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ABB XSeriesG4, User Manual

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ABB XSeriesG4 User Manual Download Page 49

2 Installation 

XSeriesG4 Remote Controller User's

 

manual

 

2103334 Rev. AB

 |  37

 

 

Dual unit 

Wiring to a XRC

G4 

6990 dual unit is reflected by two termination panels on the rear of the enclosure, two XRC

G4

 boards in the 

interior and two display and local communication ports on the front. Likewise, if units are configured for the optional keypad, 
there will be two separate keypads on the front. 

Since wiring for the dual unit configuration is identical for each unit, all discussions will focus on the single unit configuration. 
Figure 40 shows the single and dual unit termination panel. 

 

Figure 40: Single and dual unit termination panels 

 

 

XRC #1

Unit #1

XRC #2

Unit #2

P6A

P6B

P8B

P8A

P20

P23

P18

P6A

P6B

P8B

P8A

P20

P23

P18

P6A

P6B

P8B

P8A

P20

P23

P18

SINGLE UNIT PANEL

DUAL UNIT PANEL

XRC #1

Unit #1

Summary of Contents for XSeriesG4

Page 1: ...An engineering milestone in the development of remote low power powerful control and measurement devices User s manual 2103334MNAB XSeriesG4 Remote Controller G4 XRC ...

Page 2: ...Series remote controller hardware 2 Standard enclosure 4 Rack mount enclosure 6 XRCG4 board specifications 6 XSeries on board input output 9 Display function 13 Functions of the XRCG4 14 XRCG4 application licensing 15 Display annunciators 16 Laptop computer running PCCU32 18 Local PCCU connections 18 Network connectivity dynamic IP with router 19 Optional keypad 19 Optional Totalflow input output ...

Page 3: ... AC charging unit installation 34 XRCG4 6990 rack mount installation 36 XRCG4 communication field wiring 38 3 XRCG4 startup 44 Overview 44 PCCU32 installation and setup 44 Establishing initial local communication 44 Set up the XRCG4 for Ethernet communication 46 Setting up the XRCG4 55 Application licensing credit key 59 ...

Page 4: ...ck 70 Components and spare parts 71 Replacing the lithium battery 74 Replacing the XRCG4 battery pack 74 Replacing the main electronic board XRCG4 76 Replacing the CPU engine card 78 Replacing the Liquid Crystal Display LCD board 79 5 Troubleshooting 81 Overview 81 Troubleshooting visual alarm codes 83 Power troubleshooting 87 ...

Page 5: ...iv Troubleshooting communications 94 Getting technical support help 99 Returning devices 100 ...

Page 6: ... Figure 23 XRCG4 6790 inside view 24 Figure 24 XRCG4 6890 inside view 25 Figure 25 XRCG4 6990 inside view 25 Figure 26 Typical pipe saddle installation 27 Figure 27 XRCG4 pipe mounting 27 Figure 28 Model XRCG4 6490 pipe mounted 28 Figure 29 Model XRCG4 6790 pipe mounted 28 Figure 30 Model XRCG4 6890 pipe mounted 29 Figure 31 Model XRCG4 6490 wall mounted 30 Figure 32 Model XRCG4 6790 wall mounted ...

Page 7: ...cation credits 65 Figure 65 XRCG4 board analog input calibration points 66 Figure 66 XRCG4 board pulse digital input calibration points 67 Figure 67 Optional Keypad P N 2100652 xxx 68 Figure 68 XRCG4 6490 component cable locations 71 Figure 69 XRCG4 6890 component cable locations 72 Figure 70 memory backup enable jumper 75 Figure 71 XRCG4 battery and charger connections 75 Figure 72 XRCG4 board co...

Page 8: ... XRCG4 Main Electronic Board to Termination Panel Correlation Chart 36 Table 11 XRCG4 on board jumper settings 41 Table 12 XRCG4 displayed items 57 Table 13 Optional Keypad Commands 68 Table 14 XRCG4 6490 and 6890 component identifications 72 Table 15 Additional spare parts 73 Table 16 Visual alarm codes 83 Table 17 Specifications for solar panels 89 Table 18 RS 232 field wiring on XRCG4 electroni...

Page 9: ...ord WARNING indicates a potentially dangerous situation Failure to observe this safety information may result in severe injury The text may state the hazard how to avoid the hazard and what the result would be if not followed WARNING Bodily injury This symbol in conjunction with the signal word WARNING indicates a potential electrical hazard Failure to observe this safety information may result in...

Page 10: ...he back cover of this manual Storage The device does not require any special treatment if stored as dispatched and within the specified ambient conditions Although there is no limit to the storage period the warranty conditions as agreed with the Company and as specified in the order acknowledgment remain unaffected Compliance EU Directive 2012 19 EU Waste Electrical and Electronic Equipment WEEE ...

Page 11: ...wer supply 2104365 XRCG4 2103329 BD AI to SeniorSonic 3400 2104388 XRCG4 2103329 BD COMM1 RS 485 w FCU power UCI2 RS 485 to Airlink Raven XT radio RS 232 2104551 XRCG4 2103329 BD COMM2 RS 485 w FCU power UCI2 RS 485 to Airlink Raven XT radio RS 232 2104552 XRCG4 2103329 BD or ABB FCB Coriolis meter using Hart to Modbus converter 2104922 XRCG4 2103329 BD to ABB FCB Coriolis meter ABB FCB Coriolis m...

Page 12: ...ocate and select Calibrate Diff Press Sensor Calibration Units Edit Menu item names in instructions Bold text and the capitalization of names agrees with the names as displayed on the HMI menu Use the right soft key to enter the Main Menu Programs including utility and accessory programs Title capitalization Microsoft Word URL All lowercase for a fully specified URL http www microsoft com seattle ...

Page 13: ... the XRCG4 6890 can accommodate up to 14 I O modules The XRCG4 is powered by a battery system which can be charged using solar panel 24 Vdc or 120 240 Vac chargers It is optimized for extremely low power consumption and is primarily designed for remote operation in harsh environments This system is made up of a NEMA 4X enclosure which can house battery power supply remote communications equipment ...

Page 14: ...4 95 EFT 1 kV EN61000 5 5 95 Surge 1 kV line to line 2 kV line to earth EN61000 4 6 95 Conducted Susceptibility 3 Vrms EN610004 8 93 Power Frequency Magnetic Field 3 A m EN610004 11 94 Voltage DIP and interrupt XSeries remote controller hardware The Totalflow XRCG4 models are each housed in an aluminum case With the exception of the size of the cases all models use identical components Components ...

Page 15: ...partment directly behind a hinged cover plate holding the DIN rail and installed modular components XRCG4 6890 The battery sets on the floor of the main compartment and houses the various optional battery packs that are available for the XRCG4 from one 8 ampere hour battery up to two 70 ampere hour batteries Solar panel The XRCG4 is configurable for a 10 Watt 20 Watt or 30 Watt solar panel The pan...

Page 16: ...ironments cold hot wet and salty Opening the door s latch s allows access to electronics battery radio and modular components This door may be locked for security purposes Figure 1 XRCG4 6490 3 Holes for 50 NPT Cord Connector 875 2 22 cm 13 70 34 798 cm PCCU Connector 18 80 47 75 cm 641 1 628 cm 703 1 785 cm 13 69 34 77 cm 13 25 33 655 cm 15 10 38 35 cm 18 00 45 72 cm 2 Holes for 75 NPT Cord Conne...

Page 17: ...esG4 Remote Controller User s manual 2103334 Rev AB 5 PCCU CONN 20 09 51 028 cm 18 70 47 498 cm 28 81 73 177 cm 15 52 39 42 cm 65 1 651 cm 28 00 71 12 cm 2 Holes for 50 NPT Cord Connector 875 2 22 cm XRCG4 Figure 3 XRCG4 6890 ...

Page 18: ...cifications The XRCG4 board is designed as a general purpose RTU motherboard that mounts in all XSeries enclosures It has the same footprint as its counterpart the XFC board extendable flow computer motherboard The specifications for the XFC board are given in Table 3 Figure 5 identifies the parts of the board and Table 4 provides the descriptions Table 5 2103329 xxx board specifications Component...

Page 19: ...pad equipment I O expansion Dedicated I2 C serial I O bus for TFIO module expansion Security switch On Off bi level on board security see section 3 XRCG4 Startup Time base stability 7 5 ppm parts per million I O scan rate 1 time per second Analog inputs 5 Single ended channels 0 10 Vdc or 0 20 mA loop Analog to digital resolution 18 bit maximum resolution 0 00038 FS 18 bit nominal resolution 0 001...

Page 20: ...RC Controller Board 2103022 J11 J12 1 3 1 J5 3 1 J9 3 1 3 3 1 J21 1 J22 3 1 J24 3 1 J25 3 1 J26 3 1 J1 3 Jumpers J21 22 24 25 26 configure AIs 1 5 for 0 10VDC or 0 20ma operation A jumper across pins 2 3 configures the associated AI for 0 10VDC operation SD CARD RESET XU1 S2 J13 J29 USB A B DISPLAY ETHERNET J28 CPU ENGINE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 19 21 22 25 24 23 26 27 28 F...

Page 21: ...User A I User D O User D I 2 may be used as High Speed P Is DI1 and DI2 Up to 6 communication ports Interface for TFIO modules The main electronic board XRCG4 board is an enhanced replacement for previous versions of the RTU main electronic board Specifications for digital pulse input digital output and analog input follow in the next few pages For a complete overview of the XRCG4 board see Figure...

Page 22: ...Short circuit leakage current 395 µA typical Input capacitance 0 1 µfd typical Maximum allowable voltage range on input 0 5 Vdc to 15 Vdc Maximum frequency input 100Hz at 50 duty cycle with debounce enabled Maximum frequency input 20KHz at 50 duty cycle with debounce disabled Input specification Dry contact form A open collector or active voltage Minimum contact resistance to activate input 1000 Ω...

Page 23: ... 5 XRC board items 19 and 20 Digital outputs can be programmed to trigger or activate on any of several AGA3 AGA7 or Liquid Measurement limits or thresholds The following are just a few of those conditions that can trigger one of the digital outputs Differential pressure over high limit Volume set point Differential pressure under low limit Flowing temperature low Static pressure over high limit F...

Page 24: ...tance Maximum pulse current 3 A for 5 seconds Maximum continuous sink current 2 A Analog inputs Figure 10 is a typical point schematic for the analog input Figure 11 shows an example of point connections for the AI and a typical 2 wire 4 20 mA field device Figure 10 Typical AI point schematic TYPICAL SINK OUTPUT FIELD WIRING BATTERY OR POWER POSITIVE TERMINAL 24 VDC MAX SOURCE BATTERY OR POWER COM...

Page 25: ...nly and not across the transmitter load resistor series combination Display function During the operation of the XRCG4 the front panel LCD continuously scrolls through the operating parameters The system will come with a group of standard system displays Table 7 shows typical display parameters however any parameter with a register address can be displayed The duration that the parameter is displa...

Page 26: ... a design that is practical and efficient The XRCG4 is simple to use and easy to learn It performs the following with minimum effort maximum speed and greater accuracy Capabilities Monitoring the operational limits to insure detection and reporting of malfunctions or abnormal site conditions Remote communications Real time measurement and control Acceptance and storage of system parameters from PC...

Page 27: ...te many of the applications From the factory the G4 unit has four general credits installed Several system configurations are possible with those four general credits for example AGA 3 1 credit with Valve Control 1 credit and Trending 1 credit using 3 general credits total Two AGA 3 or AGA 7 tubes 1 credit each tube with Trending 1 credit using 3 general credits total AGA 3 1 credit with Valve Con...

Page 28: ... run the various applications available in the G4 product line Credits can be transferred between the laptop and the G4 unit If a G4 has extra credits more than required to be fully licensed the extra credits can be downloaded to the credit key to be used on other G4 units NOTE If the G4 controller is running an unlicensed application that fact will be reflected in any reports generated from that ...

Page 29: ... Protocol LevelMaster protocol is selected for the port assigned to this annunciator L Local Protocol Displayed when PCCU part is active and running TOTALFLOW Local Protocol Packet Protocol The Totalflow Packet Protocol is selected on this port Valve Control V Displayed when Valve Control option is on an Expanded I O board plug in RTU Other Valve Control symbols do not apply Valve Control option i...

Page 30: ...n may be made using a USB cable Local PCCU connections RS 232 serial cable The local connection serial military connector requires an RS 232 serial port on the host computer generally a laptop A PCCU cable 2015240 xxx is required to connect the host computer to the meter s round military connector see Figure 13 Connecting the PCCU cable to the meter will cause an annunciator in the LCD to display ...

Page 31: ...et local communication in a remote area may also be utilized Figure 15 Ethernet communication cable Optional keypad The XSeries models may be configured to include the optional keypad see Figure 16 located on the front cover of the unit Keypad entry allows the user to monitor programmed display items without using additional equipment See Figure 17 through Figure 20 for outline dimensions NOTE To ...

Page 32: ...20 Figure 16 Optional keypad Figure 17 XRCG4 6990 with dual keypads FRONT VIEW WITH KEYPAD SIDE VIEW WITH KEYPAD ...

Page 33: ...1 System overview XSeriesG4 Remote Controller User s manual 2103334 Rev AB 21 10 60 XFC G4 Figure 18 XRCG4 6490 with optional keypad XRC 13 72 G4 Figure 19 XRCG4 6790 with optional keypad ...

Page 34: ... Totalflow I O TFIO modules are designed to accommodate low power harsh environments and economical cost requirements The system automatically recognizes the module types and configures the I O Scanner subsystem accordingly The modules are interfaced to the XRCG4 board by an I2 C bus On top of this bus Totalflow has implemented an efficient I O protocol to exchange information between the modules ...

Page 35: ... capabilities Table 9 TFIO module loading XFC G3 XRC G3 XFCG4 XRCG4 of Modules 9 22 9 22 All modules are designed to meet Class 1 Division 2 Group C and D Certification TFIO module hardware The I O module hardware is packaged in DIN mount enclosures that employ Phoenix contact technology for field wiring The modules also interconnect with each other to provide the necessary power and interface sig...

Page 36: ...24 Figure 22 XRCG4 6490 inside view Figure 23 XRCG4 6790 inside view ...

Page 37: ...iew XSeriesG4 Remote Controller User s manual 2103334 Rev AB 25 Inside front door Battery compartment Figure 24 XRCG4 6890 inside view Figure 25 XRCG4 6990 inside view XRC 1 XRC 2 Termination XRC 1 Termination XRC 2 ...

Page 38: ...on Inspect the shipping carton for any damage If the shipping carton is damaged keep it until the contents have been inspected for damage Inspect the unit exterior for dents chipped paint etc Inspect the LCD window for breakage Open the housing by first removing the bolt and releasing the latch or latches Visually inspect the Digital PC board cables and connectors for damage Damaged components If ...

Page 39: ...ting bolts Be certain pipe is securely installed in saddle NOTE To install the XRCG4 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 customer s company policy Position the XRCG4 on the 2 mounting pipe and secure in place with two U bolts flat was...

Page 40: ...re 29 Model XRCG4 6790 pipe mounted 17 20 43 688 cm 11 00 27 94 cm XRCG4 16 00 40 64 cm 0 6 1 524 cm 4 X 0 437 2 83 7 188 cm 0 75 1 905 cm 21 20 53 85 cm 14 56 36 98 cm 20 00 50 8 cm C L C L 0 6 1 524 cm 4 X 0 437 2 Pipe 2 03 O D 2 83 7 188 cm XRCG4 ...

Page 41: ...ng hardware Enclosure mounting brackets Customer supplied materials Four 1 4 machine bolts 10 screws NOTE If the XRCG4 is to be wall mounted the wall itself should have sufficient strength to support the hanging weight of the unit There should be no obstruction s that would prevent the XRCG4 door from being opened to access interior installed components or to interfere with installation of the sol...

Page 42: ...ameter machine bolts through the XRCG4 mounting brackets into the wall Securely tighten all bolts to secure unit to the wall 17 20 43 688 cm 11 00 27 94 cm 16 00 40 64 cm 0 6 1 524 cm 4 X 0 437 2 83 7 188 cm 0 75 1 905 cm Figure 31 Model XRCG4 6490 wall mounted Figure 32 Model XRCG4 6790 wall mounted 21 20 53 848 cm 14 00 35 56 cm 20 00 50 8 cm 0 6 1 524 cm 4 X 0 437 2 83 7 188 cm 0 75 1 905 cm XR...

Page 43: ...ect power cables where they terminate on the battery pack and the connectors for breakage The battery pack is mounted behind the removable metal battery plate cover The plate is adjustable for various sized batteries Step by step instructions Insert the battery pack into the battery compartment with its long dimension facing outward Connect the battery pack connector to the digital board battery c...

Page 44: ...o J16 If installation procedures are required for mounting the solar panel on the top or side of the meter house the user should contact Totalflow s Service Department go to section 5 5 Getting technical support help for additional information Materials supplied One solar panel Two U Bolts and fastening hardware Solar panel cable standard is 12 other lengths are available Solar panel mounting brac...

Page 45: ...es 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 the majority of the day The Panel should be kept clean for maximum charging Remove CHGR Input terminal block J17 from digital board Figure 34 Battery and charger input connections Insert solar panel power cable through an access h...

Page 46: ...t all components for evidence of damage Report any damage to the shipping carrier and to Totalflow s service department DANGER Serious damage to health risk to life To prevent injury only a licensed electrician should install AC power wiring to a customer supplied primary AC power source CAUTION LOSS OF CERTIFICATION To maintain system certification all wiring must comply with NEC 501 code and app...

Page 47: ...e 36 Loosen the terminal block securing screws and insert the black wire into plus terminal top and white wire in negative terminal bottom Retighten screws and reinstall the terminal block with wires attached Plumb the conduit and associated AC wiring into the AC charger conduit box see Figure 38 The AC charger is rated at either 120 Vac 60 Hz or 240 Vac 50 Hz Connect the 120 V hot and neutral or ...

Page 48: ...le depending upon whether the user ordered a single XRCG4 6990 or a Dual Unit with two XRCG4 controller boards Terminal designations on the back panel are identical to designated pin outs on the XRCG4 main electronic board s Any wiring instruction WI or User Drawing UD applicable to the XRCG4 will be applicable to the XRCG4 6990 but wired to the corresponding plug on the rear of the enclosure Tabl...

Page 49: ... units are configured for the optional keypad there will be two separate keypads on the front Since wiring for the dual unit configuration is identical for each unit all discussions will focus on the single unit configuration Figure 40 shows the single and dual unit termination panel Figure 40 Single and dual unit termination panels XRC 1 Unit 1 XRC 2 Unit 2 P6A P6B P8B P8A P20 P23 P18 P6A P6B P8B...

Page 50: ...CG4 board COMM 0 is the local port required for reading the XRCG4 with a laptop computer running PCCU32 COMM 1 and COMM 2 can be configured for any combination of RS 232 or RS 485 See Figure 41 for on board communications wiring inside the standard XRCG4 enclosure See XRC 1 Unit 1 Communications COMM1 232 485 Communications COMM2 232 485 VBAT GND SW VBAT OPER RTS RRTS DCD BUS RXD BUS CTS BUS TXD B...

Page 51: ...board as with any electronic board is susceptible to damage by static electricity or improper handling To prevent this from occurring the user should wear a grounding strap Remove power to the unit prior to changing jumper settings or field wiring to on board I O Figure 41 XRCG4 standard communication wiring ...

Page 52: ... I2C Bus Cable P 6 A P 6 B P 8 B P 8 A P 23 P 20 P 18 VBAT GND SW VBAT OPER RTS RRTS DCD BUS RXD BUS CTS BUS TXD BUS DO 1 GND DO 2 GND DI 1 GND DI 2 GND Figure 42 XRCG4 panel mount field wiring diagram Communication modules If the unit is configured for remote communications XA1 and or XA2 will contain a 21 pin communication module specific to either RS 232 RS 422 or RS 485 If using the RS 485 com...

Page 53: ...s both voltage input and current loop input AI A jumper across pins 2 and 3 establishes the associated AI as a 0 10 Vdc voltage input A jumper across pins 1 and 2 establishes the associated AI as a 0 20 mA Current Loop Input J1 Lithium Battery Backup J1 enables or disables memory backup via the lithium cell battery A jumper across pins 1 and 2 enables RAM memory backup If the jumper is removed or ...

Page 54: ...ions COMM2 232 485 VBAT GND SW VBAT OPER RTS RRTS DCD BUS RXD BUS CTS BUS TXD BUS 1 9 10 18 Digital I O DO 3 GND DO 4 GND DI 3 GND DI 4 GND Digital I O Analog Inputs AI 1 COM AI 2 COM AI 3 COM AI 4 COM 1 9 8 16 AI 5 COM 1 10 1 4 AUXPWR OUTPUT VBAT GND SW VBAT GND To TFIO Modules I2C Bus Cable P 6 A P 6 B P 8 B P 8 A P 23 P 20 P 18 VBAT GND SW VBAT OPER RTS RRTS DCD BUS RXD BUS CTS BUS TXD BUS DO 1...

Page 55: ...2 Installation XSeriesG4 Remote Controller User s manual 2103334 Rev AB 43 Figure 44 Other field wiring I O connections ...

Page 56: ...stallation is complete click Finish A new Totalflow PCCU32 window will appear This contains the shortcuts created in the start menu Copy the PCCU32 shortcut to the desktop if desired Establishing initial local communication As discussed previously local communication may be established in different ways RS 232 MMI cable or USB cable The unit may be configured for one or the other or both TCP IP is...

Page 57: ...k on the Connect Icon instead left most icon at the top of the screen The Local Connect screen displays other screen options in addition to the Entry screen When the selected screen displays you have connected successfully to the device NOTE If the Invalid Security Code screen should appear enter four zeros 0000 for the new code and click OK The XRCG4 should have defaulted to 0000 on startup If th...

Page 58: ...net communication The XRC s factory configuration has the Ethernet port disabled To setup the XRC for Ethernet connection you must first connect locally using either the RS 232 or USB cable as described in section 3 3 Establishing initial local communication Using this local connection enable and setup Ethernet based on the required scenario Connection of the XRC to a host PC or laptop for local c...

Page 59: ... the PC or laptop click Help from the Network screen To enable and setup the Ethernet port Establish a local connection to the Entry screen as described in section 3 3 Establishing initial local communication Connect the XRC Ethernet port to the PC or laptop Ethernet port with a crossover Ethernet cable Select Communications Network tab from the navigation tree The Network screen displays with opt...

Page 60: ...al or USB port may terminate as the XRC resets When the XRC completes its startup sequence connect to the XRC using Ethernet as described in section 3 4 2 Establish local point to point connection over Ethernet Establish local point to point connection over Ethernet To establish an Ethernet connection Make sure the Ethernet cable is connected to both the XFC and laptop Ethernet ports Restart PCCU ...

Page 61: ...mask IP parameter configuration is either manual static addressing or automatic dynamic addressing For manual configuration obtain IP parameters static addresses from your IT administrator and type the values in the required fields Static addresses are permanent and remain in the device unless configuration is changed The IP address must be unique reserved for the device For automatic configuratio...

Page 62: ...me that helps to identify the device uniquely Set Network Adaptor to Enable Configure the IP parameters Select one of the options based on your addressing method a If using DHCP for dynamic addressing set Enable DHCP to Yes Figure 49 Leave the additional default IP configuration intact as it will auto configure after Ethernet is activated Figure 49 Network tab Enable DHCP for dynamic addressing ...

Page 63: ...startup sequence restart PCCU and select the Entry icon to connect again If DHCP is enabled verify that the IP parameters display the fields should have auto populated Take note of the IP address assigned to the XRC If the parameters do not display the XRC was not able to obtain the parameters from the DHCP server a Verify that the Ethernet cable is plugged correctly to the network equipment b Ens...

Page 64: ...52 Establish network connection over Ethernet using default TCP port ...

Page 65: ...tion to work For additional details on the IP addressing setup for the PC or laptop click Help from the Network screen To establish a network connection Make sure the XFC is connected to the network equipment switch Start PCCU Click Setup from the toolbar The Setup screen for communication displays Figure 51 Under Communications select TCP IP as the PCCU connect method In the Network ID field type...

Page 66: ...e instance the lower Totalflow TCP The Setup tab displays In the Port Name value field type a name to uniquely identify the port or communication instance For example to identify the TPC port use TCP 9998 The port will not be confused with the default Totalflow TCP Click Send At the warning click Yes to confirm and save changes Click Re read to verify that the user defined name of the communicatio...

Page 67: ...thernet using non default TCP port Click Close to exit setup and return to the PCCU main screen Click Entry from the toolbar When the Entry screen displays the Ethernet connection over the network is successful Setting up the XRCG4 As previously instructed once physically connected to the XRCG4 the user instructs the host software to connect to the device At this time the software will actually re...

Page 68: ...XXXX 10 digit alphanumeric Location In WinCCU the host software the location field can hold up to 24 alphanumeric characters to describe its location An example could be the county name or road number Description Format Note Location XXXXXXXXXX 24 digit alphanumeric NOTE There are additional fields stored in WinCCU for uniquely identifying the meter including fields for entering the lease holder p...

Page 69: ...anumeric identifier DEVICE ID XXXXXXXXXX 10 Character alphanumeric application or tube identifier Bi Level security system Data and configuration security in the XRC is spread across two elements the hardware XRCG4 and the software PCCU32 and WinCCU32 The meters XFC XRC or µFlo have a security switch S1 on the electronic boards Password security is bi level read only security code level 1 or read ...

Page 70: ...l simply remain unchanged There are additional fields stored in WinCCU for uniquely identifying the meter including fields for entering the lease holder producer operator and buyer These fields reside on the host computer in the ID manager not in the XRCG4 PCCU32 security Accessing the meter with PCCU32 when the security switch S1 is activated requires the appropriate security code be entered 1 To...

Page 71: ...r and buyer These fields reside on the host computer in the ID manager not in the XRCG4 Figure 55 WinCCU32 Security Code entry in meter ID NOTE MODBUS access to the meters is not protected by the security codes Application licensing credit key Credit key driver installation Step by step instructions The credit key is very easy to install on a computer Simply plug the USB credit key into an availab...

Page 72: ...credit key in an available USB port Open PCCU32 and disconnect from the unit if connected Go to the Credit Key License Utility Operate File Utilities Credit Key License Utility NOTE To go to the Credit Key License Utility the computer cannot be connected to the G4 meter or controller Simply have PCCU32 running and the initial Totalflow screen displayed When the Credit Key Status and Update Utility...

Page 73: ...y License Utility Operate File Utilities Credit Key License Utility Insert the credit key into an available USB port Select Do Phone Update Figure 58 Figure 58 Credit key telephone update The user will be asked to call Totalflow Order Entry and insure that the credit key is plugged in NOTE If the user inserts the credit key in a different USB port on the computer it will need to be installed for t...

Page 74: ... Verification Codes The Totalflow representative will ask for the three codes to verify that the credits have been properly written to the credit key When finished click Update Transferring credits from credit key to device Credits can be transferred to the XRCG4 device The user selects the type of credit and the amount of those credits to be transferred NOTE If XRCG4 has a surplus of credits thes...

Page 75: ... of credit necessary to run the application The standard credits and four general credits come with the purchase of the G4 unit The lower right pane displays the licensing status of the G4 unit It shows what credits are in the machine what credits are being used and any surplus or deficit of credits A surplus of credits is highlighted in green A deficit of credits is highlighted in red Select Tran...

Page 76: ...tall the credit key in an available USB port Click Load to view available credits NOTE This screen shows the licensing status of the G4 meter controller 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 only It shows the various applications available and the type and amount ...

Page 77: ...nalog outputs and pulse inputs Hold mode When calibrating PCCU will instruct the XRCG4 to ignore live values for the period of time the XRCG4 is being calibrated This prevents real time XRCG4 calculations from being affected during the calibration During this time the XRCG4 uses the last known value at the time calibration mode was entered This is called the HOLD mode To exit the hold mode perform...

Page 78: ...ss the terminals to convert the 4 20 mA to 1 5 Volts Figure 65 XRCG4 board analog input calibration points When calibrating an analog input select either 3 Point or 5 Point for number of calibration points 3 Point for low 50 and 100 values and 5 Point for low 25 50 75 and 100 values In the Current Value box check Update This causes the AI to look for its source at the terminals instead of a test v...

Page 79: ...ions Click K Factor enter a value and click OK Input pulses are multiplied by the K Factor To have a one to one pulse count use a factor of 1 NOTE Take into consideration that these inputs may have the debounce enabled or disabled This feature is discussed in detail in Section 1 6 XSeries on board input output Look at jumpers J5 J11 J9 and J12 on the XRCG4 board DIGITAL I O J20 A J8 B J11 J12 1 3 ...

Page 80: ...screen Validate When setting up the XRCG4 display items the user may also set data limits so that when a programmed value is changed it must be valid between the high and low limit otherwise it will return an invalid code This is called Validate Keypad Entry and must be set to yes to be active Time Out Depending on how the display setup is programmed the Scroll Lock Timeout may be set After the pr...

Page 81: ... files to a laptop s hard drive or other external storage device This safeguards the data and allows the user to re start the unit without the need to re configure the XRCG4 should any problem arise Using the Save and Restore utility The Save and Restore utility provides the ability to back up the configuration files on the Totalflow devices The procedures in these sections show how to save the fi...

Page 82: ...es When the XRC completes its boot sequence verify the unit is functioning properly Changing the XRCG4 clock When any AGA applications are instantiated on the XRCG4 changing the clock could affect the time when log period entries are made To protect the integrity of accounting audit trails the XRCG4 handles these types of clock changes as follows Clock change not crossing an hour boundary When the...

Page 83: ... backward time changes less than one 1 hour the user should wait until the current hour has progressed far enough to make a change that does not cross an hour boundary Components and spare parts The XRCG4 components are identified in Figure 68 and Figure 69 Component details and Spare part list are available in Table 14 and Table 15 respectively 4 15 6 1 23 3 16 2 17 9 8 7 10 11 12 14 13 XRCG4 5 F...

Page 84: ...t Number 1 Enclosure N A 2 PCCU Internal Cable 2000073 xxx 3 Door 6490 1800308 xxx 3 Door 6790 1800309 xxx 3 Door w keypad 6490 2100548 xxx 3 Door w keypad 6790 2100924 xxx 4 Communication Bracket 2015260 xxx 5 External PCCU Connector Cap 1215000 xxx 6 LCD Display 2012804 xxx 7 SD Card 128 MB 512 MB 1 GB 1801747 xxx 1801749 xxx 1801750 xxx 8 Ethernet Connector N A 9 CPU Engine Card Connector N A ...

Page 85: ...ional spare parts Description Spare Part Number Pipe Saddle Mounting Kit 12 1310000 012x Pipe Saddle Mounting Kit 10 1310000 010x Pipe Saddle Mounting Kit 8 S00515 Pipe Saddle Mounting Kit 6 S00510 Pipe Saddle Mounting Kit 4 S00505 Pipe Saddle Mounting Kit 3 S00500 Pipe Saddle Mounting Kit 2 S00495 Key Pad Kit 2100652 PCCU Collection Cable to Laptop 2015240 xxx Solar Panel Charger 10 Watt 1488010 ...

Page 86: ...e door see Figure 68 XRCG4 6490 component cable locations and Figure 69 XRCG4 6890 component cable locations Remove the lithium battery cover from the battery bracket by inserting the flat blade of a small screwdriver between the cover and the side of the bracket This should free the cover from the bracket allowing access to the battery Grasp the battery on each side and pull from the bracket Note...

Page 87: ...s the battery pack in its mounting location by slightly loosening the three mounting screws It is not necessary to remove the screws Remove the battery pack from the battery compartment Insert a new battery pack into the battery compartment The battery pack must be positioned so that its longest dimension fits snugly against the keeper plate when the plate is installed Figure 71 XRCG4 battery and ...

Page 88: ...this order If used disconnect the external charging source J17 Figure 72 XRCG4 board connections Item 21 Disconnect battery pack connector J16 Item 22 Slide out to the right the following green terminal strips from its associated XRCG4 board connector Do not lift the connectors upward Tape an identifier to each connector so it will be correctly reinserted into the same board mounting connector dur...

Page 89: ...MM 2 Item 18 J6 COMM 1 Item 17 On board I O J8 B Item 16 J8 A Item 15 J23 Analog Input Item 11 J20 Auxiliary Power Item 13 J16 Battery Pack Item 22 J17 Charger Item 21 If the replacement board does not include a new engine card follow the instructions in section 4 8 Replacing the CPU engine card in this section RESET Figure 72 XRCG4 board connections ...

Page 90: ...d charger connections Second remove J16 the main battery pack With power removed gently with fingertips spread the connector fingers extending down from the CPU engine card connector Figure 73 These fingers extend down to the semi circular notches on the engine card When gently spread these fingers will release the engine card and it will spring up at a 30 degree angle from the main board Gently p...

Page 91: ...tfCold previously in this section Perform a COLD start following the instructions listed in section 5 3 8 Reset procedures Figure 74 Engine card replacement Replacing the Liquid Crystal Display LCD board The LCD board is mounted on the backside of hinged doors behind the XRCG4 board To access and remove the display board perform the following procedures Step by step instructions Most of the proced...

Page 92: ... does not come in contact with any metal surface Using a 3 16 nut driver remove the four display board hexagonal mounting standoffs Lift the board from the door mounted standoffs NOTE If the LCD board is being returned to Totalflow for service it is recommended that the attached ribbon cable be left connected and returned with the display board To reinstall the display board perform procedures 4 t...

Page 93: ...t those codes that reflect errors or provide information useful to troubleshooting 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 SLEEP mode Totalflow units are designed to go into a low power SLEEP mode when an insufficient supply voltage is pres...

Page 94: ...larm Codes START Call Totalflow Technical Support Return to START END Go To Power Troubleshooting Go To COMM Troubleshooting YES NO Receive Alarm Batteries Dead COMM Trouble Still Having Trouble YES NO YES NO YES NO Return to START Return to START Return to START ...

Page 95: ...d if the XRCG4 battery charging voltage is less than 0 4 Vdc higher than the battery voltage If charging voltage is 0 4 Vdc greater than the battery voltage then the annunciator is shaded Y Measurement Application AD A to D Failure Displayed if A to D Converter absolute differential pressure absolute static pressure or temperature readings exceed maximum counts or are less than minimum counts If A...

Page 96: ...ithium battery may be found in Section 4 Maintenance Troubleshooting a low charger alarm LC The Low Charger alarm is typically displayed if battery charging voltage is less than 0 4 Vdc higher than battery voltage or low light conditions exist and the system is charged using a solar power charger Step by step instructions Check the battery pack cable It must make a good secure electrical connectio...

Page 97: ...XMV to the correct field calibration If the alarm is not corrected continue to the next step Perform a WARM start on the unit Verify that unit is not displaying a LL Low Lithium alarm then remove power from the unit Restore power to the unit If the AD Failure alarm is not corrected continue to the next step Perform the Save and Restore function Follow the procedure in section 4 2 1 Using the Save ...

Page 98: ...k wiring using the supplied diagram Figure 78 If no wiring error was found perform the RTD current source troubleshooting test in section 5 2 7 RTD current source resistive test Supply wire to RTD Signal Input wire from RTD AI 5 COM AI 5 AI 4 COM AI 4 AI 3 COM AI 3 AI 2 COM AI 2 AI 1 COM AI 1 RTD A I Jumper Settings AI1 J21 AI2 J22 AI3 J24 AI4 J25 AI5 J26 Settings 2 3 0 10V 1 2 0 20mA 1 2 3 J20 Au...

Page 99: ...nce test If readings from the RTD are still suspect following the RTD probe test follow the instructions below to test the current source on the termination board to verify it is receiving power Required equipment Ice bath Digital multimeter Step by step instructions Immerse the RTD Probe in an ice bath Perform a continuity check between any two similarly colored wires Measured resistance should b...

Page 100: ... a new installation and external equipment is being powered from the XRCG4 call Totalflow Technical Support for help in evaluating the cable and power supply installation requirements Correct and retest as necessary Go To Power Supply Test START RETURN Go To TFIO Module Isolation Test Go To Remote COMM Test Chart Power Issue Located YES NO Return to Test Sequence Perform Isolation Tests Sequential...

Page 101: ...In the northern hemisphere the panel should face due south and in the southern hemisphere it should face due north Correct and retest as necessary Check the solar panel for any physical damage or obstructions to sunlight Sunlight obstruction prevents the solar panel from receiving enough sunlight to charge the installed battery pack Clean correct and retest as necessary The solar panel should be p...

Page 102: ...n to Figure 79 Power Troubleshooting flowchart and continue testing AC charging system test If the system setup includes an AC charger connected to the XRCG4 board and it is not supplying the required voltage to the unit test the AC charger The following instructions contain the steps required to do so Step by step instructions Check the DC wiring to the XRCG4 termination block connector J17 see F...

Page 103: ...r if used Connect the current measurement troubleshooting cable Part No 2017350 xxx see Figure 82 to a known good battery and re connect to XRCG4 board Using DMM connect to the troubleshooting cable and measure the average current If equal to or greater than 80 mA at 12 Vdc disconnect the battery pack and reconnect one auxiliary item Continue to next step If the average current is less than specif...

Page 104: ...EEP mode the word SLEEP is displayed on the LCD If XRCG4 battery voltage falls below 11 Vdc the XRCG4 enters SLEEP mode If battery voltage is still below 10 9 Vdc when disconnected locally the XRCG4 returns to SLEEP mode If battery voltage is above 11 Vdc the XRCG4 remains awake The XRCG4 has a real time clock which maintains time and date during SLEEP mode and writes an event record when entering...

Page 105: ... file go to Section 2 On the main PCCU screen on the top menu select Operate File Utilities Save and Restore Utility or click the Save and Restore Utility icon on the toolbar Click Save Station Files at the bottom of the screen The Save Station files dialog box displays In the Save to field verify or define the location path to save the backup file Take note of the file location for later retrieva...

Page 106: ...G4 board green terminal block Disconnect the battery pack connector from the XRCG4 board BATT CONN connector J16 see Figure 77 The XRCG4 is now out of service To place the XRCG4 back in service connect the battery pack connector J16 see Figure 77 Connect the CHGR INPUT terminal block J17 see Figure 77 WARM start procedure software Move into Entry mode within PCCU Once this has been completed click...

Page 107: ...rify jumper and terminal pin wiring are correct END Transceiver Supply voltage within Specs YES Voltage supply from XRC unit 11 9 VDC NO Investigate Power Supply Issues Figure 5 1 Transceiver Comm Check Substitute Communication Test Cable Transceiver Supply voltage Test Investigate Transceiver Issues Unit Respond to Host Comm Request YES NO RS 485 Communication Test Is Communication RS 232 YES NO ...

Page 108: ...emote communications Transceiver supply voltage test Using wiring information and guidelines supplied by the transceiver manufacturer verify that the transceiver is receiving the manufacturer s suggested voltage If the unit is receiving sufficient voltage continue to the 12 V Communication supply voltage test NOTE If the transceiver is not receiving sufficient voltage investigate power supply issu...

Page 109: ...and held transceivers and verify the communication path between master and remote sites Voice activated interface can be used if available Verify that the transceiver is set to the correct frequency Refer to the manufacturer s documentation for checking frequency instructions If a directional antenna is used verify the orientation to the antenna to the master site NOTE If a communication problem s...

Page 110: ...Data voltage on the electronic board J8 or J10 between COMM 1 or 2 pin 2 Ground and pin 7 Receive Data When the unit is receiving data from the host the voltage should vary between 5 Vdc and 5 Vdc This would indicate that the unit is receiving data Continue to Step 2 If the unit is not receiving data investigate wiring issues see Table 18 Using an oscilloscope measure Request to Send voltage on el...

Page 111: ...ng data from the host the voltage should vary between 5 Vdc and 0 Vdc This would indicate that the unit is receiving data Using an oscilloscope measure remote request to send RRTS voltage on the XRCG4 board J6 between COMM 1 or 2 pin 2 Ground and pin 5 RRTS When the unit is transmitting data voltage should vary between 5 Vdc and 0 Vdc This would indicate that the RRTS is working correctly If any i...

Page 112: ...cement or repair call for a Return for Authorization Number See Contact us on the back cover of this manual Follow all instructions provided and Returning part s for repair If a Totalflow component needs to be returned to Totalflow for replacement or repair Affix the Return for Authorization number to the outside of the return package Use the original packaging or a secure transport container of a...

Page 113: ...e battery has been discharged to 12 Volts then only 7 Volts would remain to operate the transmitter This may not be enough to fully operate the transmitter at higher loop currents NOTE 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...

Page 114: ...btracting the 5 Volts dropped across the 250 Ohm resistor would leave 19 Vdc to power the transmitter NOTE Another possible solution would be to reduce the 250 Ohm resistor to a smaller value possibly 125 Ohms An under powered transmitter could more easily drive 20 mA into the lesser resistance Field calibrating the AI would negate any differences between the 250 Ohm and the 125 Ohm resistors Howe...

Page 115: ...ty to resolve barrels of fluid per hour has been cut in half Overall accuracy remains unchanged but only about 006 bbl 6 thousandths of a barrel or about one fluid ounce can be resolved A 4 Conclusion If the 4 20 mA transmitter cannot drive a full 20 mA through the 250 Ohm resistor one option is to reduce the resistive value However as the resistive value is reduced resolution not overall accuracy...

Page 116: ... 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 or modify the contents of this document without prior notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any ...

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