 5 sec 10 sec 20 sec 30 sec 1 min 2 min 5 min 10 min 20 min 30 min and 60 min It is recommended to leave at the default of 1 second 3 6 4 Calculated method When the G4 EX is initially powered up the calculation method must be set The user has the option of setting the calculation method to AGA 3 1985 AGA 3 1992 AGA 7 or ISO 5167 Once the calculation type has been determined the user may tog...

Page 94: ...ed or live analysis data Many decisions involved with setting up the Fpv are dictated by the user s sales contract or company policy Table 3 2 Fpv analysis data Analysis Data Default Value Units NX19 Fixed Ft Fp AGA 8 1992 Detail All Others7 Fp for Fpv method NX19 Fixed 1 000 Yes No No Ft for Fpv method NX19 Fixed 1 000 Yes No No Heating Value8 1000 0000 BTU SCF Yes Yes Yes Argon 0 0000 mol No Yes...

Page 95: ...ube gas orifice meter there are certain constants or parameters that may need to be entered or changed from the default values Table 3 3 displays the list of these constants Table 3 3 Gas Orifice Constants Parameters Default Value Units AGA 3 1985 AGA 3 1992 AGA 7 ISO 5167 Configurable Auxiliary Factor Faux 1 0 Yes Yes Yes Yes Barometric Pressure PSIA Yes Yes Yes Yes DP Zero Cutoff 0 0000 In H2O Y...

Page 96: ...992 AGA 7 ISO 5167 Configurable Dp High Limit 2047 9688 In H2O Yes Yes N A Yes DP Low Limit 0 In H2O Yes Yes N A Yes Flow Rate High Limit 1 000 000 SCF Hr Yes Yes Yes Yes Flow Rate Low Limit 0 SCF Hr Yes Yes Yes Yes RTD High Limit 420 Degrees F Yes Yes Yes Yes RTD Low Limit 0 Degrees F Yes Yes Yes Yes SP High Limit 2047 9688 PSIA Yes Yes Yes Yes Uncorrected Vol High Limit ACF N A Yes Yes Yes Uncor...

Page 97: ...ve from the meter run 3 Begin to slowly open the low side valve 4 Once both the high and low sides are completely open close both bypass valves 3 7 2 Setting G4 EX Temperature Calculation The G4 EX temperature calculations can be set to the following conditions 1 RTD Installed This uses the RTD temperature input and stores the RTD temperature unless the RTD fails Additionally it then uses and logs...

Page 98: ...ated volume programmable SCF or MCF or MMCF BATTERY NN N VOLTS Battery voltage volts DIFF PRESS NNN N IN H2O Differential pressure inches H2O STATIC PRESSURE NNN N PSIA Static pressure static PSIA FLOW TEMP NN N DEG F Flowing temperature F YEST VOL NNNN N MCF Yesterday s volume programmable SCF MCF or MMCF PERIOD VOL NNNN N SCF Previous period volume last volume calculation period volume Orifice D...

Page 99: ...ted components that can render the G4 EX inoperable 4 1 4 Front Mounted LCD The user is informed of operational problems and operational limit violations by observing the alarm codes on the LCD display Troubleshooting techniques for dealing with these alarm codes is presented later in the manual 4 1 5 Returning Parts for Repair If a Totalflow component is to be returned to Totalflow for repair sec...

Page 100: ...ive or disk The Restore function downloads these files into the G4 EX s tfCold drive This safeguards the data and allows the user to restart the unit without the obstacle of reconfiguring the G4 EX should any problem arise 4 3 1 Step by Step Instruction 1 While the user is in PCCU32 click the Save and Restore Utility icon on the window s main toolbar 2 When the Save and Restore window displays cli...

Page 101: ...4 2 Software Warm Boot There are three methods of warm booting the system from a software standpoint 4 4 2 1 Method 1 1 Open PCCU32 The user needs to ensure that they are not connected initially and are at the Totalflow splash screen 2 Click the 32 Bit Loader icon on the toolbar This takes the user to the 32 Bit Loader screen 3 Within the screen the user needs to select the Reload radio button 4 E...

Page 102: ... Method 3 1 Move into Entry mode within PCCU32 2 Once this has been completed click the Terminal icon on the PCCU32 window toolbar This will bring up the Terminal window 3 Once in the Terminal window move to the terminal prompt and type in the following BOOT WARM Press Enter on the keyboard to initiate the warm boot 4 5 Performing a Cold Boot A cold boot occurs when the user cuts power to the boar...

Page 103: ...check in the options list beside Shutdown Flash Delete tfData and Start Flash A prompt will display that warns that a cold boot is occurring Click the Yes button to initiate a cold boot There is a chance that the user will see a PCCU32 dialog box display that informs them that the Target Device Loader is not working The user will need to follow the dialog box instructions to cold boot the system 4...

Page 104: ... new flow record is then written This period is also based on a 55 minute accumulation 4 6 3 Backward Clock Change Crossing an Hourly Boundary Hourly entry is made for part of the hour that has accumulated since making the last hourly entry This is the same as a Forward Clock Change Crossing an Hourly Boundary The G4 EX advances to a new day s data flow record and maintains the balance of the day ...

Page 105: ...ht conditions on a solar charged system or setting in storage will be less likely to recover than a battery pack that was quickly discharged from a short Store batteries in a cool environment for less drainage Figure 4 3 6270 OEU Configuration 4 7 1 Step by step instructions 1 Collect the data from the unit 2 Back up the configuration files following the instructions listed previously in this chap...

Page 106: ...charger regulator 10 Reconnect the charging source to the charger regulator 11 Monitor the LCD for normal operational reading and battery voltage 4 8 Replacing the G4 EX board The G4 EX board is mounted inside of the G4 EX front end cap To access and remove the G4 EX board perform the following procedures Remove power from the device or insure the area is known to be non hazardous before removing ...

Page 107: ... the device or insure the area is known to be non hazardous before removing any enclosure cover For further information refer to the certification drawing indicated on the device s nametag and national and local electrical codes 4 Gain access to the rear termination board by loosening the countersunk hex socket locking set screw in the rear end cap Use a 1 16 hex wrench to perform this task Upon c...

Page 108: ... BOARD 2103344 XXX I O EXPANSION ETHERNET J7 USB CLIENT J4 J12 3 1 J13 3 1 SECURITY RESET 7 9 9 VBATT OPERATE COMM2 5 5 RRTS COMM2 TXD TBUS RTS TBUS RXD RBUS CTS RBUS COMM2 SW GND VBATT OPERATE COMM1 RRTS COMM1 J11 Terminates RS 485 on COMM2 J9 Terminates RS 485 on COMM1 J12 Jumper Jumper Pin1 to Pin 2 for AI Jumper Pin 2 to Pin 3 for DOUT2 J13 Jumper Jumper Pin1 to Pin 2 for DOUT Jumper Pin 2 to ...

Page 109: ...p the board out of the device Please note that the board is still connected to the device through the cables in the back 12 Unplug the sensor connector cable J6 and the ribbon cable J1 from the G4 EX board see Figure 4 7 Remove the board from the G4 EX device 16 1 4 J4 16 1 J2 SD CARD JTAG LITHIUM CONTRAST 1 R1 XA1 1 J5 J3 L1 Primary Component Side SD CARD Potentiometer Processor Card Lithium Batt...

Page 110: ...r corresponding connectors Please note that both the sensor cable and ribbon cable pin 1 wire are red The red edge pin 1 of the cable should plug into the outer most edge of the connector pin 1 14 Take the lithium battery cable and attach the cable to its corresponding connector J5 15 Align the mounting holes on the G4 EX board with the standoffs Once aligned snap the board into place within the d...

Page 111: ...ation files following the instructions listed previously in this chapter 3 Verify that the LL battery alarm is not being displayed on the G4 EX LCD Remove power from the device or insure the area is known to be non hazardous before removing any enclosure cover For further information refer to the certification drawing indicated on the device s nametag and national and local electrical codes Term B...

Page 112: ... completion remove the ribbon cable from the J1 connector Figure 4 9 This will enable the user to remove the termination board from the G4 EX device Figure 4 9 Termination board secondary component side 9 Take the replacement termination board and attach the ribbon cable to the J1 connector Please note that the ribbon cable pin 1 wire is red The red edge pin 1 of the cable should plug into the out...

Page 113: ... 1 16 hex wrench to perform this task Upon completion unscrew the end cap 5 Disconnect the power connector J16 from the board mounted connector see Figure 4 5 6 Gain access to the LCD assembly by loosening the countersunk hex socket locking set screw in the front end cap Use a 1 16 hex wrench to perform this task When completed unscrew the end cap 7 After the end cap has been removed gently pull t...

Page 114: ...e device Please note that the board is still connected to device through the cables in the back 7 After the G4 EX board has partially been removed unplug the sensor connector cable J6 and the ribbon cable J1 from the G4 EX board This will allow the board to be completely removed from the device 8 The user will now see a manufacturing plate The lithium battery assembly is located on the back of thi...

Page 115: ...r of the transducer voids the transducer warranty If the transducer requires servicing the entire assembly must be removed from the unit packaged securely for shipping and returned to Totalflow Contact Totalflow Customer Service for instructions Figure 4 10 EXIMV installation overview 4 12 1 Step by step instructions 1 Collect data from the unit 2 Back up the configuration files following the inst...

Page 116: ...ational and local electrical codes 8 Gain access to the rear termination board by loosening the countersunk hex socket locking set screw in the rear end cap Use a 1 16 hex wrench to perform this task Upon completion unscrew the end cap 9 Disconnect the power connection J16 from the termination board mounted connector Remove power from the device or insure the area is known to be non hazardous befo...

Page 117: ...y turn counter clockwise until the transducer is free from the enclosure 18 Replace the transducer and raw sensor board with a new repaired spare unit of the same type and pressure rating 19 Reconnect the high low manifold lines and restore pressure 20 Reassemble the unit by performing steps 10 14 in reverse order 21 Following the instructions in section 4 3 restore the station files 4 13 Calibrat...

Page 118: ...vious five point check and the current five point check After a secure audit trail is archived WinCCU recalculates the flow volumes based on the previous and current markers This allows more accurate results of the flow volume 4 13 3 Static pressure SP calibration checks The G4 EX allows the user to check the static pressure calibration and log pressure marker check points The user should perform ...

Page 119: ... a pressure marker for atmospheric pressure PSIA Enter zero if in Gauge mode or the barometric pressure or contract value if in Absolute mode Click the OK button 10 Close the atmospheric vent valve 11 Click on the Enter Pressure Check Value 12 Connect Calibration Standard to the calibration test port 13 Pressure to the next preferred verification pressure 14 When the current reading stabilizes ent...

Page 120: ...adjustment Enter a low mid low mid mid high and high value During normal operation of the G4 EX the display provides continuous DP readouts however during this procedure the G4 EX is placed in a temporary Hold mode 4 13 4 1 Step by step instructions 1 Enter the Calibration menu s Check screen This places the G4 EX on HOLD Select the preferred measurement tube from the tree view 2 Select DP from th...

Page 121: ...U32 software When performing the following procedures wait for the G4 EX display to stabilize If the G4 EX is not in Calibration mode the display will not necessarily match applied cell pressures The G4 EX uses an absolute static pressure SP cell Absolute pressure measures the pressure referenced to a vacuum or sealed chamber This is different than a gauge cell which measures the pressure referenc...

Page 122: ...closed see Figure 4 12 7 Open both the high and low equalizer valves 8 Close both the downstream and upstream tap valves 9 Open the atmosphere vent valve 10 Click on the Low Cal Point button Verify the current reading is continuously updated This should represent the lowest calibration point 11 When the current reading stabilizes click the OK button otherwise enter a different value and then click...

Page 123: ...table Select 3 or 5 Point Calibration 3 Set the Transducer DP Pressure Range in the Calibration window before proceeding This should match the range reading from the tag or label attached to the transducer Target values based on the selected range will display in the Calibration table 4 Verify that the vent valve is closed see Figure 4 12 5 Open both the high and low equalizer valves 6 Close both ...

Page 124: ...was entered This is referred to as a Hold mode To exit Hold mode 1 Exit Calibration mode 2 Unplug the PCCU cable at the G4 EX connector 4 14 2 Calibrating onboard analog inputs The G4 EX comes standard with two analog inputs on the G4 EX board As the user enters Calibration mode the G4 EX moves into Hold mode and displays the current values When the user selects the Update checkbox the Current Val...

Page 125: ...re apply five volts to the AI terminals 8 Enter a value that represents the full range and represents the desired engineering units Upon completion click the OK button 9 If 3 Point calibration was selected move to the 50 Cal parameter field Once there apply three volts to the AI terminals 10 Enter a value that represents 50 and represents the preferred engineering units If performing a 5 Point cal...

Page 126: ...issues arise By using the Zero Transducer command all references to previous pressure markers are non existent eliminating the ability to adjust volumes based on previous markers Using the Zero Transducer capability assumes that the shift is linear This means that at different levels of pressure the transducer is off by exactly the same amount If this is not the case the user needs to recalibrate ...

Page 127: ...1 SHLD 2 Out 3 Plus 4 Minus 5 In If the user elects to calibrate using an 100 OHM RTD probe refer to the PCCU32 Help Files to view resistance and corresponding temperature readings 2 Select the RTD tab within the Analog Inputs tab sub menu under Onboard I O in the Calibration window 3 Select whether to perform a 3 Point 5 Point or Bias calibration Note that if a 3 Point is selected there will be 3...

Page 128: ...RTD s temperature will always be biased by this value however the RTD Installed box on the Setup tab must be checked for the RTD temperature and bias to be used If the bias needs to be negative enter a minus sign before the value The current temperature value under the Tf heading will increase or decrease to reflect the effect of the bias The bias does not affect the Fixed Temperature that is spec...

Page 129: ...ithin PCCU32 Next select the preferred measurement tube and then click on the Commands tab Change the value for the Reset Log Period to Yes This forces a new record to be written based on the old orifice plate size Additionally if the user wants to simultaneously zero the accumulated volume they can use the Reset Volume command instead It is recommended to perform either the Reset Log Period or th...

Page 130: ......

Page 131: ...ct errors or provide information that is useful in troubleshooting the device Alarm codes indicate that an operational problem exists The user is informed of operational problems and operational limit violations by observing the alarm codes on the right side of the LCD display 5 1 3 Sleep mode Totalflow units are designed to move into a low power mode Sleep when an insufficient supply voltage is p...

Page 132: ...n determining the probable cause and the steps required to correct the condition For the purposes of troubleshooting only those codes considered alarms or codes used to assist troubleshooting are discussed here The entire list of status and alarm codes can be found in Chapter 1 Table 5 1 contains a description of each G4 EX alarm code An alarm can be a word character letter or symbol ...

Page 133: ...r absolute differential pressure absolute static pressure or temperature readings exceed maximum counts or are less than the minimum counts If the A to D Converter readings are within range AD is shaded Y Communication Protocols Transmitting Data Sending a response N Receiving Data Processing request N Nak Negative Acknowledgement w packet list N Ack Positive Acknowledgement of receipt request N W...

Page 134: ... termination board 5 2 2 Troubleshooting a Low Lithium alarm LL When the Low Lithium alarm displays the lithium battery should be replaced immediately Failure to replace the lithium battery could result in a loss of data following a power loss Instructions for replacing the lithium battery can be found in Chapter 4 5 2 3 Troubleshooting an Analog to Digital Failure alarm AD The G4 EX must have a M...

Page 135: ...nged properly or the manifold may have blockage If the alarm is still present replace the transducer If the alarm is caused by the temperature channel move to Step 9 otherwise move to the next step 5 Set the EXIMV back to Factory calibration If this corrects the alarm recalibrate the EXIMV to correct field calibration If the alarm is not corrected continue to the next step 6 Perform a Warm start o...

Page 136: ...tified in step 4 to the probe or shield If there is continuity the RTD is defective Replace the probe If there is no continuity continue to the next step 9 Check the continuity of each second wire pair white as identified in step 7 to the probe or shield If there is continuity the RTD is defective Replace the probe If there is no continuity continue to the next step 10 Check the continuity of each...

Page 137: ...OHM Resistor 31 0 F to 33 0 F 123 OHM Resistor 140 8 F to 142 8 F 10 If either of the measured values are outside of the range remove power and replace the RTD 11 Return power and perform steps 9 and 10 again If either of the measured values are outside of range remove power and replace the main termination board 12 Return power and perform steps 9 and 10 If either of the measured values are outsi...

Page 138: ...blem that exists with the powering of the unit 5 3 2 Power supply test Various equipment configurations will necessitate moving to one or more additional tests from this location 5 3 2 1 Step by step instructions 1 Check that the power supply voltage setting the power supply current rating and the cables used for the installation meet the recommended requirements 2 If this is a new installation an...

Page 139: ... J5 J6 J3 AI DI DO RTD OUT SHIELD RTD RTD RTD IN TXD TBUS RTS TBUS RXD RBUS CTS RBUS COMM2 SW GND 2 3 4 6 8 2 3 4 6 7 8 1 2 XFCG4 6200EX POWER TERM BOARD 2103344 XXX I O EXPANSION ETHERNET J7 USB CLIENT J4 J12 3 1 J13 3 1 SECURITY RESET 7 9 9 VBATT OPERATE COMM2 5 5 RRTS COMM2 TXD TBUS RTS TBUS RXD RBUS CTS RBUS COMM2 SW GND VBATT OPERATE COMM1 RRTS COMM1 J11 Terminates RS 485 on COMM2 J9 Terminat...

Page 140: ...5 Ω 25W 17 8V 30 30W 16 8V 21V 10 Ω 40W 17 8V 5 3 4 Solar panel charging system test If the system setup includes a solar panel charger connected to the 6270 Optional Equipment Unit OEU and is not supplying the required voltage and current to the G4 EX unit the user may need to test the solar panel The following instructions contain the steps required to test the solar panel 5 3 4 1 Required equip...

Page 141: ...and clipping the negative lead of the DMM to the second wire If the solar panel is not above the minimum continue to the next step 8 Using the selected resistor from Table 5 2 for the solar panel wattage attach the selected resistor between the two solar panel wires 9 Clip the positive lead of the DMM to the upper side of the test resistor 10 Clip the negative lead of the DMM to the lower side of ...

Page 142: ...o be performed if the battery pack output voltage is not remaining consistent and no errors were found during the previous Power Supply Solar Panel Charging System or AC Charging Circuit troubleshooting tests 5 3 6 1 Step by step instructions 1 Disconnect the solar panel charger or AC charger located in the Optional 6270 enclosure 2 Disconnect the battery pack cable from the charger regulator This...

Page 143: ...battery voltage is above 11 VDC the G4 EX remains awake The G4 EX has a real time clock which maintains time and date during Sleep mode and writes an event record when entering and leaving the Sleep mode Upon wake up the G4 EX performs the following functions Stores present calculation period accumulations in the historical record Zeroes present calculation period accumulations Ends the current da...

Page 144: ...ubleshooting procedures are applicable to the G4 EX with an installed radio in the optional 6270 OEU Enclosure unit Use Figure 5 7 as an aid in troubleshooting communication problems The three basic types of radio communication that can be used between the G4 EX and a radio receiver are RS 232 Communications port programmable RS 485 Communications port programmable RS 422 Communications port progr...

Page 145: ...n board to the radio START Does Unit Respond to Host Comm Request RS 232 Communication Test YES NO Verify unit ID Security Code and Protocol are Correct NO YES Verify jumper and terminal pin wiring are correct END Transceiver Supply voltage within Specs YES Voltage supply from unit 11 9 VDC NO Investigate Power Supply Issues Figure 5 4 Transceiver Comm Check Substitute Communication Test Cable Tra...

Page 146: ...ter in conjunction with the RS 232 troubleshooting cable to test RS 485 remote communications 5 4 3 Transceiver supply voltage test Using the wiring information and guidelines supplied by the transceiver s manufacturer verify that the transceiver is receiving the manufacturer s suggested voltage If the unit is receiving sufficient voltage continue to the 6270 OEU Wiring Voltage Test If the transce...

Page 147: ...lined in the Power Troubleshooting section 5 4 5 Transceiver check 5 4 5 1 Step by step instructions 1 If available use a wattmeter to check the transceiver output power Refer to the manufacturer s documentation for measuring instructions 2 If available use two hand held transceivers and verify the communication path between the master and remote sites Voice activated interface can be used if avai...

Page 148: ...ate Comm1 Operate Comm1 Operate Comm2 Operate Comm2 Pin 5 Mirror Request to Send RRTS COMM1 Mirror Request to Send RRTS COMM2 Pin 6 Request to Send RTS Request to Send RTS Pin 7 Transmit Data TXD Transmit Data TXD Pin 8 Receive Data RXD Receive Data RXD Pin 9 Clear to Send CTS Clear to Send CTS When troubleshooting RS 232 mode verify the settings of COMM 1 SW 1 and COMM 2 SW2 on the termination bo...

Page 149: ...een COMM 1 J19 Pin 2 GND and Pin 7 TXD or COMM 2 J20 Pin 2 GND and Pin 7 TXD When the unit is transmitting to WinCCU the voltage should vary between 5 VDC and 5 VDC This would indicate that the unit is transmitting data If the unit is still not responding continue to the next test as directed in Figure 5 7 5 4 9 RS 232 OEU termination strip test Generally speaking these tests performed on the term...

Page 150: ...he data is being transmitted from the G4 EX unit the voltage should vary between 5 VDC and 5 VDC 4 Repeat steps 1 through 3 on the transceiver side of the termination strip 5 If any inaccuracy exists investigate wiring errors Figure 5 8 OEU termination strip 5 4 10 RS 485 communication test The following RS 485 serial communication test procedure is directed from Figure 5 7 and will assist the use...

Page 151: ...nCCU software must continuously be polling the meter Generally speaking these tests performed on the termination board will only verify incorrect or damaged wiring If all previous testing passed and all wiring jumper and terminations have been verified correct the termination board may need to be replaced but does not typically fail Contact Totalflow Customer Service See the Getting Help section f...

Page 152: ...omplies with Totalflow wiring instruction drawings For the purposes of these instructions the user may need to adapt for their individual installation 1 Using an oscilloscope if available measure the line driver voltage on the G4 EX side of the OEU termination strip see Figure 5 8 between BUS and BUS When the unit is receiving data from WinCCU the voltage should vary between 5 VDC and 0 VDC This i...

Page 153: ...or downloads with search capabilities Download Center Data Sheet XFC G4 6200 6201EX OVERVIEW 2104390 Start up Guide XFC6200 6201EX START UP GUIDE 2104263 User Drawing XFC G4 EX TERM BD COMM 1 COMM 2 GENERIC RS232 WIRING 2104215 User Drawing XFC G4 EX TERM BD COMM 1 COMM 2 GENERIC RS 485 WIRING 2104216 User Drawing XFC G4 EX 2103344 BD COMM1 TO MICRO MOTION 1700 2700 CORIOLIS RS 485 2104235 User Dr...

Page 154: ... 6 Flat Washer 4 each 6 32 x 625 Hex Female Spacer 4 each 6 32 x 75 LG M F Standoff 1 each I O Daughter Card Generic Wiring Diagram 1 each CD ROM with Specified Flash and Configuration Files 6 2 2 I O daughter card specifications This card expands the capabilities of the explosion proof flow computer by adding an additional 12 points of fixed analog and digital I O points Specifications for the I ...

Page 155: ...nstalled 6 2 4 Upgrading the flash 1 Open PCCU32 but do not connect 2 Once PCCU32 has loaded click on the 32 Bit Loader icon on the window s main toolbar The 32 Bit Loader screen will display Figure 6 2 32 Bit Loader screen Termination Board J21 PCCU Connector I O Daughter Card ...

Page 156: ...tification drawing indicated on the device s nametag and national and local electrical codes 1 Gain access to the termination board by loosening the countersunk hex socket locking set screw in the rear end cap Use a 1 16 hex wrench and then unscrew the end cap 2 Remove the four 6 32 x 625 standoffs located at the four corners of the termination board 3 Gently lift the termination board out of the ...

Page 157: ...ard to the termination board Do not over tighten 6 Reapply power to the unit Make the local connection using PCCU32 and the MMI cable Once physically connected open PCCU32 and move into Entry mode 7 In the PCCU32 tree view select the I O Interface application Once expanded click on the 6200EX I O Card sub menu If the user is communicating properly they will see the setup screens for the daughter c...

Page 158: ...mplementation This drawing does not completely illustrate the installation methods required for hazardous locations Prior to any installation in a Classified Hazardous Location verify the installation methods by the Control Drawing referenced on the product s name tag and national and local codes DO1 DO2 DO3 DO4 DO1 DO2 DO3 DO4 J3 1 8 AI1 AI2 AI3 AOut AI1 AI2 AI3 AOut 1 DI1 DI2 DI3 DI4 DI1 DI2 DI3...

Page 159: ...RTD IN 2 3 4 5 6 8 2 3 4 6 7 8 1 2 I O EXPANSION 1 2 3 4 ON OFF 1 2 3 4 ON OFF SW1 SW2 5 DB 9 Connector to XFCEX Board I O Expansion Connector J2 Mounted on Back DO1 DO2 DO3 DO4 DO1 DO2 DO3 DO4 J3 1 8 AI1 AI2 AI3 AOut AI1 AI2 AI3 AOut 1 DI1 DI2 DI3 DI4 DI1 DI2 DI3 DI4 8 1 8 J1 J2 I O Daughter Card P N 2102458 To Third Party Analog Devices SEE SHEET 2 To Third Party Digital Output Devices To Third ...

Page 160: ...Page 30 2104349 rev AD Analog Outputs The 0 20 48 mA analog output circuit is SINK mode only and requires the use of an external power supply The analog inputs must be defined in PCCU32 ...

Page 161: ...al inputs also function as event counters Digital Outputs Optically isolated type 1A switches Have a maximum ON resistance of 2 5Ω which can switch 48V AC DC at up to 200 mA at 60 C The outputs are isolated AC voltage for 1 minute at 25 C RH 60 between input and output from each other as well as the control circuit by 1500Vrms The digital inputs must be defined in PCCU32 ...

Page 162: ...igned to accept relatively high speed approximately 20Khz signals Therefore if a reed switch or other mechanical device subject to bouncing contacts is used the application will require the use of a capacitor across the contact of the switching device a value of 0 1 uF should be a good starting place Active Signal Must be capable of being connected to a 1K load which is tied to a 8 2V voltage sour...

Page 163: ...2104349 rev AD Page 33 ...

Page 164: ... 12 volts then only 7 volts would remain to operate the transmitter This may not be enough to fully operate the transmitter at higher loop currents The following discussion does not pertain to 1 5 VDC transmitters Totalflow flow meters employ a 250 OHM resistor to convert the 4 20 mA transmitter current loop to a 1 5 VDC signal In some meters this conversion is made by attaching a 250 OHM resistor...

Page 165: ...be used to power the 4 20 mA transmitter loop In other words VCC would now be 24 VDC Subtracting the 5 volts dropped across the 250 OHM resister would leave 19 VDC to power the transmitter VCC 2 wire line powered 4 20ma transmitter 250Ω User supplies 250Ω resistor and wires it across the AI input pins Flowmeter External to flowmeter VCC 2 wire line powered 4 20ma transmitter 250Ω Onboard 250Ω resi...

Page 166: ... range 20 mA through the 250 OHM resistor the user may want to reduce the value of the resistor For this example the following will drop it to 125 OHM or half A 4 20 mA current would now be converted to a 5 2 5 VDC voltage range Again during field calibration the user would have the 4 mA current represent 10bbls per hour and the 20 mA signal represent 100bbls per hour The voltage conversion using ...

Page 167: ...culated as shown in the figure below VCC 2 wire line powered 4 20ma transmitter R1 250 Ohm Onboard 250 ohm resistor selected using three pin shunt Flowmeter External to flowmeter 1 3 R2 250 Ohm External resistor added across onboard resistor Equivalent Resistance R1 x R2 R1 R2 250 x 250 250 250 62500 500 125 Ohms ...

Page 168: ... Texas Office Odessa 8007 East Business 20 Odessa TX 79765 Ph 1 432 272 1173 Texas Office Houston 3700 W Sam Houston Parkway S Suite 600 Houston TX 77042 Ph 1 713 587 8000 California Office Bakersfield 4300 Stine Road Suite 405 407 Bakersfield CA 93313 Ph 1 661 833 2030 Texas Office Pleasanton 150 Eagle Ford Road Pleasanton TX 78064 Ph 1 830 569 8062 We reserve the right to make technical changes ...

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