EFLOW EF-Series Instruction Manual
Flow Computer Division
eFlow EF-Series Flow Computer
Instruction Manual
Form A6103
February 2001
Loose-leaf version: Part Number D301149X012
Bound version: Contact FAS
EF-Series Instruction Manual
Revision Tracking Sheet
February 2001
This manual may be revised periodically to incorporate new or updated information. The date revision
level of each page is indicated at the bottom of the page opposite the page number. A major change in
the content of the manual also changes the date of the manual which appears on the front cover. Listed
below is the date revision level of each page.
Page Revision
All pages 2/01
Fisher Controls International, Inc. 2001. All rights reserved.
Printed in the U.S.A.
While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from
reliance upon such information.
performance, merchantability, fitness or any other matter with respect to the products
process in conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the
products described herein.
ii Rev 2/01
Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the
, nor as a recommendation to use any product or
EF-Series Instruction Manual
Table of Contents
SECTION 1 — GENERAL INFORMATION ............................................................ 1-1
1.1 Manual Overview ........................................................................................................................ 1-1
1.2 Section Contents .......................................................................................................................... 1-2
1.3 Additional Information ................................................................................................................ 1-2
1.4 Product Overview ........................................................................................................................ 1-3
1.5 Installation Requirements ............................................................................................................ 1-7
1.6 Mounting.................................................................................................................................... 1-12
1.7 Power Consumption Calculation ............................................................................................... 1-15
1.8 Startup and Operation ................................................................................................................ 1-20
SECTION 2 — USING THE EF-SERIES UNIT ........................................................ 2-1
2.1 Scope............................................................................................................................................ 2-1
2.2 Section Contents .......................................................................................................................... 2-1
2.3 Product Functions ........................................................................................................................ 2-3
2.4 Product Electronics ...................................................................................................................... 2-8
2.5 Connecting the EF-Series unit to Wiring................................................................................... 2-15
2.6Configuration.............................................................................................................................2-26
2.7Calibration.................................................................................................................................2-27
2.8 Troubleshooting and Repair....................................................................................................... 2-28
2.9 Specifications............................................................................................................................. 2-35
SECTION 3 — COMMUNICATION CARDS ........................................................... 3-1
3.1 Scope............................................................................................................................................ 3-1
3.2 Section Contents .......................................................................................................................... 3-1
3.3 Product Descriptions.................................................................................................................... 3-2
3.4 Initial Installation and Setup........................................................................................................ 3-8
3.5 Connecting Communications Cards to Wiring.......................................................................... 3-10
3.6 Troubleshooting and Repair....................................................................................................... 3-13
3.7 Communication Cards Specifications........................................................................................ 3-15
Rev 2/01 iii
EF-Series Instruction Manual
Table of Contents (Continued)
SECTION 4 — THE FLOW SENSOR ........................................................................ 4-1
4.1 Scope ............................................................................................................................................4-1
4.2 Description ...................................................................................................................................4-1
4.3 Process Connections..................................................................................................................... 4-2
4.4 Sensor Wiring............................................................................................................................... 4-2
4.5 Configuration ...............................................................................................................................4-3
4.6 Calibration....................................................................................................................................4-4
4.7 Specifications ...............................................................................................................................4-8
GLOSSARY OF TERMS ............................................................................................. G-1
INDEX ..............................................................................................................................I-1
iv Rev 2/01
EF-Series Instruction Manual
SECTION 1 — GENERAL INFORMATION
1.1 MANUAL OVERVIEW
This manual describes the eFlow™ EF-Series Flow Computer, part of the family of flow computers
manufactured by Fisher Controls. Included in this manual are the following sections:
♦
Table of Contents Table of Contents
♦
Section 1 General Information
♦
Section 2 Using the EF-Series Unit
♦
Section 3 Communications Cards
♦
Section 4 Flow Sensor
♦
Glossary Glossary of Terms
♦
Index Topical Index
Table of Contents lists each section and information contained in that section of the document.
Section 1, which you are now reading, describes this manual and mentions related manuals. This
section also provides a summary of the EF-Series hardware, installation requirements, mounting the
unit, and power requirements.
Section 2 provides information and specifications concerning the use of the EF-Series Flow Computer.
Topics covered include the Main Electronics Board, wiring, configuration, and troubleshooting.
Section 3 provides information and specifications for the communications cards.
Section 4 describes the flow sensor included with the unit for sensing static pressure and differential
pressure.
Glossary of Terms defines terms used in this document and related documents.
Topical Index alphabetically lists the items contained in this manual along with their page numbers.
Rev 2/01 1-1
General Information
1.2 SECTION CONTENTS
This section contains the following information:
Information Section Page Number
Manual Overview 1.1 1-1
Additional Information 1.3 1-2
Product Overview 1.4 1-3
Options 1.4.1 1-6
Installation Requirements 1.5 1-7
Environmental Requirements 1.5.1 1-7
Site Requirements 1.5.2 1-8
Compliance with Hazardous Area Standards 1.5.3 1-9
Power Installation Requirements 1.5.4 1-9
Grounding Installation Requirements 1.5.5 1-10
I/O Wiring Requirements 1.5.6 1-11
Mounting 1.6 1-12
Mounting the EF-Series Unit 1.6.1 1-12
Mounting a Radio 1.6.2 1-14
Accessing the Battery Compartment 1.6.3 1-14
Power Consumption Calculation 1.7 1-15
Determining I/O Channel Power Consumption 1.7.1 1-15
Determining Auxiliary Power Consumption 1.7.2 1-16
Totaling Power Requirements 1.7.3 1-16
Solar-Powered Installations 1.7.4 1-17
Batteries 1.7.5 1-19
Startup and Operation 1.8 1-20
Startup 1.8.1 1-20
Operation 1.8.2 1-20
1.3 ADDITIONAL INFORMATION
The following manuals may be used to acquire additional information, not necessarily found in this
manual:
! ROCLINK for Windows Configuration Software User Manual – Part Number
D301138X012
! ROCLINK Configuration Software User Manual – Part Number D301101X012
! ROC/FloBoss Accessories Instruction Manual – Part Number D301061X012
1-2 Rev 2/01
EF-Series Instruction Manual
1.4 PRODUCT OVERVIEW
The eFlow EF-Series units are 32-bit microprocessor-based Electronic Flow Measurement (EFM)
computers that provide functions required for measuring the flow at a single meter run. The EF-Series
unit measures differential pressure, static pressure, and temperature; in addition, it provides the
functions required for gas orifice metering.
The EF-Series Unit computes gas flow for both volume and energy. The unit provides on-site
functionality and supports remote monitoring, measurement, data archival, and communications. The
design allows you to configure specific applications including those requiring gas flow calculations,
data archival, and remote communications.
The EF-Series Unit provides the following standard components and features:
♦
Weather-tight enclosure.
♦
Main Electronics Board.
♦
Built-in Liquid Crystal Display (LCD) with two-line alphanumeric viewing.
♦
A 32-bit microprocessor, 512K of flash ROM, and 512K of static memory storage.
♦
Built-in Sensor for orifice metering.
♦
Built-in Resistance Temperature Detector (RTD) input.
♦
Built-in Discrete Output (DO) for sampler or odorizer control.
♦
Up to 28 amp-hour battery capacity.
♦
Operator interface (LOI) port.
♦
Host communications port for optional communications card.
Physically, the unit consists of a printed-circuit Main Electronics Board and a display housed in a
compact, weather-tight case. The EF-Series unit is packaged in a NEMA 4 windowed enclosure that
can mount on a wall or a pipestand. A cover is provided for the display to protect it from adverse
weather conditions. Refer to Figure 1-1.
The steel enclosure protects the electronics from physical damage and harsh environments. The
enclosure consists of two pieces: the body and the door. A foam-rubber gasket seals the unit when the
hinged door is closed. The hinge, located on the left side, is stainless steel and fastened to the body
with machine screws, allowing removal of the door. The door is secured by a lockable hasp. Refer to
Figure 1-2 on page 1-13 for dimensional details.
The Main Electronics Board mounts on quick-fastener stand-offs located on top of the swing-out
panel. The dimensions of the board are approximately 5 by 7.5 inches. The majority of the
components are surface-mounted, with the top side of the board used for components. The Main
Electronics Board provides built-in I/O capabilities, an LCD display, and provisions for an optional
communications card. For more information on the Main Electronics Board, refer to Section 2.
Rev 2/01 1-3
General Information
Mounting Flange
Display
Cover
Operator
Interface
Connector
Sensor
Figure 1-1. eFlow EF-Series Flow Computer
The built-in Liquid Crystal Display (LCD) provides the ability to look at data and configuration
parameters while on site without using the local operator interface (LOI) and a PC. The LCD display
is factory-mounted directly to the Main Electronics Board and visible through the window on the front
panel. Through this display, you can view pre-determined information stored in the unit. Up to 16
items can be defined for display. The display automatically cycles through the configured list of items
displaying a new value approximately every three seconds.
A Motorola 32-bit CMOS microprocessor runs at 14.7 MHz and has low-power operating modes,
including inactivity and low battery condition. The EF-Series Unit comes standard with 512K of builtin, super capacitor-backed static random access memory (SRAM) for storing data and history. The
unit also has 512K of programmable read-only memory (flash ROM) for storing operating system
firmware, applications firmware, and configuration parameters.
The built-in inputs and outputs (I/O) on the EF-Series Unit consist of a port for the Sensor, a 4-wire
Resistance Temperature Detector (RTD) input interface, and a discrete output (DO). Three diagnostic
inputs are dedicated to monitoring battery voltage, charger voltage, and enclosure/battery temperature.
Refer to Section 2 for more information.
1-4 Rev 2/01
EF-Series Instruction Manual
The orifice-metering Sensor measures differential pressure and absolute or gauge (static) pressure by
converting the applied pressure to electrical signals and making the readings available to the Main
Electronics Board. The Sensor housing fastens to a flanged adapter, which in turn mounts with four
bolts to the bottom of the enclosure. The Sensor cable plugs directly into the Main Electronics Board.
For more information on the Sensor, refer to Section 4.
An RTD temperature probe typically mounts in a thermowell on the metering pipe. RTD wires
should be protected either by a metal sheath or conduit connected to a liquid-tight conduit fitting on the
bottom of the EF-Series enclosure. The RTD wires connect directly to the four-terminal RTD
connector on the Main Electronics Board inside the enclosure.
The built-in discrete output (DO) is capable of directly driving a sampler or odorizer. The DO may
be used as a Timed Duration Output (TDO).
The operator interface (LOI) port, located on the bottom left-hand side of the enclosure (refer to
Figure 1-1), provides for a direct, local link between the EF-Series Unit and a personal computer
through an Operator Interface Cable. With the personal computer running the ROCLINK
Configuration Software, you can configure the functionality of the unit and monitor its operation.
User-level security can be enabled or disabled for the LOI port.
The host communications port (located at COM1) is available for use with an optional
communications card to permit serial communication protocols, as well as dial-up modem
communications. User-level security can be enabled or disabled for the host communications port
The I/O parameters, Sensor inputs, flow calculations, power control, and security are configured and
accessed using the ROCLINK Configuration Software. Refer to the ROCLINK for Windows User
Manual (or the DOS-based ROCLINK user manual) for details concerning software capabilities.
The firmware, contained in flash ROM on the electronics board, determines much of the functionality
of the EF-Series Unit, such as:
♦
Memory logging of 240 alarms and 240 events.
♦
Archival of data for up to 15 history points for up to 35 days.
♦
Power cycling control for a radio or cell phone through the EIA-232 communications card.
♦
Flow calculations (AGA and API standards) for a single meter run.
♦
Communications support alarm call-in to host.
♦
User-level security.
Refer to Section 2.3 for more information about the functionality provided by the firmware.
Rev 2/01 1-5
General Information
1.4.1 Options and Accessories
The EF-Series Unit supports the following options and accessories:
♦
Communications Cards for host communications.
♦
Bracket for internally-mounted radio.
♦
Local Operator Interface (LOI) cable.
♦
Batteries.
♦
Solar Panels.
A variety of plug-in communication cards are available that allow you to customize the EF-Series
Unit installation for most communications requirements. The communication cards provide an
interface for the host communications port. These cards permit serial communication protocols, as
well as dial-up modem communications. One card of the following types can be accommodated:
♦
EIA-232 (RS-232) for asynchronous serial communications.
♦
EIA-485 (RS-485) for asynchronous serial multi-drop communications.
♦
Dial-up modem for communications over a telephone network.
Stand-offs on the Main Electronics Board allow the communications cards to be added easily. Refer to
Section 3 for more information.
A radio with an integral modem can also be mounted inside the enclosure using the optional radio
bracket (see Section 1.6). The radio bracket allows a radio up to 2.25 inches high to be mounted
securely in the battery compartment inside the enclosure. Power for the radio can be controlled
through the EIA-232 communications card. Clearance is provided for the radio antenna cable to exit
the bottom of the enclosure.
The local operator interface (LOI) port provides for a direct, local link using an Operator Interface
Cable between the EF-Series Unit and a personal computer. With the personal computer running the
ROCLINK Configuration Software, you can configure the functionality of the unit and monitor its
operation. The Operator Interface Cable is available as an accessory.
The EF-Series Unit enclosure can hold up to four sealed lead-acid batteries. The 12-volt batteries
provide approximately 7 amp-hours each, resulting in up to 28 amp-hours of backup capacity. The
batteries are mounted behind the electronics swing-out panel and are retained by the panel when it is
secured. The batteries are connected to a wiring harness that allows the batteries to be changed
without removing power from the unit. Refer to Section 1.7.5 for more information.
A solar panel can be installed to recharge the backup batteries; it connects to the POWER charge
inputs on the Main Electronics Board. Circuitry on the Main Electronics Board monitors and regulates
the charge based on battery voltage, charging voltage, and temperature. The typical panels used are
12-volt panels with output ratings of 5 or 10 watts. The panels are typically bracket-mounted on a pole
or pipe, and the wiring is brought into the bottom of the enclosure through a liquid-tight fitting.
1-6 Rev 2/01
EF-Series Instruction Manual
1.5 INSTALLATION REQUIREMENTS
This section provides generalized guidelines for successful installation and operation of the EF-Series
Unit. Planning helps to ensure a smooth installation. Be sure to consider location, ground conditions,
climate, and site accessibility while planning an installation.
The versatility of the EF-Series Unit allows it to be used in many types of installations. For additional
information concerning a specific installation, contact your Fisher Representative. For detailed wiring
information, refer to Section 2.
The Installation Requirements section includes:
♦
Environmental Requirements
♦
Site Requirements
♦
Compliance with Hazardous Area Standards
♦
Power Installation Requirements
♦
Grounding Installation Requirements
♦
I/O Wiring Requirements
NOTE
The EF-Series Unit has been tested and found to comply with the limits for a Class
A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can
radiate radio frequency energy. If not installed and used in accordance with this
instruction manual, the EF-Series Unit may cause harmful interference to radio
communications. Operation of the equipment in a residential area is likely to cause
harmful interference, in which case you will be required to correct the interference
at your own expense.
1.5.1 Environmental Requirements
The EF-Series Unit case is classified as a NEMA 4 equivalent enclosure. This provides the level of
protection required to keep the units operating under a variety of weather conditions.
The unit is designed to operate over a wide range of temperatures. However, in extreme climates it
may be necessary to moderate the temperature in which the unit must operate.
The unit is designed to operate over a -40 to 75°
temperature range is -25 to 70° C (-13 to 158° F). When mounting the unit, be aware of external
devices that could have an effect on the operating temperature. Operation beyond the recommended
temperature range could cause errors and erratic performance. Prolonged operation under extreme
conditions could also result in failure of the unit.
Rev 2/01 1-7
C (-40 to 167° F) temperature range. The LCD
General Information
Check the installation for mechanical vibration. The EF-Series Unit should not be exposed to levels of
vibration that exceed 2 G for 15 to 150 hertz and 1 G for 150 to 2000 hertz.
1.5.2 Site Requirements
Careful consideration in locating the EF-Series Unit on the site can help prevent future operational
problems. The following items should be considered when choosing a location:
♦
Local, state, and federal codes often place restrictions on monitoring locations and dictate
site requirements. Examples of these restrictions are fall distance from a meter run,
distance from pipe flanges, and hazardous area classifications.
♦
Locate the unit to minimize the length of signal and power wiring.
♦
Orient solar panels to face due South (not magnetic South) in the Northern Hemisphere and
due North (not magnetic North) in the Southern Hemisphere. Make sure nothing blocks the
sunlight from 9:00 AM to 4:00 PM.
♦
Antennas are equipped for radio communications and must be located with an unobstructed
signal path. If possible, locate antennas at the highest point on the site and avoid aiming
antennas into storage tanks, buildings, or other tall structures. Allow sufficient overhead
clearance to raise the antenna.
♦
To minimize interference with radio communications, locate the unit away from electrical
noise sources such as engines, large electric motors, and utility line transformers.
♦
Locate the unit away from heavy traffic areas to reduce the risk of being damaged by
vehicles. However, provide adequate vehicle access to aid in monitoring and maintenance.
1-8 Rev 2/01
EF-Series Instruction Manual
1.5.3 Compliance with Hazardous Area Standards
The EF-Series Unit has hazardous location approval for Class I, Division 2, Groups A to D exposures.
The Class, Division, and Group terms are defined as follows:
Class defines the general nature of the hazardous material in the surrounding atmosphere.
Class I is for locations where flammable gases or vapors may be present in the air in
quantities sufficient to produce explosive or ignitable mixtures.
Division defines the probability of hazardous material being present in an ignitable
concentration in the surrounding atmosphere. Division 2 locations are presumed to be
hazardous only in an abnormal situation.
Group defines the hazardous material in the surrounding atmosphere. Groups A to D are
defined as follows:
♦
Group A – Atmosphere containing acetylene.
♦
Group B – Atmosphere containing hydrogen, gases or vapors of equivalent nature.
♦
Group C – Atmosphere containing ethylene, gases or vapors of equivalent hazards.
♦
Group D – Atmosphere containing propane, gases or vapors of equivalent hazards.
For the EF-Series Unit to be approved for hazardous locations, it must be installed according to the
National Electrical Code (NEC) Article 501.
CAUTION
When installing units in a hazardous area, make sure all installation
components selected are labeled for use in such areas. Installation and
maintenance must be performed only when the area is known to be nonhazardous.
1.5.4 Power Installation Requirements
The typical source of primary power for EF-Series Unit installations is solar power.
Refer to Section 1.7, Power Consumption Calculation, on Page 1-15 concerning solar power, auxiliary
device power, and batteries.
Rev 2/01 1-9
General Information
1.5.5 Grounding Installation Requirements
Ground wiring requirements for are governed by the National Electrical Code (NEC).
Proper grounding of the EF-Series Unit helps to reduce the effects of electrical noise on the unit’s
operation and protects against lightning. Lightning protection is designed into the unit, especially for
the built-in field wiring inputs and outputs. You may want to consider installing a telephone surge
protector for the dial-up modem communications card.
All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured
with a ground system tester. The grounding conductor should have a resistance of 1 ohm or less between
the EF-Series Unit case ground lug and the earth ground rod or grid.
The grounding installation method for the unit depends on whether the pipeline has cathodic protection.
On pipelines with cathodic protection, the EF-Series Unit must be electrically isolated from the pipeline.
Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the
meter run. In this case, the EF-Series Unit could be flange mounted or saddle-clamp mounted directly on
the meter run and grounded with a ground rod or grid system.
On pipelines without cathodic protection, the pipeline itself may provide an adequate earth ground and the
EF-Series Unit could mount directly on the meter run. Test with a ground system tester to make sure the
pipeline to earth impedance is less than 25 ohms. If an adequate ground is provided by the pipeline, do
not install a separate ground rod or grid system. All grounding should terminate at a single point.
If the pipeline to earth impedance is greater than 25 ohms, the installation should be electrically isolated
and a ground rod or grid grounding system installed.
The recommended cable for I/O signal wiring is an insulated, shielded, twisted pair. The twisted pair
and the shielding minimize signal errors caused by EMI (electromagnetic interference), RFI (radio
frequency interference), and transients. A ground bar is provided for terminating shield wires and
other connections that require earth ground. A lug on the outside of the enclosure is provided to
ground the enclosure. Note that the ground bar should be directly wired to the ground lug, rather than
depending on the enclosure to make the connection between the ground bar and ground lug. Refer to
Section 2 for further details.
CAUTION
Do not connect the earth ground to any wiring terminal on the Main Electronics Board.
1-10 Rev 2/01
EF-Series Instruction Manual
1.5.6 I/O Wiring Requirements
I/O wiring requirements are site and application dependent. Local, state, or NEC requirements
determine the I/O wiring installation methods. Direct burial cable, conduit and cable, or overhead
cables are options for I/O wiring installations. Section 2 contains detailed information on connecting
I/O wiring to the EF-Series Unit.
The Main Electronics Board containing the field wiring terminal connections is accessed by opening
the door after removing the lock (if installed) and releasing the hasp on the right-hand side. The input
terminal wiring is arranged on the lower edge of the Main Electronics Board. The terminal
designations are printed on the circuit board.
Rev 2/01 1-11
General Information
1.6 MOUNTING
When choosing an installation site, be sure to check all clearances. Provide adequate clearance for the
enclosure door to be opened for wiring and service. The door is hinged on the left side. The LCD
display should be visible and accessible for the on-site operator. When using a solar panel, there
should be adequate clearance, and view of the sun should not be obstructed. Allow adequate clearance
and an obstructed location for antennas when using radios.
The Sensor is factory-mounted directly to the EF-Series Unit enclosure with four bolts. This mounting
uses a special coupler to join the Sensor to the four-bolt mounting pattern on the bottom of the
enclosure. See Section 4 for more information.
The Mounting section includes:
♦
Mounting the EF-Series Unit
♦
Mounting a Radio
♦
Accessing the Battery Compartment
1.6.1 Mounting the EF-Series Unit
Mounting of the EF-Series Unit can be accomplished using either of the following methods:
♦
Pipe mounted. The enclosure provides top and bottom mounting flanges with holes for
2-inch pipe clamps (U-bolts and brackets supplied). The 2-inch pipe can be mounted to
another pipe with a pipe saddle, or it can be cemented into the ground deep enough to
support the weight and conform to local building codes.
♦
Wall or panel mounted. Fasten to the wall or panel using the mounting flanges on the
enclosure. Use 5/16-inch bolts through all four holes. Mounting dimensions are given in
Figure 1-2.
CAUTION
Do not mount the EF-Series Unit with the Sensor supporting the entire weight of
the unit. Due to the weight of the unit with batteries and possibly an internally
mounted radio or cell phone, the unit does not meet vibration requirements unless
it is installed using its enclosure mounting flanges.
With either mounting method, the pressure inputs must be piped to the process connections on the
Sensor. For more information on process connections, refer to Section 4.
1-12 Rev 2/01
EF-Series Instruction Manual
Notes: All dimensions are in inches.
Figure 1-2. Outline and Mounting Dimensions
The EF-Series Unit must be mounted vertically with the Sensor at its base as shown in
Figure 1-2.
Rev 2/01 1-13
CAUTION
General Information
1.6.2 Mounting a Radio
A radio up to 2.25 inches high can be mounted inside the EF-Series Unit enclosure by using the
optional radio bracket. This bracket allows most radios to be secured in the compartment. Fasten the
radio to the bracket using one of the predrilled mounting patterns and the four 6-32 × 0.25 pan-head
screws (supplied).
For an MDS radio:
Remove the winged brackets supplied with the radio.
1.
Fasten the radio through the bottom of the radio bracket using the four 6-32 × 0.25 flat-head
2.
screws supplied.
Place the radio and bracket into the enclosure, aligning the assembly over the two studs on the
3.
back panel of the enclosure and the screw next to the swing-out panel.
Slide the bracket to the right to engage the slots, and tighten the screw.
4.
Route the radio antenna either to the right or to the left and then out the bottom of the
5.
enclosure.
1.6.3 Accessing the Battery Compartment
As many as four 7-amp-hour batteries can be mounted inside the EF-Series Unit enclosure. Refer to
Section 1.7.5, Batteries, on page 1-19. To access the battery compartment:
Unscrew the two captive screws on the left side of the swing-out mounting panel containing the
1.
main electronics board.
Unplug the printed-circuit cable going to the Sensor by pressing down on the connector tab and
2.
pulling straight out.
Push down on the detent immediately below the Sensor (P/DP) connector and swing the
3.
mounting panel out. You now have full access to the battery compartment.
Refer to Section 2 for information on battery wiring.
1-14 Rev 2/01
EF-Series Instruction Manual
1.7 POWER CONSUMPTION CALCULATION
System power consumption determines solar panel and battery sizing for solar power. Table 1-1
provides information to assist in determining power requirements. The EF-Series Unit has low power
consumption due to a typical duty cycle of 10 to 20% for its microprocessor; the other 80 to 90% of the
time the microprocessor is shut off, with external wake-up signals reactivating it.
The Power Consumption Calculation section includes:
♦
Determining I/O Channel Power Consumption
♦
Determining Auxiliary Power Consumption
♦
Totaling Power Requirements
♦
Solar-Powered Installations
♦
Batteries
1.7.1 Determining I/O Channel Power Consumption
In estimating total I/O power requirements, the “duty cycle” of the built-in discrete output (DO)
channel must be estimated. For example, if the DO is active for an average of 15 seconds out of every
60 seconds, the duty cycle is:
Duty Cycle = Active time/(Active time + Inactive time) = 15 sec/60 sec = 0.25
Table 1-1. Power Consumption of the EF-Series Unit and Powered Devices
Device Power Consumption
(mW) in 12V System
P
min
Main Electronics Board; includes
base DO power consumption, RTD,
and Flow Sensor.
Built-in Discrete Output (load
dependent with a maximum of 300
milliamps at 12 volts). See Section
1.7.1.
Serial Communications Card 30 N/A
Dial-up Modem Comm Card 250 N/A
Aux. Devices from Section 1.7.2 N/A N/A N/A
190 400 1 N/A
0 3600 1
P
max
Quantity Duty Cycle Subtotal
(mW)
Tot al
Rev 2/01 1-15
General Information
1.7.2 Determining Auxiliary Power Consumption
In determining power requirements for auxiliary devices such as a radio or cell phone, the duty cycle
for the device must be estimated. The duty cycle is the percentage of time the device is transmitting
(TX). For example, if a radio is transmitting 1 second out of every 60 seconds, and for the remaining
59 seconds the radio is drawing receive (RX) power, the duty cycle is:
Duty Cycle = TX time/(TX time + RX time) = 1 sec/60 sec = 0.0167
To calculate the total power consumed by a radio, obtain the power (P) consumption values for
transmit and receive from the radio manufacturer’s literature, then use the following equation to
calculate the power consumption for a particular duty cycle:
Power = (PTX x Duty Cycle) + [PRX (1 - Duty Cycle)]
Determine the power consumption for all devices that use power from the EF-Series Unit, and enter
the total calculated value in Table 1-1.
1.7.3 Totaling Power Requirements
To adequately meet the needs of the EF-Series system, it is important to determine the total power
consumption, size of solar panel, and battery backup requirements accordingly. For total EF-Series
Unit power consumption, add the device values in Table 1-1. Although Table 1-2 takes into account
the power supplied by the EF-Series Unit to its connected devices, be sure to add the power
consumption (in mW) of any other devices used with the EF-Series Unit in the same power system, but
not accounted for in the table.
Convert the total value (in mW) to Watts by dividing it by 1000.
mW / 1000 = Watts
For selecting an adequate power supply, use a safety factor (SF) of 1.25 to account for losses and other
variables not factored into the power consumption calculations. To incorporate the safety factor,
multiply the total power consumption (P) by 1.25.
= P x 1.25 = _____ Watts
P
SF
To convert P
I
SF
to current consumption in amps (ISF), divide PSF by the system voltage (V) of 12 volts.
SF
= PSF / V = _____ Amps
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EF-Series Instruction Manual
1.7.4 Solar-Powered Installations
Solar power allows installation of the EF-Series Unit in remote locations. The two important elements
in a solar installation are solar panels and batteries. Solar panels and batteries must be properly sized
for the application and geographic location to ensure continuous, reliable operation.
A 12-volt solar panel can be installed to provide charging power for the backup batteries. The panel
can be rated at 5 or 10 watts (to correspond to the CSA rating of the unit) and is sized depending upon
the power requirements of the unit. In pipe-mount installations, the solar panel may be mounted to the
same 2-inch pipe that supports the EF-Series Unit. The panel wiring is brought into the enclosure
through the pre-punched holes in the bottom of the enclosure and is terminated at the charge (CHG)
power terminals on the Main Electronics Board.
The panel must face due South (not magnetic South) in the Northern Hemisphere and due North (not
magnetic North) in the Southern Hemisphere. The panel must also be tilted at an angle from horizontal
dependent on latitude to maximize the energy output. The angles for different latitudes are normally
included in the solar panel documentation. At most latitudes, the performance can be improved by less
of an angle during the summer and more of an angle during the winter.
Since a site may have additional power requirements for cell phones or radios, repeaters, and other
monitoring devices, power supply and converter accessories may be used to minimize the number of
separate power sources required for an installation.
Solar arrays are used to generate electrical power for the EF-Series Unit from solar radiation. The size
and number of solar panels required for a particular installation depends on several factors, including
the power consumption of all devices connected to the solar array and the geographic location of the
installation. Refer to the following paragraphs.
To determine solar panel output requirements, first determine the solar insolation for your geographic
area. The map in Figure 1-3 shows solar insolation (in hours) for the United States during winter
months. Call your local Fisher Representative for a map detailing your specific geographic area.
Insolation (from map) = _____ hours
Next, calculate the amount of current required from the solar array per day using the following
equation. ISF is the system current requirement. Refer to Section 1.7.3 on page 1-16.
= [I
I
array
(amps) × 24 (hrs)]/Insolation (hrs) = _____ amps
SF
Finally, the number of solar panels can be determined using the following equation:
Number of Panels = I
Rev 2/01 1-17
array
amps/(I
amps/panel) = _____ panels
panel
General Information
Figure 1-3. Solar Insolation in Hours for the United States
NOTE
The “I
” value varies depending on the type of solar panel installed. Refer to
panel
the vendor’s specifications for the solar panel being used.
For example, if I
equals 0.54 amps, and I
array
equals 0.29 amps for a 5-watt panel, then the number
panel
of panels required equals 1.86, which would be rounded up to 2 (panels connected in parallel).
Alternatively, the next larger solar panel can be used, which in this case would be a 10-watt panel.
Table 1-2 gives I
values for solar panels recommended by Fisher Controls.
panel
Table 1-2. Solar Panel Sizing
Panel I
panel
4.5 watt 0.27 amps
5 watt 0.29 amps
10 watt 0.58 amps
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EF-Series Instruction Manual
1.7.5 Batteries
In solar installations, batteries provide power for the EF-Series Unit whenever the solar panels are not
generating sufficient output.
The standard battery configurations use a 12-volt, sealed, lead-acid battery (approximately 6.0 x 2.6 x
3.7 inches). These configurations can provide 7, 14, 21, or 28 amp-hour capacities. Recommended 7
amp-hour battery types (up to four batteries) for EF-Series Units are listed below. If other batteries are
used, Fisher Controls recommends rechargeable, sealed, gel-cell, lead-acid batteries.
♦
Powersonic PS-1270 7.0 Amp-Hour
♦
Panasonic LCR12V7.2P 7.2 Amp-Hour
♦
Yuasa NP7-12 7.0 Amp-Hour
The batteries are connected in parallel by a supplied wiring harness to achieve the required capacity.
The amount of battery capacity required for a particular installation depends upon the power
requirements of the equipment and days of reserve (autonomy) desired. Battery requirements are
calculated based on power consumption of the EF-Series Unit and all devices that will be powered by
the batteries.
Battery reserve is the amount of time that the batteries can provide power without discharging below
20 percent of their total output capacity. For solar-powered units, a minimum reserve of five days is
recommended, with ten days of reserve preferred. Add 24 hours of reserve capacity to allow for
overnight discharge. Space limitations, cost, and solar panel output are all factors that affect the actual
amount of battery capacity available.
To determine the system capacity requirements, multiply the system current load (ISF) on the batteries
by the amount of reserve time required. Compute “ISF” as described in Section 1.7.3, Totaling Power
Requirements. The equation is as follows:
System Requirement = I
amps × Reserve hrs = _____ amp-hrs
SF
Finally, determine the number of batteries required for the calculated power consumption by rounding
up to the nearest multiple of 7 amps: 7, 14, 21, or 28 amp-hour capacity. If more than 28 amp-hours
are required, an external battery enclosure with additional batteries may be used.
Rev 2/01 1-19
General Information
1.8 STARTUP AND OPERATION
Before starting the EF-Series Unit, perform the following checks to ensure the unit is properly
installed.
♦
Make sure the enclosure has a good earth ground connected to the earth ground bus inside the
enclosure.
♦
Check the field wiring for proper installation. Refer to Section 2.
♦
Make sure the input power has the correct polarity.
♦
Make sure the input power is fused at the power source.
CAUTION
It is important to check the input power polarity before turning on the power.
Incorrect polarity can damage the EF-Series Unit.
CAUTION
When installing equipment in a hazardous area, ensure that all components are
approved for use in such areas. Check the product labels.
1.8.1 Startup
Apply power to the EF-Series Unit by plugging the input power terminal block into the connector
labeled POWER located at the bottom left of the Main Electronics Board. After the EF-Series Unit
completes start-up diagnostics (RAM and other internal checks), the LCD displays the date and time to
indicate that the EF-Series Unit completed a valid reset sequence. If the LCD does not come on, refer
to the Troubleshooting and Repair paragraphs in Section 2 for possible causes.
1.8.2 Operation
Once startup is successful, it is necessary to configure the EF-Series Unit (see Section 2.6 for more
information) to meet the requirements of the application. The ROCLINK User Manual provides
detailed information for using the ROCLINK software to configure the EF-Series Unit and to calibrate
its I/O (see Section 2.7 for more information about calibration). Once the EF-Series Unit is configured
and calibrated, it can be placed into operation.
CAUTION
Local configuration or monitoring of the EF-Series Unit through its LOI port must
be performed only in an area known to be non-hazardous.
During operation, the EF-Series Unit can be monitored (to view or retrieve current and historical data)
either locally or remotely. Local monitoring is accomplished either by viewing the LCD panel detailed
in Section 2.4.3, or by using ROCLINK on a PC connected through the LOI port (see the ROCLINK
User Manual). Remote monitoring is normally performed through the host port of the EF-Series Unit,
using the eFlow Internet Measurement Services (IMS).
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EF-Series Instruction Manual
SECTION 2 — USING THE EF-SERIES UNIT
2.1 SCOPE
This section describes the EF-Series flow computer, focusing on how it works and how to connect
wiring. Major topics include:
♦
Product Functions
♦
Product Electronics
♦
Connecting the Wiring
♦
Configuration
♦
Calibration
♦
Troubleshooting and Repair
♦
Specifications
2.2 SECTION CONTENTS
This section contains the following information:
Information Section Page Number
Product Functions 2.3 2-3
Flow Measurement 2.3.1 2-3
History Points 2.3.2 2-4
Security 2.3.3 2-6
Power Control 2.3.4 2-6
Report By Exception (RBX) Alarming 2.3.5 2-7
Product Electronics 2.4 2-8
Main Electronics Board Overview 2.4.1 2-8
Microprocessor and Memory 2.4.2 2-8
Liquid Crystal Display 2.4.3 2-10
Communications Ports 2.4.4 2-10
Built-In Discrete Output 2.4.5 2-11
RTD Input 2.4.6 2-12
Real-Time Clock 2.4.7 2-12
Diagnostic Monitoring 2.4.8 2-12
Automatic Self Tests 2.4.9 2-12
Low Power Modes 2.4.10 2-13
Connecting the EF-Series unit to Wiring 2.5 2-15
Making Wiring Connections 2.5.1 2-15
Connecting Ground Wiring 2.5.2 2-16
Connecting Main Power Wiring 2.5.3 2-17
Auxiliary Output Power 2.5.4 2-21
Rev 2/01 2-1
Using the EF-Series Unit
Information Section Page Number
RTD Wiring 2.5.5 2-21
Discrete Output Wiring 2.5.6 2-23
Connecting Communications Wiring 2.5.7 2-24
Sensor Wiring 2.5.8 2-25
Configuration 2.6 2-26
Calibration 2.7 2-27
Troubleshooting and Repair 2.8 2-28
Backup Procedure Before Removing Power 2.8.1 2-28
Resetting the EF-Series Unit 2.8.2 2-29
After Installing Components 2.8.3 2-33
Replacing the Main Electronics Board 2.8.4 2-33
Sensor Replacement 2.8.5 2-35
Specifications 2.9 2-35
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EF-Series Instruction Manual
2.3 PRODUCT FUNCTIONS
This section describes the functions of the eFlow EF-Series flow computer, most of which is determined by firmware. The features provided by the firmware, much of which must be configured by
using the ROCLINK configuration software, are:
♦
Flow calculations for an orifice meter.
♦
Archival of data for up to 15 history points.
♦
Memory logging of 240 alarms and 240 events.
♦
Security with local and remote password protection.
♦
Power cycling control for a radio.
♦
Report-by-exception (RBX) capability.
2.3.1 Flow Measurement
The primary function of the EF-Series Unit is to measure the flow of natural gas through an orifice in
accordance with the 1992 American Petroleum Institute (API) and American Gas Association (AGA)
standards. The flow calculation is in accordance with ANSI/API 2530-92 (AGA Report No. 3 1992),
API Chapter 14.2 (AGA Report No. 8 1992 2nd printing 1994), and API Chapter 21.1. The flow
calculation may be configured for either Metric or English units.
The primary inputs used for the orifice metering flow measurement function are differential pressure,
static pressure, and temperature. The differential and static pressure inputs, which are sampled once
per second, come from the Flow Sensor. The temperature input, which is sampled and linearized once
per second, comes from an RTD probe.
Flow Time
The differential pressure stored for each second is compared to the configured low flow cutoff. If the
differential pressure is less than or equal to the low flow cutoff or the converted static pressure is less
than or equal to zero, flow is considered to be zero for that second. Flow time for a recalculation
period is defined to be the number of seconds for which the differential pressure exceeded the low flow
cutoff.
Input and Extension Calculation
Every second the EF-Series unit stores the measured input for differential pressure, static pressure, and
temperature and calculates the flow extension (defined as the square root of the absolute upstream
static pressure times the differential pressure).
Flow time averages of the inputs and the flow extension over the configured recalculation period are
calculated unless there is no flow for an entire recalculation period. If there is no flow, averages of the
inputs are recorded to allow monitoring during no flow periods.
Rev 2/01 2-3
Using the EF-Series Unit
Instantaneous Rate Calculations
The instantaneous value of the flow extension is used with the previous recalculation period’s Integral
Multiplier Value (IMV) to compute the instantaneous flow rate. The IMV is defined as the value
resulting from the calculation of all other factors of the flow rate equation not included in the Integral
Value (IV). The IV is defined as the flow extension. The instantaneous flow rate is used with the
volumetric heating value to compute the instantaneous energy rate.
Flow and Energy Accumulation
The averages of the differential and static pressure, temperature, and flow extension are used with the
flow time to compute the flow and energy over the recalculation period. The flow and energy are then
accumulated and stored at the top of every hour. At the configured contract hour, the flow and energy
are then stored to the Daily Historical Log and zeroed for the start of a new day.
2.3.2 History Points
A total of fifteen history points may be logged and accessed in the EF-Series unit. The first eight are
pre-configured for flow metering history and cannot be changed. They are as follows:
♦
Flowing Minutes Today (Accumulate archive type)
♦
Differential Pressure (Average)
♦
Static or Line Pressure (Average)
♦
Temperature (Average)
♦
IMV, Integral Multiplier Value, or C Prime (Average)
♦
Pressure Extension or IV, Integral Value (Average)
♦
Instantaneous Flow (Accumulate)
♦
Instantaneous Energy (Accumulate)
History Point 2, History Point 3, History Point 4, and History Point 6 are all set up as an Average
Archive Type that employs one of the following techniques:
♦
Flow dependent time-weighted linear averaging (default selection)
♦
Flow dependent time-weighted formulaic averaging.
♦
Flow-weighted linear averaging.
♦
Flow-weighted formulaic averaging.
For the history points above, the averaging technique is selected by using ROCLINK. In the Meter
menu, select Setup, then select Inputs. In the Inputs screen, select the desired Averaging Technique.
The selected technique will then be applied to the meter inputs.
The seven user-configurable history points may be configured as described in the ROCLINK User
Manual (see Configure - History).
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EF-Series Instruction Manual
2.3.2.1 Minute Historical Log
The EF-Series unit has a 60-minute historical log for every history point. The Minute Historical Log
stores the last 60 minutes of data from the current minute. Each history point has Minute Historical
Log entries associated with it.
2.3.2.2 Hourly Historical Log
The EF-Series unit has a total of 840 hourly historical logs available for every history point. The
Hourly Historical Log is also called the Periodic Log. The Hourly Log is recorded every hour at the
top of the hour. The time stamp for periodic logging consists of the month, day, hour, and minute.
2.3.2.3 Daily Historical Log
The EF-Series unit has a total of 35 daily historical logs for every history point. The Daily Log is
recorded at the configured contract hour every day with a time stamp that is the same as the Hourly
Log. Each history point has daily historical log entries.
2.3.2.4 Alarm Log
The Alarm Log contains the change in the state of any signal that has been enabled for alarms. The
system Alarm Log has the capacity to maintain and store up to 240 alarms in a “circular” log (where
the oldest log is in effect overwritten by the newest). The alarm log has information fields which
include time and date stamp, alarm clear or set indicator, and either the tag of the point which was
alarmed along with its current value or a 14 ASCII character description.
In addition to providing functionality for appending new alarms to the log, it allows host packages to
request the index of the most recently logged alarm entry. Alarm logging is available internally to the
system and to external host packages. Alarm Logs are not stored to the flash ROM during the
ROCLINK Save Configuration function.
The Alarm Log operates in a circular fashion with new entries overwriting the oldest entry when the
buffer is full. The alarm log provides an audit history trail of past operation and changes. The Alarm
Log is stored separately to prevent recurring alarms from overwriting configuration audit data.
2.3.2.5 Event Log
The event log contains changes to any parameter within the EF-Series unit made through the native
protocol. This event log also contains other EF-Series unit events such as power cycles, cold starts,
and disk configuration downloads.
The system event log has the capacity to maintain and store up to 240 events in a circular log. The
event log has information fields which include point type, parameter number, time and date stamp,
point number if applicable, the operator identification, and either the previous and current parameter
values or a 14-byte detail string in ASCII format.
Rev 2/01 2-5
Using the EF-Series Unit
In addition to providing functionality for appending new events to the log, it allows host packages to
request the index of the most recently logged event entry. Event logging is available internally to the
system and to external host packages.
Event logs are not stored to flash ROM when the Save Configuration function is issued in the
ROCLINK Configuration Software. The event log operates in a circular fashion with new entries
overwriting the oldest entry when the buffer is full. The event log provides an audit trail history of
past operation and changes. The event log is stored separately to prevent recurring alarms from
overwriting configuration audit data.
2.3.3 Security
The EF-Series unit provides for security within the unit. A maximum of 16 log-on identifiers (IDs)
may be stored. In order for the unit to communicate, the log-on ID supplied to the ROCLINK
Configuration Software must match one of the IDs stored in the EF-Series unit. The Operator
Interface port (Security on LOI) has security Enabled by default. The host port Comm1 can likewise
be configured to have security protection, but is disabled by default. Refer to the ROCLINK software
user manual concerning the device security in the ROC menu.
2.3.4 Power Control
The Power Control function (called Radio Power Control in the ROCLINK software) is used with the
RS-232 communications card to provide power savings when using a radio or cell phone for
communications. Two modes of Power Control are possible: Second and Minute. In Second mode,
the time base for the timers is in 100 millisecond increments and is primarily used with radios. In
Minute mode, the time base for the timers is in 1 minute increments and is primarily used with cell
phones. Three cycling zones are provided (see Table 2-1 below for eFlow defaults), but zones can be
disabled as desired. The RS-232 card provides the switching mechanism by means of contacts (see
Section 3.5.1) or the DTR signal.
The Power Control function calculates which zone should be currently active. In Second mode, the
Power Control begins in the ON state and continues with a full On Time and then goes to the OFF state
for the full Off Time. In Minute mode, the Power Control determines if it should be ON or OFF and
how much time it needs until it switches.
2-6 Rev 2/01
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