Emerson Fisher FLOBOSS 407 Instruction Manual

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Field Automation Systems

FLOBOSS

Instruction Manual

™

407 FLOW MANAGER

Form A6013

May 2000

Loose-leaf version: Part Number D301080X012 Bound version: Contact FAS

FloBoss 407 Instruction Manual

Revision Tracking Sheet

May 2000

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 5/00

Previous Editions:

November 1998 - Added changes for 1.05/1.06 firmware and added references to ROCLINK.



FloBoss is a trademark of Fisher Controls International, Inc. HART is a registered trademark of the HART Communication Foundation.

Printed in the U.S.A. While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfact ory 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 desi gns or specifications of the products described herein.

ii Rev 5/00

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

FloBoss 407 Instruction Manual

(For a more detailed listing, see the Section Contents at the front of each section.)

SECTION 1 — GENERAL INFORMATION ............................................................1-1

1.1 Scope of Manual...............................................................................................................................1-1

1.2 Section Contents...............................................................................................................................1-2

1.3 Product Overview.............................................................................................................................1-2

1.4 Installation Guidelines......................................................................................................................1-5

1.5 Power Consumption Calculation......................................................................................................1-9

1.6 Startup and Operation.....................................................................................................................1-13

1.7 Keypad Operation...........................................................................................................................1-14

1.8 Service Bulletins.............................................................................................................................1-15

SECTION 2 — THE FLOBOSS 407 BASE UNIT ..................................................... 2-1

2.1 Scope..................................................................................................................................................2-1

2.2 Product Description............................................................................................................................2-2

2.3 Installation........................................................................................................................................2-11

2.4 Connecting the FloBoss 407 to Wiring............................................................................................2-14

2.5 Troubleshooting and Repair.............................................................................................................2-19

2.6 Specifications...................................................................................................................................2-32

SECTION 3 — INPUT/OUTPUT MODULES ...........................................................3-1

3.1 Scope.................................................................................................................................................3-1

3.2 Product Descriptions.........................................................................................................................3-2

3.3 Initial Installation and Setup.............................................................................................................3-7

3.4 Connecting the I/O Modules to Wiring............................................................................................3-8

3.5 Troubleshooting and Repair ...........................................................................................................3-29

3.6 Removal, Addition, and Replacement Procedures .........................................................................3-37

3.7 I/O Module Specifications..............................................................................................................3-40

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Table of Contents (Continued)

SECTION 4 — COMMUNICATIONS CARDS.........................................................4-1

4.1 Scope.................................................................................................................................................4-1

4.2 Product Descriptions.........................................................................................................................4-1

4.3 Initial Installation and Setup.............................................................................................................4-8

4.4 Connecting Communication Cards to Wiring ................................................................................4-11

4.5 Troubleshooting and Repair ...........................................................................................................4-18

4.6 Communications Card Specifications.............................................................................................4-20

SECTION 5 — DISPLAY AND KEYPAD..................................................................5-1

5.1 Scope.................................................................................................................................................5-1

5.2 Product Description..........................................................................................................................5-1

5.3 Keypad Functions.............................................................................................................................5-4

5.4 Display of Parameters.......................................................................................................................5-9

5.5 Security...........................................................................................................................................5-17

5.6 Troubleshooting and Repair ...........................................................................................................5-18

APPENDIX A — LIGHTNING PROTECTION MODULE.................................... A-1

A.1 Scope................................................................................................................................................A-1

A.2 Product Description .........................................................................................................................A-1

A.3 Initial Installation.............................................................................................................................A-2

A.4 Connecting the LPM to Wiring .......................................................................................................A-3

A.5 Troubleshooting and Repair ............................................................................................................A-4

A.6 Specifications...................................................................................................................................A-4

APPENDIX B — MULTI-VARIABLE SENSORS....................................................B-1

B.1 Scope................................................................................................................................................B-1

B.2 Description....................................................................................................................................... B-1

B.3 MVS Mounting................................................................................................................................B-3

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Table of Contents (Continued)

B.4 Field Wiring.....................................................................................................................................B-7

B.5 Configuration................................................................................................................................. B-13

B.6 Calibration .....................................................................................................................................B-14

B.7 MVS Troubleshooting and Repair.................................................................................................B-18

B.8 Specifications................................................................................................................................. B-19

APPENDIX C — I/O SIMULATION ......................................................................... C-1

C.1 Scope................................................................................................................................................C-1

C.2 Analog Outputs to Analog Inputs.................................................................................................... C-1

C.3 Analog Outputs to a meter...............................................................................................................C-2

C.4 Discrete Outputs to Discrete Inputs................................................................................................. C-3

C.5 Discrete Outputs to Pulse Inputs......................................................................................................C-4

C.6 Potentiometer to Analog Inputs....................................................................................................... C-5

C.7 Switch to Discrete Inputs.................................................................................................................C-6

C.8 Switch to Pulse Inputs .....................................................................................................................C-7

GLOSSARY OF TERMS.............................................................................................G-1

INDEX ..............................................................................................................................I-1

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SECTION 1 — GENERAL INFORMATION

1.1 SCOPE OF MANUAL

This manual describes the FloBoss™ 407 Flow Manager (also called the ROC407), part of the family of FloBoss Flow Managers manufactured by Fisher Controls. Both the Standard version and the Measurement Canada version of the FloBoss 407 are covered in this manual. Included are the following sections:

♦ Section 1 General Information ♦ Section 2 FloBoss 407 Base Unit ♦ Section 3 Input/Output Modules ♦ Section 4 Communications Cards ♦ Section 5 Display and Keypad ♦ Appendix A Lightning Protection Module ♦ Appendix B Multi-Variable Sensors ♦ Appendix C I/O Simulation ♦ Glossary Glossary of Terms ♦ Index Topical Index

Section 1 describes this and related manuals. Section 1 also provides a summary of the FloBoss 407 hardware, installation guidelines, and information on power consumption, startup, and keypad operation.

Section 2 provides information and specifications concerni ng the tw o ma in com ponen ts of the FloBoss 407, the p r o cessor board and the te r minat i o n boar d.

Section 3 provides information and specifications for t he op tio nal I/O modules available for the FloBoss

407.

Section 4 provides information and specifications for the communications card options available for the FloBoss 407.

Section 5 describes the operation of the keypad and the display.

Appendix A describes t he op tional lig htn ing pro tectio n m odu le.

Appendix B describ es the M u lti-Varia b le Sensors a v ailable fo r t h e F loBoss 407.

Appendix C shows various ways to set up I/O simulation for troubleshooting I/O components and

configurations.

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1.2 SECTION CONTENTS

This section contains the following information:

Information Section Page Number

Product Overview 1.3 1-2 Related Documents and Compatibility 1.3.1 1-4 Installation Guidelines 1.4 1-5

Environmental Requirements 1.4.1 1-5 Site Requirements 1.4.2 1-5 Compliance with Hazardous Area Standards 1.4.3 1-6 Power Installation Requirements 1.4.4 1-7 Grounding Installation Requirements 1.4.5 1-7 I/O Wiring 1.4.6 1-8

Power Consumption Calculation 1.5 1-9

Determining I/O Channel Power Consumption 1.5.1 1-9 Determining Radio Power Consumption 1.5.2 1-12 Totaling Power Requirements 1.5.3 1-12

Startup and Operation 1.6 1-13

Startup 1.6.1 1-13

Operation 1.6.2 1-13 Keypad Operation 1.7 1-14 Service Bulletins 1.8 1-15

1.3 PRODUCT OVERVIEW

The FloBoss 407 is a microprocessor-based flow computer (see Figure 1-1) that provides functions required for gas flow measurement and custody transfer in accordance with standards such as AGA 1985 or 1992 orifice metering. More generally, the unit provides on-site functionality for applications where there is a need for remote monitoring, measurement, data archival, communications, and control. The design allows the user to configure the FloBoss 407 for specific applications including those requiring calculations, logic, and sequencing control using function sequence tables, as well as PID loop control.

The FloBoss 407 is available in two versions based on the type of approval: the standard hazardous area version, and the Measurement (Industry) Canada custody transfer version, which includes hazardous area approval. These versions have a number of differences both in firmware and hardware. Both of these versions are further subdivided by the type of orifice metering calculations (either AGA 1992 or AGA 1985) included in the firmware.

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Figure 1-1. FloBoss 407 Flow Manager

Physically, the FloBoss 407 consists of two printed circuit cards, a keypad, and a display housed in a compact weather-tight case. The printed circuit cards are the processor board and the termination board.

Built into the termination board are two analog input (AI) channels. Moving a jumper on the termination board changes one of the built-in analog inputs to a pulse input (PI). The pulse input can be wired either as a FloBoss-powered or a device-powered, medium-speed pulse counter. The pulse circuitry is optically coupled to isolate the termination board from the input signal.

In addition, the termination board has slots for four plug-in input/output (I/O) modules (also called modular I/O). The plug-in I/O modules allow any combination of discrete inputs, discrete outputs, analog inputs, analog outputs, or pulse inputs an application requires.

NOTE

I/O modules must not be used as flow inputs for Industry Canada approved FloBoss 407 units.

The built-in Liquid Crystal Display (LCD) and membrane keypad provide the ability to look at data and configuration parameters while on site. The keypad also permits limited editing of parameter values.

The FloBoss 407 can have up to four Multi-Variable Sensor (MVS) devices connected to it. The MVS provides the differential pressure, static pressure, and temperature inputs needed for performing orifice flow calculations. As many as four MVS devices (one of which can be an integral MVS) can be used with a FloBoss 407. The integral MVS is factory-mounted to the bottom of the enclosure with a coupler and further secured with a stiffening plate. For detailed information on the MVS, refer to Appendix B.

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The FloBoss has two communication ports built in: a local operator interface port and an EIA-232 serial port. A variety of optional plug-in communication cards are available that allow you to add another communications channel: EIA-232 serial, EIA-422/485 serial, dial-up modem, radio modem, or leased-line modem communications.

The FloBoss 407 is packaged in a NEMA 4X windowed enclosure that can mount on a wall or a pipestand. The enclosure, which protects the electronics from physical damage and harsh environments, is fabricated of die-cast, low-copper aluminum alloy. It consists of four pieces: the body, the electronics cover, the keypad cover, and the lower cover. Silicone-rubber gaskets seal the unit when the covers are closed. All covers are secured by captive screws.

Note that for the Measurement Canada version of the FloBoss 407, the electronics cover, and the lower cover are secured by special captive screws. These screws have holes through the heads for adding security wire seals according to Measurement (Industry) Canada requirements.

For the standard version of the FloBoss 407, an optional padlock adapter can be added in the field. This adapter is installed on the captive screw that secures the electronics cover. With the shank (up to 0.25 inch diameter) of the padlock running through the adapter, the screw is inaccessible and the cover cannot be opened. Refer to Section 2.3 for adapter installation instructions.

The FloBoss 407 unit can be mounted either on a wall or on a 2-inch pipestand (U-bolt mounting kit is supplied). For installation information, refer to Section 1.4 and Section 2.3.

Configuration of the FloBoss 407, including installing user programs (special versions may be needed for the Measurement Canada FloBoss), requires a personal computer and ROCLINK Configuration Software. See Section 1.3.1 for compatible configuration software and its documentation.

For a more details about the FloBoss 407, refer to Section 2.

1.3.1 Related Documents and Compatibility

For software aspects such as configuration, refer to the following manual:

♦ Type RL101 ROCLINK Configuration Software User Manual (Form A6051) – ROCLINK

Version 2.1 or greater is required for all Measurement Canada FloBoss 407 units as well as standard FloBoss units with Version 1.05 firmware or greater. ROCLINK Version 2.1 also works with standard FloBoss units that have an earlier version of firmware. ROCLINK Version 2.0 can be used for standard FloBoss units with Version 1.04 or earlier firmware.

For FST information, refer to the following manual:

♦ Function Sequence Table User Manual (Form A4625) – Provides information on setting up

an FST to run in the FloBoss, including how to use the FST Editor supplied with the configuration software.

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For accessories, refer to the following manual:

♦ ROC/FloBoss Accessories Instruct ion M anua l (Form A 4637) – Provides information

concerning accessories such as RTD sensors for the MVS.

1.4 INSTALLATION GUIDELINES

This manual provides generalized guidelines for successful installation and operation of the FloBoss

407. Planning helps to ensure a smooth installation. Be sure to consider location, ground conditions, climate, and site accessibility as well as the suitability of the FloBoss 407 application while planning an installation.

The variety of application firmware (software) in the FloBoss 407 allows it to be used in many types of installations. For additional information concerning a specific installation, contact your Fisher Representative.

1.4.1 Environmental Requirements

The FloBoss 407 case is classified as a NEMA 4X enclosure. This provides the level of protection required to keep the units operating under conditions such as harsh weather and corrosive atmospheres.

NOTE

In salt spray environments, it is especially important to ensure that the enclosure is sealed properly, including all entry and exit points. If salt is allowed to enter, it can shorten the life of the lithium battery in the FloBoss 407 and cause the battery to leak corrosive chemicals.

The FloBoss 407 is designed to operate over a wide range of temperatures, as detailed in the Environmental specifications (see Section 2.6). Outside of this range, it may be necessary to moderate the temperature in which the unit operates.

1.4.2 Site Requirements

Careful consideration in locating the FloBoss 407 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.

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♦ Locate the FloBoss 407 to minimize the length of signal and power wiring. By Code, line

power wiring must not cross meter runs.

♦ Orient solar panels used with solar-powered FloBoss 407s to face True South (not magnetic)

in Northern hemispheres. Orient solar panels used with solar-powered FloBoss 407s to face True North (not magnetic) in Southern hemispheres. Make sure nothing blocks the sunlight from 9:00

to 4:00 PM.

♦ Antennas for FloBoss 407s equipped for radio communications must be located with an

unobstructed signal path. If possible, locate antennas at the highest point on the site and avoid aiming antennas into storage tanks, buildings, or other tall structures. Allow sufficient overhead clearance to raise the antenna.

♦ To minimize interference with radio communications, locate the FloBoss 407 away from

electrical noise sources such as engines, large electric motors, and utility line transformers.

♦ Locate FloBoss 407s 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.

1.4.3 Compliance with Hazardous Area Standards

The FloBoss 407 has hazardous location approval for Class I, Division 2, Groups A, B, C, and D exposures. The class, division, and group terms are defined as follows:

Class defines the general nature of the hazardous material in the surrounding atmosphere. Class

I is for locations where flammable gases or vapors may be present in the air in quantities sufficient to produce explosive or ignitable mixtures.

Division defines the probability of hazardous material being present in an ignitable

concentration in the surrounding atmosphere. 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 hazards. ♦ Group C - Atmosphere containing ethylene, gases or vapors of equivalent hazards. ♦ Group D - Atmosphere containing propane, gases or vapors of equivalent hazards.

For the FloBoss 407 to be approved for hazardous locations, it must be installed according to the National Electrical Code (NEC) Article 501.

CAUTION

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When installing units in a hazardous area, make sure components selected are labeled for use in such areas. Installation and maintenance must be performed only when the area is known to be non-hazardous.

NOTE

Measurement Canada approved units normally require a sealed installation. Refer to your local codes for specifics.

1.4.4 Power Installation Requirements

Typical sources of primary power for FloBoss 407 installations are line power and solar power. Care must be taken to route line power away from hazardous areas, sensitive monitoring devices, and radio equipment. Local and company codes generally provide guidelines for line power installations. Adhere rigorously to all local and National Electrical Code (NEC) requirements for line power installations.

Solar power allows installation of the FloBoss 407 in locations where line power is not available. The two important elements in a solar installation are solar panels and batteries. Each must be properly sized for the application and geographic location to ensure continuous, reliable operation. Information contained in the accessories manual can help you determine the solar panel and battery requirements to fit your installation.

As a site may have additional power requirements for radios, repeaters, and other monitoring devices, Fisher Controls Field Automation Systems offers power supply and converter accessories to minimize the number of separate power sources required for an installation.

1.4.5 Grounding Installation Requirements

Grounding wiring requirements for line-powered equipment are governed by the National Electrical Code (NEC). When the equipment uses line power, the groundi ng system must terminate at the ser vice disconnect. All equipment ground ing conductors must provide an unin terrupted electr ical path to the service disconnect.

The National Electrical Code Article 250-83 (1993), paragraph c, defines the material and installation requirements for grounding electrodes.

The National Electrical Code Article 250-91 (1993), paragraph a, defines the material requirements for grounding electrode conductors.

The National Electrical Code Article 250-92 (1993), paragraph a, provides installation requirements for grounding electrode conductors.

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The National Electrical Code Article 250-95 (1993) defines the size requirements for equipment grounding conductors.

Proper grounding of the FloBoss 407 helps to reduce the effects of electrical noise on the units operation and protects against lightning. Lightning Protection Modules (LPM) are available to provide additional lightning protection for field wiring inputs and outputs. A surge protection device installed at the service disconnect on line-powered sy stems offers l ightni ng and power surge protect ion for t he installed equipmen t.

All earth grounds must have an earth to g round ro d or g rid im pedance of 2 5 ohm s or le ss as measured with a ground system tester. The g roundi ng conductor sho uld have a resis tance of 1 oh m or less between the FloBoss 407 case ground lug and the earth g r ound ro d or gr id .

The grounding installation met hod f or t he F loBoss 407 depend s on whether the pipeline has cathodic protection. On pipelines wi th cathod ic pro tectio n, the FloB os s 4 07 must be elec trical ly isolated from the pipeline.

Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the meter run. In this case, the F loBoss 407 c oul d be f lang e moun ted or sadd le-clamp mou nted directly on the meter run and grounded with a ground rod or g rid system.

Another way of providing electrical iso lation wo uld be t o moun t the FloBoss 407 on a pipe stand and use a remote Multi-Variable Sensor instal led w ith non-con duct ive condu it. Groun d t he case of the Fl oB oss 407 to a ground rod or grid system.

On pipelines without cathod ic pro tection, the p ipel ine it self may provide an adequate earth ground and the FloBoss 407 could mount direct ly on the meter run. Test with a ground sy stem tes ter to make sure t he pipeline to earth impedance is less than 25 o hms . If an adequate ground is provided by the pipeline, do not install a separate ground rod or g rid system. All grounding shou ld termina te at a si ng le poi nt.

If the pipeline to earth impedance is g reater than 25 o hms, t he FloB os s 40 7 installation should be electrically isolated and a ground r od or g rid g roundi ng system installed.

1.4.6 I/O Wiring

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. Sections 2 and 3 contain detailed information on connecting I/O wiring to the FloBoss 407.

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1.5 POWER CONSUM PTION CALCULATION

A ROC/FloBoss system’s power consumption determines power supply and battery sizing for both line and solar power supplies. Table 1-1 and Table 1-2 provide information to assist in determining power requirements. For non-analog I/O, size the I/O module scaling resistors (see Section 3) for optimal current to minimize current drain on the power supply.

1.5.1 Determining I/O Channel Power Consumption

In estimating total I/O power requirements, the “duty cycle” of each I/O channel (built-in I/O or modular I/O) must be estimated. For a non-analog I/O channel, the duty cycle is essentially the percentage of time that the I/O channel is active (maximum power consumption). For example, if a discrete output is active for 15 seconds out of every 60 seconds, the duty cycle is:

Duty Cycle = Active time/(Active time + Inactive time) = 15 sec/60 sec = 0.25

For an analog I/O channel, the duty cycle is approximated by estimating the percentage of time the channel spends in the upper half of its range (span) of operation. For example, if an analog input wired as a current loop (4 to 20 mA) device operates in the upper half of its range 75% of the time, then 0.75 would be used as the duty cycle. If the analog channel generally operates around the midpoint of its span, use 0.5 as the duty cycle.

To calculate the total power consumed by an I/O channel, first select either the 12 or 24 volt column in Table 1-1 or Table 1-2. Then, read the minimum (P

) and maximum (P

min

) power consumption value

max

from the table for the desired I/O channel. Use the following equation to calculate the power consumption for a channel with the duty cycle taken into account:

Power = (P

x Duty Cycle) + [P

max

(1 - Duty Cycle)]

min

Multiply this value by the quantity (Qty) of I/O channels with the same duty cycle and enter the calculated value in the Subtotal column. Repeat the procedure for all other I/O channels used. For a FloBoss 407, total the values in the Subtotal column in Table 1-2, and enter the value in the I/O Modules row of Table 1-1.

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Table 1-1. Power Consumption of the FloBoss 407 and Powered Devices

POWER CONSUMPTION (mW)

DUTY SUB-

DEVICE 12V System 24V System QTY CYCLE TOTAL

Processor and I/O Termination Board (includes minimum built-in I/O power

min

N/A 800 N/A 1200 1 N/A

max

min

max

consumption) Built-in Analog Input — ROC/FloBoss -

130 440 130 440

Powered Current Loop Built-in Analog Input — Externally-

0 65 0 275

Powered Voltage Signal Built-in Pulse Input — ROC/FloBoss-

012024

Powered Built-in Pulse In put — Externally-Powered 0 0 0 0 Serial Communications Card 135 135 N/A Dial-up Modem Communications Card 395 395 N/A Leased-Line Communications Card 110 110 N/A Radio Modem Communications Card 110 110 N/A

(mW)

MVS (Integral or Remote) N/A 240 N/A 480 N/A I/O Modules Total from Table 1-2 N/A N/A N/A Radio (from Section 1.4.2) N/A N/A N/A

TOTAL

NOTE: 1. For the Analog Input, the Duty Cycle is the percent of time spent in the upper half of the operating range.

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Table 1-2. Power Consumption of the I/O Modules

POWER CONSUMPTION (mW)

I/O MODULE 12V System 24V S ys tem QTY CYCLE TOTAL

min

max

min

max

AI Loop 170 495 170 495 AI Differential 75 75 75 75 AI Source 110 305 130 470 AO Source 145 585 145 585

RTD Input (P P

is at 100° C)

max

is at -50° C;

min

240 475 475 930

DI Isolated 1 10 1 10 DI Source 1 55 1 205 PI Isolated 1 30 1 30 PI Source 1 70 1 230 SPI Isolated 1 10 1 10 SPI Source 1 55 1 205

DUTY SUB-

(mW)

Low-Level PI 1 45 1 45 DO Isolated 1 25 1 25

DO Source (P

is at 57 mA)

max

30 815 30 1585

DO Relay 12V 15 375 N/A N/A DO Relay 24V N/A N/A 20 470 HART Interface Module 85 685 85 1285

TOTAL

NOTES: 1. For analog I/O channels, the Duty Cycle is the percent of time spent in the upper half of the operating range.

2. The P

amount includes any power drawn by a ROC/FloBoss-powered field device, such as a transmitter.

max

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1.5.2 Determining Radio Power Consumption

In determining power requirements for radios, the duty cycle for the radio must be estimated. The duty cycle is the percentage of time the radio 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 radios that use power from the ROC/FloBoss, and enter the total calculated value in Table 1-1.

1.5.3 Totaling Power Requirements

To adequately meet the needs of the ROC/FloBoss system, it is important to determine the total power consumption, size solar panel, and battery backup requirements accordingly. For total power consumption, add the device values in Table 1-1. Although Table 1-1 and Table 1-2 take into account the power supplied by the ROC/FloBoss to its connected devices, be sure to add the power consumption (in mW) of any other devices used with the ROC/FloBoss in the same power system, but not accounted for in the tables.

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

To convert P 24 volts.

to current consumption in amps (ISF), divide PSF by the system voltage (V), either 12 or

ISF = PSF / V = _____ Amps

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1.6 STARTUP AND OPERATION

Before starting the FloBoss 407, perform the following checks to ensure the unit is properly installed.

♦ Make sure the enclosure has a good earth ground con nected to the eart h gr ound bus inside the

enclosure.

♦ Seat and secure all I/O modules in the ir s ockets . ♦ Check the field wiring for proper insta llat ion . ♦ Make sure the input power is fused a t the power source. ♦ Make sure the input power has the correct polar ity . ♦ Make sure the input power is at least 12.5 volts (unless Switch S1 on the ter mination board of

newer FloBoss units—see Section 2—is depre ssed du ring power-up ).

CAUTION

Check the input power polarity before turning on the power. Incorrect polarity can damage the ROC/FloBoss.

CAUTION

When installing units in a hazardous area, ensure components selected are labeled for use in such areas.

1.6.1 Startup

Observe cautions above, and then apply power to the FloBoss 407. After the FloBoss completes startup diagnostics of Random Access Memory (RAM) and other internal checks, the STATUS LED on the processor board turns on. This LED should turn on, and stay on, to show that the FloBoss 407 completed a valid reset sequence. If the LED indicator does not come on, refer to the Troubleshooting and Repair paragraphs in Section 2 of this manual for possible causes.

1.6.2 Operation

Once startup is successful, it is necessary to configure the FloBoss 407 to meet the requirements of the application. The manual that comes with the configuration software describes in detail the procedures for configuring the FloBoss and calibrating the I/O. Once the FloBoss is configured and calibrated, it can be placed into operation.

CAUTION

Configuration of the FloBoss must be performed only in an area known to be nonhazardous.

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1.7 KEYPAD OPERATION

Table 1-3 provides a brief description of the keypad functions and the expected displays. For a detailed description, refer to Section 5 of this manual.

To activate the display, press any key, for example

I/O SUMMARY

the display. Enter the numeric password with the keypad and press

. This returns a password prompt to

ENTER.

A date and time message

shows on the LCD. Refer to Section 5.5 concerning password security.

Select one of the categories to view from the keypad. The information scrolls on the LCD. Press

DISPLAY

display until the

to stop the list from scrolling on the LCD. The FloBoss 407 continuously updates the current

HOLD DISPLAY

key is pressed again to return the list to the scroll mode.

Table 1-3. FloBoss 407 Keypad Functions

KEY DISPLAY

Log On Press Any Key Password prompt

Enter Password Date and time I/O SUMMARY Tag, value, and alarm for each I/O point

ALT, I/O DETAIL Parameters for selected I/O point

FLOW RATES Flow parameters for selected meter run

ALT, COMM PORTS Parameters for selected communications port

FLOW COMP Gas composition for selected meter run Parameter ALT, SYS PARAM System parameters: address, contract hour, etc. Lists METER CONFIG Meter configuration for selected meter run

ALT, TIME Date and time

CONTROL Parameters for selected PID loop

ALT, FST Parameters for selected FST

USER LIST 1,2,3 User defined parameter list 1, 2, or 3

ALT, CALIBRATE Calibration procedure

HOLD

ALARMS Alarm log

ALT, MIN/MAX Minimum and maximum history log History ALT, MINUTE HIST Minute history log Functions ALT, HOURS HIST Hours history log

ALT, DAY HIST Day history log Display UP, DOWN Manually scrolls parameter list

Control ALT, PREV/NEXT SET Selects previous or next set of parameters

HOLD DISPLAY Stops scroll; updates value; press again to resume

EDIT Allows edit of current parameter; enter to save Keypad BACKSPACE Edit mode backspace erase Control CANCEL Stops edit mode; resumes list display

ALT, CANCEL Cancels the operation in progress

QUIT ALT, PASSWORD Logs out current user; displays password prompt

ALT, DISPLAY OFF Logs out current user; shuts the display off

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The

DOWN ARROW

The

UP ARROW

key displays the next parameter in the list or changes the display to the next point.

key displays the previous parameter in the list or changes the display to the previous

point.

The “7” key would activate the selected I/O point.

key activates the key functions labeled below each key. For example, pressing

ALT

function which would display the entire set of parameters for the

activates the

DISPLAY OFF

function and turns off the LCD. Press

ALT

I/O DETAIL

and

ENTER

ALT

and the

any key to reactivate the LCD.

The

key activates the functions labeled in red on each key. This includes the numeric digits, the

EDIT

“-”, the “.”, and the backspace (←) key. The backspace key is an edit-only function. Those parameters that allow editing can be changed if the edit mode is selected. The

CANCEL

key stops the edit mode and

resumes list display.

1.8 SERVICE BULLETINS

Fisher issues service bulletins periodically to provide information related to hardware and software products. Fisher Representatives are responsible for local distribution of service bulletins to customers as required. Contact your Fisher Representative for more information.

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SECTION 2 — THE FLOBOSS 407 BASE UNIT

2.1 SCOPE

This section describes the FloBoss 407 and its main components: the processor board and termination board. For options, refer to the remaining sections of this manual. Topics covered in this section are:

Information Section Page Number

Product Description 2.2 2-2

Functionality 2.2.1 2-2 Processor Board Description 2.2.2 2-5 FloBoss 407 Termination Board Description 2.2.3 2-8

Installation 2.3 2-11

Installing the FloBoss 407 Unit 2.3.1 2-11 Installing FloBoss 407 Options and Accessories 2.3.2 2-12

Connecting the FloBoss 407 to Wiring 2.4 2-14

Connecting Ground Wiring 2.4.1 2-14 Connecting Main Power Wiring 2.4.2 2-14 Built-in Analog Input Wiring 2.4.3 2-15 Built-in Pulse Input Wiring 2.4.4 2-16 Connecting Communications Wiring 2.4.5 2-17 Multi-Variable Sensor Wiring 2.4.6 2-19

Troubleshooting and Repair 2.5 2-19

LED Indicators 2.5.1 2-19 Backup Procedure Before Removing Power 2.5.2 2-21 After Installing Components 2.5.3 2-22 Warm Start 2.5.4 2-23 Cold Start 2.5.5 2-23 Fuses 2.5.6 2-24 RAM Backup and Real-Time Clock Battery 2.5.7 2-25 Calibrating the Board Temperature Input 2.5.8 2-26 Testing the Built-in Analog Input Channels 2.5.9 2-26 Testing the Built-in Pulse Input Channel 2.5.10 2-27 Replacing the Processor Board 2.5.11 2-28 Replacing the Termination Board 2.5.12 2-29 Replacing the Flash ROM 2.5.13 2-31 Keypad and Display Replacement 2.5.14 2-32 Integral MVS Replacement 2.5.15 2-32

Specifications 2.6 2-32

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2.2 PRODUCT DESCRIPTION

This section describes the functionality of the FloBoss 407, as well as its processor and termination boards. The processor board has the microprocessor, memory components, the keypad, display interfaces, and the connectors for mounting the communications board. The termination board has the power supply circuitry, the communications ports, I/O ports, and the on-board monitoring circuitry.

2.2.1 Functionality

This section describes the functions of the FloBoss 407, most of which are determined by its firmware, programmed by the factory into flash memory (see Section 2.2.2). The features and applications provided by the firmware, which must be configured by using ROCLINK Configuration Software, are:

♦ Either 1985 or 1992 AGA3 flow calculations for an orifice meter, plus AGA7 flow

calculations for a turbine meter.

♦ Archival of data for up to 50 history points. ♦ Memory logging of 240 alarms and 240 events (plus audit log events for the Measurement

Canada version).

♦ Logic and sequencing control using a user-defined FST program. ♦ Closed loop control (PID) capability. ♦ Power cycling control for a radio (not available in Measurement Canada version). ♦ Report-by-exception (RBX) alarming capability (Version 1.05 and greater). ♦ Capability to load and run user programs, such as the Modbus Protocol Emulation Program.

2.2.1.1 Flow Measurement

One of the primary functions of the FloBoss 407 is to measure the flow of natural gas in accordance with the 1985 or 1992 American Petroleum Institute (API) and American Gas Association (AGA) standards. The FloBoss performs either 1985 or 1992 AGA3 orifice calculations, depending on which was ordered (firmware Version 1.04 and earlier contains both). In addition, all versions of FloBoss 407 firmware contain the AGA7 turbine meter flow calculation function.

The primary inputs used for the orifice metering flow measurement function are differential pressure, static pressure, and temperature. These inputs typically come from the Multi-Variable Sensor (MVS). The temperature input typically comes from an RTD probe, whether connected to the MVS or not.

The 1985 flow calculation is in accordance with AGA Report No. 3 1985 and AGA Report No. 8 1985 (ANSI/API 2530-85 and API Chapter 14.2), and API Chapter 21.1. The 1985 flow calculation may be configured for either Metric or English units.

The 1992 flow calculation is in accordance with AGA Report No. 3 1992 (ANSI/API 2530-92), AGA Report No. 8 1992 2nd printing 1994 (API Chapter 14.2), and API Chapter 21.1. The 1992 flow calculation may be configured for either Metric or English units.

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The primary inputs used for the turbine metering flow measurement function are meter pulse input, static pressure, and temperature. These inputs typically come through I/O modules installed on the FloBoss 407. The flow calculation is in accordance with AGA Report No. 7. The flow calculation may be configured for either Metric or English units.

2.2.1.2 History Points

A total of 50 history points may be set up and accessed in the FloBoss 407. The first six or eight are pre-configured for flow history on Meter Run #1 (required for EFM reporting). These points can be changed if needed. The time stamp for periodic logging consists of the month, day, hour, and minute. The exception is for FST Second logging, in which the time stamp consists of the day, hour, minute, and second.

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

The FloBoss has a total of 840 hourly historical logs available for every history point. The Hourly Historical Log is also called the Periodic Log. Normally, the Hourly Log is recorded every hour at the top of the hour. The exception is for FST-controlled logging.

The FloBoss has a total of 35 daily historical logs for every history point. The Daily Log is recorded at the configured contract hour every day with a time stamp that is the same as the Hourly Log. Each history point has daily historical log entries unless the history point is configured for FST-controlled logging.

2.2.1.3 Alarm and Event Lo gs

Alarm and event logs are stored in non-volatile RAM in the FloBoss. Note that they are not stored to flash ROM when the Save Configuration function is used in the ROCLINK Configuration Software.

The Alarm Log records instances when exceptions from field inputs and calculations occur. The system Alarm Log has the capacity to maintain and store up to 240 alarms in a “circular” log. The alarm log has information fields which include time and date stamp, alarm clear or set indicator, and either the tag name of the point which was alarmed with the current value or a 14 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, to external host packages, to FSTs, and to User C programs. Alarm Logs are not stored to the flash ROM during the ROCLINK Save Configuration function. The Alarm Log operates in a circular fashion with new entries overwriting the oldest entry when the buffer is full. The alarm log provides an

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audit history trail of past operation and changes. The Alarm Log is stored separately to prevent recurring alarms from overwriting configuration audit data.

Event logs contain a record of operator changes and system events such as power-downs. The event log operates in a circular fashion, with new entries overwriting the oldest entry when the buffer is full. The event log provides a history of past operation and changes. The event log is stored separate from the alarm log to prevent recurring alarms from overwriting configuration change events.

In addition to providing functionality for appending new events to the log, it allows host packages to request the index of the most recently logged event entry. Event logging is available internally to the system, to external host packages, and to the FST.

The Audit Log is a specialized type of event log set up only for the Measurement/Industry Canada version of the FloBoss. It contains changes to any flow-related parameter made through the protocol. The Audit Log has the capacity to maintain and store up to 240 events. Once the Audit Log fills up, a flag must be cleared by saving the log to a disk file; then the FloBoss will allow parameter changes and resume recording audit events. The 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 ASCII description.

2.2.1.4 Function Sequence Tables (FSTs)

The FloBoss supports FST user programmability. The FST program can be as many as 300 lines of code, depending upon the FST. The FST code resides in static RAM and is backed up to flash memory when the “save configuration” function is issued through the ROCLINK Configuration Software. See the configuration software user manual and the Function Sequence Table (FST) User Manual (Form

A4625).

2.2.1.5 PID Control

The PID Control functionality is used to provide control of a process variable to a user-entered setpoint by automatically adjusting the output to a regulating device, such as a control valve. PID Control can only be implemented if I/O modules are installed in the FloBoss to provide a control output. This output can be achieved either through an Analog Output or a through a pair of Discrete Outputs for open/close control. Override Control of a secondary variable may also be set up.

2.2.1.6 Power Control

The Power Control function (available in Standard firmware only) is used with communications port to provide power savings when using a radio or cell phone for communications. Three cycling “zones” are provided, but zones can be disabled as desired. Either a Discrete Output module (for COM1 or COM2) or the DTR signal (for COM2 only) provides the switching mechanism.

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The Power Control function calculates which zone should be currently active. 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.

2.2.1.7 Report By Exception ( R BX) Alarming

The RBX Alarming function (added for Version 1.05 and greater) allows a communications port to be set up to enable the FloBoss to contact the host computer when specified alarm conditions exist.

2.2.2 Processor Board Description

The processor board components define the functionality of the FloBoss 407. The processor board provides the following:

♦ NEC V25+ microprocessor ♦ On-board static RAM ♦ Flash memory for program storage ♦ Keypad port ♦ Display port ♦ Communications card port ♦ Real-time clock ♦ Battery backup power ♦ Status indicator ♦ Reset switch

Figure 2-1 shows a view of the processor board mounted on the door of the FloBoss 407 case and the termination board mounted in the FloBoss 407 case.

The FloBoss 407 derives processing power from a NEC V25+ microprocessor. The NEC V25+ is a 16bit CMOS microprocessor featuring dual 16-bit internal data buses and a single 8-bit external data bus. The unit can address up to one megabyte of memory and features high-speed direct memory access.

The processor board has 512 Kbytes of static random access memory (SRAM) for storing interrupt vectors, Function Sequence Tables (FSTs), ROC displays, alarms, events, user program data, and history data.

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+T POWER SUPPLY JUMPER (P15 or W1)

COM2 (CO M M BOAR D I/O)

COMM BOARD CONNECTORS

BACKUP BATTERY

PROCESSOR

BOARD RESET STATUS

INDICATOR

LV START (S1)

COM1 (RS-232)

RJ11 BRACKET

POWER INDICATOR

POWER CONNECTOR

Figure 2-1. Processor and Termination Boards

AI/PI JUMPER (P4)

PI STATUS INDICATOR

EXTERNAL GROUNDING TERMINAL

OPER AT OR INTE R FAC E P ORT

TERMINATION BOARD

I/O MODULE CONNECTORS

I/O MODULE TERMINALS AI/PI ON-BOARD I/O TERMINAL AI ON-BOARD I/O TERMINAL

MVS PORT

GROUND BUS BAR

ROC407.wmf-mod

The processor board also has a 512 Kbyte flash memory chip for storing firmware such as the operating system, factory code, user programs, and configuration parameters. A protected 64K block of flash memory contains the operating system kernel (boot block). There are four different flash chips, which determine the 407 version as follows:

♦ W68044 – Standard AGA92 Version 1.05 or greater (same part number as earlier FloBoss versions) ♦ W68073 – Standard AGA85 Version 1.05 or greater ♦ W68057 – Measurement Canada AGA92 Version 1.05 or greater ♦ W68074 – Measurement Canada AGA85 Version 1.05 or greater

Table 2-1 shows how the FloBoss 407 memory is allocated. Each memory location range (such as 00000 to 0FFFF) represents 64 Kbytes of memory.

A two-line LCD panel mounts on the display connector on the rear of the processor board. This positions the display for viewing through the main door of the enclosure.

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Table 2-1. FloBoss 407 Memory Map

MEMORY LOCATION USE

00000 to 003FF Interrupt Vectors 00400 to 0FFFF Boot Block Data 10000 to 1FFFF Events, Alarms, ROC Displays,

20000 to 2FFFF Scratch Pad/Flash Program Buffer 30000 to 3FFFF History Data 40000 to 4FFFF History Data 50000 to 5FFFF History Data

RAM

FST Data, Audit Log (Measure-

ment Canada version only), and

other Flash Program Data

60000 to 6FFFF User Program Data 70000 to 7FFFF User Program Data

FLASH MEMORY

80000 to 87FFF 88000 to 8FFFF

Configuration Save Area

Factory Program

90000 to 9FFFF Factory Program

A0000 to AFFFF User Program

B0000 to BFFFF User Program C0000 to CFFFF User Program

D0000 to DFFFF Factory Code

E0000 to EFFFF Factory Code F0000 to FFFFF Boot Block

A membrane keypad mounts on the main door of the enclosure and provides a local operator interface with the FloBoss 407. A gasketed door mounted on the main door of the enclosure protects the keypad from the elements. The keypad connects to the processor board with a ribbon cable.

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The communications connectors on the processor board provide the FloBoss 407 with electrical access and mounting provisions for the optional communications boards. The communication board mounts directly on the connectors on the processor board and is held in place with a screw passing through the communications board to a standoff on the processor board. The communications boards available for the FloBoss 407 allow the options of serial data communication, modem, radio modem, or leased-line modem communications.

A 3.6 volt lithium battery provides backup power for the RAM and the real-time clock. The backup battery mounts on the processor board with a spring clip to hold it in place. The processor board has provisions for mounting a second backup battery. This provision allows the user to replace the battery without losing backup power to the FloBoss 407.

The real-time clock provides the FloBoss 407 with the time of day date, month, year, and day of the week. The time chip automatically switches to battery power when the board loses primary input power.

An LED indicator on the processor board shows the system status. The system status indicator, when on, indicates the unit is normal; when blinking, indicates the processor board is not running; and when off, it means a missing or out-of-tolerance input voltage.

The RESET switch permits a special type of cold start from the factory default configuration (contained in the boot block of flash memory) rather than from the configuration saved to permanent memory (as in a normal Cold start). Hold the RESET switch down during power-up to initiate this cold hard start; otherwise, the switch has no effect. Perform the RAM backup procedure before performing a Cold start. Refer to Section 2.5.2, Backup Procedure Before Removing Power on page 2-21.

2.2.3 FloBoss 407 Termination Board Description

Refer to Figure 2-1. The termination board provides the following functionality to the FloBoss 407:

♦ 11 to 30 volts dc input power supply ♦ Board temperature and voltage monitor inputs ♦ Built-in field input terminals ♦ Expansion I/O module terminals ♦ External modem port ♦ Communications board port ♦ MVS port ♦ Operator interface serial port

The FloBoss 407 operates with an 11 to 30 volt dc power input to the termination board. A power indicator LED lights when an input voltage with the proper polarity and level is applied to the power terminal block if the power input fusing/protection is operational.

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The FloBoss 407 power supply circuitry provides supply voltages of +5, -5, and +8.5 volts. In addition, +12/24 volts (+T) is provided for transmitter power by means of a switching regulator.

The +T voltage is used by the built-in field I/O and the plug-in I/O modules to provide power for looppowered instruments such as transmitters. The +T voltage depends on the setting of a jumper on the termination board (P15 or W1--see Figure 2-1 on page 2-6). If Jumper P15 is set to 24V or if the W1 pins are not connected (factory default), then the +T voltage is 24 volts or greater (if the input power voltage to the FloBoss 407 exceeds 24 volts, the switching regulator shuts down and the +T voltage follows the input voltage). If Jumper P15 is set to 12V or if the W1 pins are connected (by the supplied jumper plug), then the switching regulator no longer operates, so that the +T voltage is 12 volts, provided the input power is 12 volts. This setting should only be used when all the I/O loops for this FloBoss 407 require a 12-volt source.

For Revision D or later of the termination card, the +T voltage can be software-switched. This feature allows the +T supply to be turned on or off for field devices not requiring continuous +T power. To control the +T voltage, use the Aux Out #1 or Transmitter flag in the Configuration Software.

The FloBoss 407 termination board provides a +B voltage for the plug-in field I/O modules that require it. For example, the discrete output (DO) relay modules can have either a 12 volt or a 24 volt coil. The +B voltage is the same as the input voltage applied to the FloBoss 407 and the relay module used needs to match the power supply input.

One over-current device and a soldered fuse on the termination board provide input power protection. The over-current device protects the fuse. Another over-current device on the termination board protects the +T outputs.

The LV START switch (Switch S1, found on Revision E or later or the termination card) allows the FloBoss to power up under low-voltage conditions. Normally, the FloBoss will not start up below 12.5 volts; this is a cut-off feature designed to avoid draining down the power supply battery. Hold the LV START switch down during power-up to initiate this startup. Refer to Figure 2-1 on page 2-6 to see the location of this switch.

Three diagnostic analog inputs monitor input power voltage, +T voltage, and board temperature. These values can be observed with the Configuration Software (as Analog Input points E1, E2, and E5) or with the local display panel.

The on-board (built-in) field I/O channels provide two analog inputs (AIs); one of which you can configure as a pulse input (PI). These I/O channels are suitable for use as flow inputs, including flow measurement in the Measurement Canada version of the FloBoss 407.

Two plug-in terminal blocks provide termination for the built-in I/O channels. Jumper P4 on the termination board provides the input type selection for the AI/PI channel. With P4 set to “PI,” the channel becomes pulse input. The pulse input can be connected as either a sourced or an isolated input. An LED indicator (PI IND) shows when the field input to the pulse input channel is active. Refer to Figure 2-1, Processor and Termination Boards, on page 2-6.

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The FloBoss 407 termination board has four I/O module connectors (also called slots) to accommodate a variety of I/O modules. The four plug-in I/O modules allow any combination of discrete inputs (DIs), discrete outputs (DOs), analog inputs (AIs), analog outputs (AOs), or pulse inputs (PIs) an application requires. I/O modules should not be used for flow inputs on a Measurement Canada FloBoss 407.

When installed, optional surge protection devices (lightning protection modules) protect the built-in and modular input channels from voltage transients. These devices replace the field wiring terminal blocks, providing terminations for connecting the I/O wiring to the FloBoss 407. See Appendix A for more information about the lightning protection modules.

The COM1 terminal block on the termination board provides wiring access to a built-in EIA-232 serial interface.

If the FloBoss 407 processor board has an optional communications card installed, the COM2 terminal block on the termination board provides wiring access for the communications card. Depending on the type of card, this port allows the FloBoss 407 to connect to a radio, to public, leased, or customerowned telephone lines, to another device via serial communications. The termination board has a bracket to hold an RJ11 connector for communications cards that provide a telephone line hook-up.

For installations using radio communications, battery power can be conserved by cycling power to the radio. The radio power is controlled by either the DTR signal (COM2 only) or a discrete output module. Radio power cycling can be implemented for COM1 and COM2. Refer to the ROCLINK Configuration Software User Manual for detailed information.

The MVS port on the termination board allows the FloBoss 407 to communicate directly with a MultiVariable Sensor (MVS). The MVS is a flow monitoring device that collects temperature and pressure data, making it available to the FloBoss 407 through this specialized serial port. This port can function as a multi-drop port for installations with as many as four MVS units connected to the FloBoss 407. Refer to Appendix B for details on the MVS.

The operator interface connector provides direct communications between the FloBoss 407 and the serial port of an operator interface device such as a notebook computer. The interface allows you access to the FloBoss 407 for configuration (using the ROCLINK software) and for transferring stored data.

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2.3 INSTALLATION

Before installing the FloBoss 407 or any of its options or accessories, be sure to read Section 1.3, which describes installation guidelines.

2.3.1 Installing the FloBoss 407 Unit

CAUTION

Take precautions to make sure the unit is handled properly to prevent equipment damage, and ensure that personnel are aware of any site hazards.

The FloBoss 407, with or without an integral MVS, can be mounted either on a wall or on a 2-inch pipestand. When mounting the FloBoss 407 on a wall or panel, fasten with 5/16-inch bolts (8 mm) through each of the four mounting holes. See Figure 2-2 for outline and mounting dimensions. If the FloBoss 407 has an integral MVS, refer to Appendix B for outline and mounting dimensions.

To mount the FloBoss 407 on a pipestand, with or without an integral MVS, use the U-bolt mounting kit supplied (contains 5/16-inch U-bolts). For further information on dimensions, as well as other specifications, refer to Section 2.6.

NOTE

To prolong hinge life, the FloBoss 407 should be mounted vertically. If it is necessary to mount the FloBoss 407 horizontally, make sure the hinges are located on top.

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.38 DIA MTG HOLES

9.32

2.81

4.36

11.15 12.00

DOC0205A

Figure 2-2. FloBoss 407 Outline and Mounting Dimensions

2.3.2 Installing FloBoss 407 Options and Accessories

To install a Remote MVS, refer to the instructions in Appendix B. To install I/O Modules in the FloBoss 407, refer to Section 3.3. To install a communications card in the FloBoss 407, refer to Section 4.3.

To install a padlock adapter on the FloBoss 407, follow the procedure below. Installation of other accessories for the FloBoss 407, such as solar panels and battery enclosures, is discussed in the ROC/FloBoss Accessories Instruction Manual (Form A4637).

The optional padlock adapter (not available for the Measurement Canada FloBoss 407) installs on the captive screw that secures the electronics cover. With the shank of the padlock (purchased separately) running through the stainless steel adapter, the screw is inaccessible and the cover cannot be opened. The padlock shank can be up to 0.25 inch in diameter, and the body of the padlock can be up to 1.5 inches wide.

To install the padlock adapter:

1. Open the main (electronics) cover of the FloBoss 407.

2. Remove the old retaining washer from the screw and discard the washer.

3. Position the screw, adapter, and new washer as displayed in Figure 2-3.

4. Thread the screw through the washer and into the enclosure using a screwdriver.

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5. Rotate the adapter as required using a padlock shank.

6. Install the padlock.

PADLOCK

COVER SCREW

PADLOCK ADAPTOR

FRONT VIEW

SHOWN WITH ADAPTOR

AND PADLOCK INSTALLED

Figure 2-3. Padlock Adapter Installation

RETAINING WASHER

MAIN COVER

SIDE VIEW

MAIN COVER SHOWN

OFFSET FOR CLARITY

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2.4 CONNECTING THE FLOBOSS 407 TO WIRING

The following paragraphs describe how to connect the FloBoss 407 to power, ground, I/O devices, and communications devices. Use the recommendations and procedures described in the following paragraphs to avoid damage to equipment or injury to personnel. The FloBoss 407 terminal blocks

can accommodate up to 12 AWG wire.

CAUTION

Always turn the power to the F loBoss o ff before you attem pt any t ype o f wirin g.

2.4.1 Connecting Ground Wiring

Equipment Required: Small flat-blade screwdriver

The FloBoss 407 and related components must be connected to earth ground. The National Electrical Code (NEC) governs the ground wiring requirements for all line-powered devices.

The FloBoss 407 has a ground bus bar located in the lower section of the enclosure. The ground bus bar is electrically bonded to the enclosure and provides space to connect ground wires from I/O devices, power input, and grounding conductors from devices used in the installation. For line-powered devices, the grounding conductor must end at the service disconnect. The grounding conductor can be wire or metallic conduit as long as the circuit provides a low impedance ground path.

With stand-alone units, a grounding terminal on the outside of the housing allows you to ground the FloBoss 407 directly to an earth ground. It is recommended that 12 AWG wire be used for the ground wiring. Make sure the installation has only one ground point to prevent creation of a ground loop circuit. A ground loop circuit could cause erratic operation of the system.

2.4.2 Connecting Main Power Wiring

Equipment Required: Small flat-blade screwdriver

It is important that good wiring practice be used when sizing, routing, and connecting power wiring. All wiring must conform to state, local, and NEC codes. The terminal blocks can accommodate up to 12 AWG wire. Use 18 AWG wire or larger for all power wiring.

Connect power to the FloBoss 407 through the plug-in PWR terminal block on the termination board. Connect the DC power source to the “+” and “-” terminals. Make sure the polarity is correct. Figure 2-4 shows the location of the power indicator and the power wiring terminal block.

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POWER INDICATOR

DOC0250A

Figure 2-4. Power Wiring Connections

2.4.3 Built-in Analog Inpu t Wi ring

Equipment Required: Flat-blade (1/8-inch width) screwdriver

POWER TERMINAL BLOCK

The analog input channels have three field terminals per channel. The “+T” terminal provides +24 volts dc for loop-powered devices. Each channel has a current regulator in series with the “+T” terminal to provide short-circuit protection. The maximum output of each terminal is 25 milliamps. The FloBoss 407 is shipped with a 250-ohm scaling resistor between the “+” and “-” analog input terminals.

The “+” terminal is the positive signal input and the “-” terminal is the negative signal input. These terminals accept a voltage signal in the 1 to 5 volt range. Since the “-” terminal is internally connected to common, the analog input channels function as a single-ended input only.

For use with a 4 to 20 milliamp current signal, leave the 250-ohm resistor installed between the “+” and “-” terminals. Wire the device “+” lead to the FloBoss 407 “+T” terminal and the device “-” lead to the FloBoss 407 “+” terminal. Figure 2-5 shows the wiring for a typical current signal.

For use as a voltage input, remove the 250-ohm resistor from the analog input terminal block. Figure 2-6 shows a typical voltage signal analog input.

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ROC-POWERED CURRENT LOOP DEVICE

EXTERNAL/ SELF-POWERED DEVICE

Vs = 11 TO 30 VDC +T = 24 VDC +SIGNAL = 4 TO 20 mA

250 OHM

Figure 2-5. Current Signal on Built-in Analog Input

Vs = 11 TO 30 VDC +T = 24 VDC +SIGNAL = 1 TO 5 VDC

Figure 2-6. Voltage Signal on Built-in Analog Input

1 LIMIT

DOC0098A Modified

2.4.4 Built-in Pulse Input Wiring

Equipment Required: Flat-blade (1/8-inch width) screwdriver

Changing the P4 jumper to the “PI” position allows the built-in AI/PI input channel to be used as either an isolated or a sourced pulse input. This pulse input signal is optically isolated from the FloBoss 407 circuit board. The pulse input can operate at up to 10 kHz, with a maximum 50% duty cycle.

The AI/PI channel has three field terminals. Terminal “+T” is a positive source voltage, either +24 volts or a level that follows the voltage of the FloBoss 407 input power. Terminal “+” is the positive signal input; terminal “-” is the negative signal input. Be sure to remove the supplied 250-ohm resistor from the terminal block when using the AI/PI channel as a pulse input.

To use the channel as an isolated input shown in Figure 2-7, connect the “+” and “-” field wires to terminals “+” and “-” on the FloBoss 407 Pulse Input channel. When the field device sends a voltage through terminal “+” on activation, the PI indicator LED on the termination board lights to show an active circuit and the signal triggers the optical circuitry to signal the FloBoss 407.

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AI/PI

2.5K

EXTERNALLY OR SELF POWERED PULSE DEVICE

DOC0209A

Figure 2-7. Externally-Powered Built-in Pulse Input

For use as a sourced input shown in Figure 2-8, connect the field device positive wire to terminal “+T” and the field negative lead to terminal “+”. When the discrete field device conducts, the source power flows through the LED to show an active circuit and triggers the optical circuitry to signal the FloBoss

407.

AI/PI

2.5K

DOC0210A

ROC-POWERED PULSE DEVICE

Figure 2-8. FloBoss-Powered Built-in Pulse Input

2.4.5 Connecting Communications Wiring

Equipment Required: None

The FloBoss 407 has the flexibility to communicate to external devices using several different formats and protocols. A special 3-pin connector provides a port for an operator interface device. Terminal blocks located on the termination board provide connections to the COM1 and COM2 ports. Figure 2-9 shows the COM1, COM2, and Operator Interface port locations.

The Operator Interface port provides connections for a built-in EIA-232 communications interface to a configuration and monitoring device. The configuration and monitoring device typically is a notebookstyle PC. A null modem cable (transmit and receive wires cross-connected, plus ground) must be used

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between the operator interface connector and the PC. A prefabricated operator interface cable is available as an accessory.

The FloBoss 407 has a built-in EIA-232 serial interface accessible through the COM1 communications port. The port is an 8-terminal connector located on the termination board. Refer to Table 2-2 for a description of the signals available at each terminal.

COM1

COM2

OPERATOR INTERFACE PORT

DOC0217A

Figure 2-9. Operator Interface, COM1, and COM2 Ports

Table 2-2. COM1 Port Signals

TERMINAL 1 2 3 4 5 6 7 8

COM1 Signal RXD TXD RTS CTS DCD DTR* DSR COM

*This signal is permanently enabled (connected to +10 Vdc).

The COM2 port provides communications access to an optional plug-in communications card. Section 4 details the types of communications cards available for the FloBoss 407 and has information on connecting wiring to the COM2 connector.

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2.4.6 Multi-Variable Sensor Wiring

For information on MVS wiring, refer to Appendix B.

2.5 TROUBLESHOOTING AND REPAIR

Troubleshooting and repair procedures are designed to help the technician identify and replace faulty boards and modules. Return faulty boards and modules to your Fisher Representative for repair or replacement. To troubleshoot I/O modules and communications cards, refer to Sections 3.5 and 4.5, respectively.

The following tools are required for troubleshooting:

♦ IBM-compatible personal computer ♦ ROCLINK Configuration Software ♦ Battery-powered digital multi-meter, Fluke 8060A or equivalent.

The configuration software runs on the personal computer and is required for a majority of the troubleshooting performed on the FloBoss 407. Refer to the configuration software manual as needed.

2.5.1 LED Indicators

The FloBoss 407 has three LED indicators to verify operational functionality. Figure 2-10 shows the location of the indicators and Table 2-3 gives the indicator functions.

When lit, the POWER LED shows that power is applied to the FloBoss 407.

The STATUS LED, located on the processor board, gives a first-level indication of the operation of the FloBoss 407. After the power is switched on, the STATUS indicator should come on, and remain on to indicate normal operation. If the STATUS indicator does not remain on, check Table 2-3 for possible causes.

The PI LED located on the termination board shows the state of the Pulse Input channel. When the LED is on, the PI channel is active.

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PULSE INPU T IN D ICATOR

LV START SWITCH

POWER INDICATOR

DOC0207A-mod

STATUS INDICATOR

Figure 2-10. FloBoss 407 Indicator Locations

Table 2-3. Indicator Functions

INDICATOR STATUS DESCRIPTION

STATUS ON Successful startup and the processor is running. STATUS BLINKING Processor is not running and is attempting to restart.

Can result from bad clock battery (see Section 2.5.7).

STATUS OFF No input power, circuit protection devices

overloaded, insufficient voltage available to power up (see Section 2.5.3), or input power polarity reversed.

POWER ON

Power is connected. Must be minimum of 12.5 volts, unless LV START switch is used (see Figure 2-10

and Section 2.5.3). POWER OFF Power not applied. PI IND ON Input active. PI IND OFF Input not active.

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2.5.2 Backup Procedure B efore Removing Power

Use the following backup procedure when removing or adding FloBoss 407 components. This procedure preserves the current FloBoss 407 configuration and data held in RAM.

Before removing power to the FloBoss for repairs, troubleshooting, or enhancements, perform the backup procedure to avoid losing the FloBoss configuration and other data held in RAM. The procedure assumes you are using ROCLINK Configuration Software Revision 2.10 or greater.

User programs cannot be saved out of the FloBoss. You need to reload user programs from their original disk files as instructed in Section 8 of the ROCLINK User Manual.

CAUTION

There is a possibility of losing the FloBoss configuration and historical data held in RAM while performing the following procedure. As a precaution, save the current configuration and historical data to permanent memory as follows.

CAUTION

When installing devices in a hazardous area, make sure each device is labeled for use in such areas. Procedures involving switching power on or off, or procedures for installing or removing any wiring or components, must be performed only when the area is known to be non-hazardous.

CAUTION

To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap.

1. Save the current configuration data to internal configuration memory as instructed in the ROCLINK User Manual for the ROC Flags display. This action saves most of the FloBoss configuration into the permanent memory accessed when a cold hard start is performed.

2. Save the current configuration data to disk by using the Download/Save ROC Configuration To Disk function described in Section 2.10 of the ROCLINK User Manual. When replacing or physically upgrading a Flash memory chip, the only way to preserve configuration data is to save the data to disk and then retrieve the information after the chip is installed.

3. Save all historical database logs (Minute, Hourly, and Daily) to disk as explained in Section 7 (or Section 2.9) of the ROCLINK User Manual.

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4. Save the Event and Alarm logs to disk as explained in Section 7 (or Section 2.9) of the ROCLINK User Manual. If you have a Measurement Canada FloBoss, also save the Audit Log to disk. This action clears the audit flags but not the entries, enabling 240 new entries to come into the Audit Log. The AGA Reports utility also clears the flags when reports are saved to disk.

5. Save each Function Sequence Table (FST) program (up to four possible) to disk using the “Write FST” function in the FST Editor utility of the ROCLINK software. See Section 4.2 of the FST User Manual (Form A4625) for more information.

2.5.3 After Installing Compon ents

After removing power to the FloBoss and installing components as needed, perform the following steps to start your FloBoss and reconfigure your data. You must use configuration software that is compatible with the firmware version of the FloBoss 407, as described in Section 1.3.

NOTE

For Measurement Canada units, maintenance and resealing of the FloBoss must be performed by authorized personnel only.

CAUTION

Ensure all input devices, output devices, and processes remain in a safe state upon restoring power.

1. Connect the PWR terminal block to restore power.

Due to a cut-out feature designed to avoid draining down the power supply

NOTE

battery, the FloBoss 407 normally requires a minimum of 12.5 volts to start up. However, this feature can be bypassed on newer FloBoss 407s by depressing the LV START switch (see Figure 2-10 on page 2-20) while applying power.

2. Using the configuration software, check the configuration data (including ROC displays) and FSTs. If the configuration contained in RAM was lost or corrupted, the configuration contained in flash memory will automatically be used.

3. Load or modify the configuration and FSTs as required.

4. Load and start any user programs as needed. User programs need to be reloaded from their original disk files as instructed in Section 8 of the ROCLINK User Manual.

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5. Verify the FloBoss performs as required.

6. If you changed the configuration, save the current configuration data to permanent configuration memory.

7. If you changed the configuration or any FSTs, save them to disk. See Section 2.5.2 for more information on performing these saves.

2.5.4 Warm Start

A warm start temporarily suspends all input/output (I/O) scanning. I/O processes are restarted from their last calculated values. A warm start clears and restarts all user-enabled flags. A warm start also starts all FSTs to the first instruction.

NOTE

If your FloBoss is semi-functional, perform the RAM Backup Procedure before removing power from your FloBoss. Refer to Section 2.5.2, Backup Procedure Before Removing Power, on page 2-21.

To perform a warm start, remove power from your FloBoss and reapply power.

2.5.5 Cold Start

A cold start reloads all configuration data from electrically erasable read only memory (EEPROM), clears all history, events, and alarm logs, disables all user program tasks, and disables all user data types. The RESET switch permits a restart from the boot block of the flash memory (cold hard start) rather than from RAM (warm start). Hold the RESET switch down during power-up to initiate a cold hard start; otherwise, the switch has no effect.

NOTE

If your FloBoss is semi-functional, perform the previously described RAM Backup Procedure before removing power from your FloBoss. Refer to Section 2.5.2, Backup Procedure Before Removing Power on page 2-21.

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CAUTION

The cold hard start reloads all restart configuration data from programmable ROM (flash memory). Generally, a Cold Hard Start should not be used on a FloBoss that is actively gathering data and performing control. Save or document all data and parameter values that could be affected before performing the cold hard start. Refer to Section 2.5.2, Backup Procedure Before Removing Power on page 2-21.

The following list shows the values that are saved to memory and restored after a Cold Hard Start.

♦ Device Address and Group. ♦ Station name. ♦ Number of history points in each module. ♦ Contract hour. ♦ User program enable flags – COM1, COM2, and USER/CALC ♦ All communication port settings, including power control settings. ♦ History point configuration. ♦ Discrete input parameters. ♦ Discrete output parameters. ♦ Analog input parameters. ♦ Analog output parameters. ♦ Pulse input parameters. ♦ AGA parameters. ♦ PID parameters. ♦ Configurable Opcode parameters. ♦ AI Calibration. ♦ FST tags. ♦ FST registers. ♦ FST run flag is cleared. ♦ FST instruction pointer is reset to the first instruction. ♦ Softpoints tags are set to their default values and all registers are set to zero.

2.5.6 Fuses

The FloBoss 407 uses the overload protection devices listed in Table 2-4. The overload protection devices are not field replaceable.

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Table 2-4. Overload Protection Devices

ID RATING USE

F1 3A 100 VA power limiting fuse. PTR1 1.25A Input power protection. PTR2 0.30A Analog input 24 volts dc power (“+T” terminal).

2.5.7 RAM Backup and Real-Time Clock Battery

There is a battery on the processor board (installed in position B1 or B2) that provides power to the real-time clock and backup power for the RAM. If this battery fails, the clock will stop running and the FloBoss 407 will stop operating (the STATUS LED should be blinking). The battery is a 3.6volt lithium type and is secured with a hold-down clip. Under normal usage, this battery should last 5 to 10 years. However, if the FloBoss 407 is powered down for long periods of time, battery life will be shortened.

To check the condition of the clock battery, install a new battery (see the following procedure) in the unused battery socket location on the processor board, remove the existing battery, and use a multimeter to measure the voltage at the terminals of the removed battery. Leave the new battery installed if the voltage of the old battery is less than 3.2 volts. If the old battery is still good, you can re-install it into its socket and remove the new battery.

To install a clock battery into a functioning FloBoss 407 (if power is applied, it can remain applied):

NOTE

For Measurement Canada units, maintenance and resealing of the FloBoss must be performed by authorized personnel only.

CAUTION

To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap.

1. Locate the unused battery socket (typically B2) on the processor board. Insert the new battery in this position.

2. Remove the old battery from the other battery socket (typically B1) by sliding the hold-down clip to one side and lifting the battery from the board. If the clip does not readily rotate, you may need to loosen the screw that secures it.

3. Move the hold-down clip to the new battery (tighten the clip screw if you loosened it in Step 2).

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If the old battery was too weak to power the clock (the STATUS LED blinks when power is applied), you need to reset the clock and reload the configuration. Refer to Section 2.5.3.

2.5.8 Calibrating the Board T e mper ature Input

The board temperature input (diagnostic analog input E5) normally does not need to be calibrated. If you want to calibrate it, consult the factory.

2.5.9 Testing the Built-in Anal og Input Channels

Equipment Required: Multimeter

1K ohm resistor 0-5K ohm potentiometer Personal computer with ROCLINK software installed

If a built-in analog input does not function correctly, first determine if problem is with the field device or the FloBoss 407 I/O circuitry.

1. Disconnect the I/O terminal block to isolate the field device from the FloBoss 407 I/O.

2. If the FloBoss 407 provides loop power source, measure the voltage between terminal “+T”

and “-” of the AI channel under test. The loop power should be 23 volts dc minimum with jumper P15 in the 24V position (W1 open in older units), or near to input power voltage with jumper P15 in the 12V position (W1 installed).

3. Disconnect the battery terminal block. With an ohmmeter check between terminals “+T”

and “-” of the AI channel under test. If 0 ohms, the input has a shorted diode.

4. With an ohmmeter, check between terminals “+” and “-” of the AI channel under test. If 0

ohms, the input has shorted components.

5. Replace the termination board if the above tests indicate a fault. Refer to Section 2.5.10.

6. Connect a lead of a 250 ohm resistor and a 5K ohm potentiometer to the “+” terminal of the

AI channel. Connect the other resistor lead to terminal “-” and the potentiometer to terminal “+T” of the AI channel under test.

7. Connect the FloBoss 407 to a computer running the ROCLINK configuration software.

Power up the FloBoss 407.

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8. Turn the potentiometer to vary the input to simulate a transmitter. Use the ROCLINK

software to confirm the input value changes.

A positive result on the above tests would show the FloBoss 407 input is operational. Check the field wiring and transmitters for a fault.

2.5.10 Testing the Built-in Pulse Input Channel

Equipment Required: Multimeter

Jumper wire Personal computer with ROCLINK software installed

Use the following tests to verify operation of the AI/PI channel when it is configured as a pulse input (AI/PI jumper in the PI position).

1. Isolate the field device from the FloBoss 407 by disconnecting the AI/PI terminal block.

2. If the FloBoss 407 provides power to the field device, measure the voltage between terminal

“+T” and “-” of the AI/PI channel. This voltage should be 23 volts dc minimum with jumper P15 in the 24V position (W1 open in older units), or near to input power voltage with jumper P15 in the 12V position (W1 installed).

3. Connect a jumper from terminal “+T” to terminal “+” on the AI/PI connector. The LED

labeled PI IND on the termination board should light.

4. Connect the FloBoss 407 to a computer running the ROCLINK configuration software.

5. Again connect a jumper from terminal “+T” to terminal “+” on the pulse input connector.

The PI LED on the termination board should light. Use the ROCLINK software to confirm that the input value changes for point A7.

Replace the termination board if the above tests indicate failure. Refer to Section 2.5.12. A positive result on the above tests would show that the input is operational. Check the field wiring and transmitters for a fault.

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2.5.11 Replacing the Process o r Board

Equipment Required: Hex nut driver

Personal computer with ROCLINK software installed

Refer to Figure 2-1. Proceed as follows to replace the FloBoss 407 processor board:

NOTE

For Measurement Canada units, maintenance and resealing of the FloBoss must be performed by authorized personnel only.

CAUTION

There is a possibility of losing the configuration and historical data held in RAM while performing the following procedure. As a precaution, save the current configuration and historical data to permanent memory. Refer to Section 2.5.2.

CAUTION

To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap.

CAUTION

During this procedure, all power will be removed from the FloBoss and devices powered by the FloBoss. Ensure that all connected input devices, output devices, and processes will remain in a safe state when power is removed from the FloBoss and also when power is restored to the FloBoss.

1. Perform the RAM backup procedure. Refer to Section 2.5.2, Backup Procedure

Before Removing Power on page 2-21.

2. Disconnect the PWR input connector from the termination board.

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The FloBoss 407 requires a minimum of 12.5 volts to start up. However, a newer FloBoss 407 can be restarted below 12.5 volts by depressing the LV START switch (see Figure 2-10 on page 2-20) while applying power.

3. Unplug the processor board power supply cord on the termination board at P1.

4. Disconnect the ribbon cable at P3 on the processor board.

5. Disconnect the keypad ribbon connector at P4 on the processor board.

6. Remove the communications card if present by removing its retaining screw and unplugging

the card from its mating connectors.

7. Remove the six nuts securing the processor board, and lift the board out of the case.

8. Remove the LCD from the processor board.

9. Install the LCD on the new processor board.

10. Place the new processor board in the case. Install the screws to secure the board to the case.

11. Install the keypad ribbon connector at P4 on the processor board.

NOTE

12. Install the ribbon cable at P3 on the processor board.

13. Install the communications card if required.

14. Plug the processor board power supply cord into P1 on the termination board.

15. Refer to Section 2.5.3, After Installing Components on page 2-22.

2.5.12 Replacing the Termination Board

Equipment Required: Small Philips screwdriver

Personal computer with ROCLINK software installed

Refer to Figure 2-1. Proceed as follows to replace the termination board:

CAUTION

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FloBoss 407 Instruction Manual

To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap.

For a Measurement Canada FloBoss 407, resealing of the case must be performed by authorized personnel only.

1. Perform the RAM backup procedure. Refer to Section 2.5.2 on page 2-21.

2. Disconnect the PWR input connector (terminal block) from the termination board.

CAUTION

NOTE

3. Disconnect all connected field wiring, including MVS, built-in inputs, and I/O

modules. This can be done by unplugging the terminal blocks.

4. Disconnect all communication card and RJ11 wiring if necessary.

5. Disconnect the ribbon cable at P3 on the termination board.

6. Disconnect operator interface port wiring on the termination board at P2.

7. Disconnect the processor board power connector from the termination board at P1.

8. Remove the five screws securing the termination board, and lift the board out of the case.

9. Place the new termination board in the case and install the securing screws to the case.

10. Connect the ribbon cable at P3 on the processor board.

11. Connect the communication card wiring if required.

12. Connect the field wiring.

13. Connect the operator interface port wiring on the termination board at P2.

14. Connect the processor board power connector to the termination board at P1.

15. Plug the processor board power supply cord into P1 on the termination board.

16. Refer to Section 2.5.3, After Installing Components on page 2-22.

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2.5.13 Replacing the Flash ROM

Equipment Required: Flash ROM extractor

Personal computer with ROCLINK software installed

Note that a firmware upgrade can also be performed without removing the flash chip; see the Update Firmware procedure described in Section 2 of the ROCLINK user manual. Proceed as follows to physically replace the FloBoss 407 flash ROM chip (refer to Figure 2-1):

CAUTION

During the following procedure, configuration data held in Flash ROM will be lost. There is also a possibility of losing the configuration and historical data held in RAM. Therefore, save the current configuration and historical data to permanent memory. Refer to Section 2.5.2.

CAUTION

To avoid circuit damage when working with the unit, use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap.

CAUTION

NOTE

For a Measurement Canada FloBoss 407, resealing of the case must be performed by authorized personnel only.

1. Perform the RAM backup procedure. Refer to Section 2.5.2, Backup Procedure

Before Removing Power on page 2-21.

2. Disconnect the PWR input connector from the processor board.

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3. Using a Flash ROM Extractor, remove the flash ROM chip located at U2 on the

termination board.

4. Gently press the new flash ROM chip into the socket located at U2 on the

termination board. The flash ROM chip should fit securely into the socket.

5. Connect the PWR input connector to the processor board.

6. Refer to Section 2.5.3, After Installing Components on page 2-22.

7. Refer to the ROCLINK Configuration Software User Manual, which explains how to

load updated firmware and user programs into the flash ROM (if required).

NOTE

2.5.14 Keypad and Display Replacement

To replace a damaged or faulty keypad or display, contact your Fisher Representative.

2.5.15 Integral MVS Replac ement

If an MVS that is integral with a FloBoss 407 needs to be replaced or repaired, contact your Fisher Representative.

2.6 SPECIFICATIONS

The following pages provide a table of specifications for the FloBoss 407.

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FloBoss 407 Specifications

PROCESSOR

NEC V25+ running at 10 MH z.

MEMORY

Program:

programmable) for firmware, configuration, etc.

Data: Memory R es e t :

switch enables a cold start from factory defaults.

TIME FUNCTIONS

Clock Type:

supply, battery-backed. Year/Month/Day and Hour/Minute/Second.

Clock Accuracy: Watchdog Timer:

1.2 seconds and resets the processor. Processor restart is automatic.

DIAGNOSTICS

These values are monitored and alarmed: RAM validity/operation, analog input mid-scale voltage, power input voltage, and board tem per atur e.

COMMUNICATIONS PORTS

Operator Interface:

Software configured; 300 to 9600 BPS baud rate selectable. Screw-cap protected connecto r.

COM1:

Software configured; 300 to 9600 BPS baud rate selectable. Eight-terminal connector provided on I/O board.

COM2:

communications card. Nine-terminal connector provided on I/O board.

POWER

Input:

for input sourcing, I/O modules, MVS, and communications card.

Loop/Source:

for transmitter power at the “+T” terminals (25 mA maximum) and at the “A” terminals on the modular I/O channels.

ANALOG INPUTS (BUILT-IN)

Quanti ty/Type:

(current loop if scaling resistor is used).

Terminals:

negative input ( common) .

Voltage:

mA, with a 250 ohm resistor install ed across ter minals “+” and “-”.

512 Kbyte flash ROM (electrically

512 Kbyte battery-backed SRAM.

When used during power-up, Reset

32 kHz crystal oscillator with regulated

0.01%. Hardware monitor expires after

EIA-232 (RS-232D) format.

EIA-232 (RS-232D) format for general use.

Serial or modem interface, with optional

11 to 30 Vdc. 0.8 W typical, excluding power

Normally 23 Vdc minimum provided

1 or 2 singl e- end ed voltage-sense

“+T” loop power, “+” positive input, “-”

0 to 5 Vdc, software configurable. 4 to 20

ANALOG INPUTS (CONTINUED)

Accuracy: Impedance: Filter: Resolution: Conversion Time:

PULSE INPUT (BUILT-IN)

Sample Period: Quanti ty/Type:

pulse counter input when PI jumper is set.

Terminals:

negative input ( common) .

Voltage:

state).

Frequenc y: Sample Period:

MVS INTERFACE

Type:

power for as many as 4 MVS units located up to 4000 feet from the FloBoss.

Terminals: Polling Period:

I/O MODULES (OPTIONAL)

Four slots provided for optio nal I/O modul es. Any type and combinati on o f I / O modu le s can be u sed.

FRONT-PANEL USER INTERFACE

Display:

0.75 by 3.25 inches.

Keypad:

allow numerical entries.

ENVIRONMENTAL

Operating Temperature:

°F), excluding display, which is -20 to 70 °C (-4 to 158 °F).

Storage Temperature:

185 °F).

Operating Humidity: Vibration:

racy when tested to SAMA PMC 31.1, Section 5.3, Condition 3.

ESD Susceptibility: EMI Susceptibility: RFI Susceptibility:

when tested per SAMA PMC 33.1 in field classified as 3-abc with field strength of 30 V/m, circuit board properly mounted, and doors closed.

0.1% over operating temperature range. One megohm.

Double-pole, low-pass.

12 bits.

30 microseconds.

50 ms mi ni mu m.

1 high-speed source or isolated

“+T” source power, “+” positive input, “-”

8 to 30 Vdc (ON st ate) ; 0 t o 4 V d c (O FF

10 kHz ma xi mu m.

50 ms mi ni mu m.

High-speed, multi-drop, serial interface with

“A” and “B” for data; “+” and “-” for power.

1 sec max.

2 line by 20 chara cte r LCD. Ove rall siz e is

15 multi-function, membrane keys. Keys

-40 to 75 °C (- 40 to 167

-50 to 85 °C (-58 to

To 95% non-condensing.

Less than 0.1% effect on overall accu-

Meets IEC 801-2, Level 3.

Meets IEC 801-4, Level 4.

No effect on operation of unit

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Specifications (Continued)

DIMENSIONS

Overall, FloBoss 407 only:

by 4.4 in. D (305 mm by 236 mm by 112 mm).

Overall, with Integral MVS:

by 5.1 in. D (457 mm by 236 mm by 130 mm).

Wall Mounting:

mm) between mounting hole centers. Mounting hole diameter is 0.37 in. (9.4 mm).

Pipestand Mounting:

U-bolt mounting kit (included).

ENCLOSURE

Die-cast low-copper aluminum alloy with three 0.75 in.

NPT holes in bottom. Single-piece gasketed doors. Coated with ANSI 61 gray polyurethane paint. Meets CSA Type 4X rating.

2.8 in. W by 12.1 in. H (71 mm by 308

12.0 in. H by 9.3 in. W

18.0 in. H by 9.3 in. W

Mounts on 2-inch pipe with

WEIGHT

FloBoss 407: With Integral MVS:

APPROVALS

Standard Version:

hazardous locations Class I, Division 2, Groups A, B, C, and D.

Measurement Canad a Ver sio n:

Measurement (Industry) Canada for gas custody transfer, in addition to app roval by CSA for hazardou s locations (see Standard Version). Note that I/O Modules must not be used to supply flow inputs to the FloBoss in a Measurement Canada installation.

7 lb. (3.2 kg).

17 lb. (7.7 kg).

Approved by CSA for

Approved by

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SECTION 3 — INPUT/OUTPUT MODULES

3.1 SCOPE

This section describes the I nput/Ou tpu t (I/O) Modules used with the FloBoss™ 407 Flow Manager and ROC300-Series products (except RO C30 6). This section contains the following information:

Information Section Page Number

Product Descriptions 3.2 3-2

Analog Input Loop and Differential Modules 3.2.1 3-3 Analog Input Source Module 3.2.2 3-4 Analog Output Source Module 3.2.3 3-4 Discrete Input Source and Isolated Modules 3.2.4 3-4 Discrete Output Source and Isolated Modules 3.2.5 3-4 Discrete Output Relay Module 3.2.6 3-5 Pulse Input Source and Isolated Modules 3.2.7 3-5 Slow Pulse Input Source and Isolated Modules 3.2.8 3-5 Low-Level Pulse Input Module 3.2.9 3-6 RTD Input Module 3.2.10 3-6 HART Interface Module 3.2.11 3-6

Initial Installation and Setup 3.3 3-7

Calibrating an I/O Module 3.3.1 3-7

Connecting the I/O Modules to Wiring 3.4 3-8

Analog Input Loop Module 3.4.1 3-8 Analog Input Differential Module 3.4.2 3-10 Analog Input Source Module 3.4.3 3-12 Analog Output Source Module 3.4.4 3-13 Discrete Input Source Module 3.4.5 3-14 Discrete Input Isolated Module 3.4.6 3-15 Discrete Output Source Module 3.4.7 3-16 Discrete Output Isolated Module 3.4.8 3-17 Discrete Output Relay Module 3.4.9 3-18 Pulse Input Source Module 3.4.10 3-19 Pulse Input Isolated Module 3.4.11 3-20 Slow Pulse Input Source Module 3.4.12 3-21 Slow Pulse Input Isolated Module 3.4.13 3-22 Low-Level Pulse Input Module 3.4.14 3-23 RTD Input Module 3.4.15 3-24

Calibrating the RTD Module 3.4.15.1 3-24 Connecting RTD Module Field Wiring 3.4.15.2 3-25

HART Interface Module 3.4.16 3-28

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Information Section Page Number

Troubleshooting and Repair 3.5 3-29

Analog Input Modules 3.5.1 3-29 Analog Output Modules 3.5.2 3-30 Discrete Input Source Module 3.5.3 3-32 Discrete Input Isolated Module 3.5.4 3-32 Discrete Output Source Module 3.5.5 3-33 Discrete Output Isolated Module 3.5.6 3-33 Discrete Output Relay Module 3.5.7 3-33 Pulse Input Source and Isolated Modules 3.5.8 3-34 Slow Pulse Input Source Module 3.5.9 3-34 Slow Pulse Input Isolated Module 3.5.10 3-35 Low-Level Pulse Input Module 3.5.11 3-35 RTD Input Module 3.5.12 3-36 HART Interface Module 3.5.13 3-36

Removal, Addition, and Replacement Procedures 3.6 3-37

Impact on I/O Point Configuration 3.6.1 3-37 Removing/Installing an I/O Module 3.6.2 3-38

I/O Module Specifications 3.7 3-40

3.2 PRODUCT DESCRIPTIONS

The I/O modules plug into the I/O module sockets and accommodate a wide range of process inputs and outputs. Units used in Measurement/Industry Canada installations must not employ I/O modules for flow measurement. The following modules are available:

♦ AI Loop ♦ AI Differential ♦ AI Source ♦ AO Source ♦ DI Source ♦ DI Isolated ♦ DO Source ♦ DO Isolated ♦ DO Relay ♦ PI Source ♦ PI Isolated ♦ Slow Pulse Input Source ♦ Slow Pulse Input Isolated ♦ Low-Level Pulse Input ♦ RTD Input ♦ HART® Interface

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Adjacent to each I/O module socket is a plug-in terminal block for field wiring connections. The plugin terminal blocks permit removal and replacement of the modules without the need to disconnect field wiring. The ROC/FloBoss accommodates any number of modules in any combination up to the limit of the I/O module rack or board. Figure 3-1 shows a typical I/O module.

STATIC

SENSITIVE

DOC0034C

Figure 3-1. Typical I/O Module

3.2.1 Analog Input Loop and Differential Modules

The Analog Input Loop (AI Loop) and Analog Input Differential (AI Differential) modules are used for monitoring current loop and voltage output devices. Each AI module uses a scaling resistor for scaling loop current to achieve the proper input voltage.

The AI Loop module provides a source voltage for powering current loop devices and can also be used as a single-ended voltage output. The AI Differential module monitors loop current or voltage input from externally-powered devices and provides electrical isolation from the ROC/FloBoss power supplies.

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3.2.2 Analog Input Source Module

The Analog Input Source (AI Source) module monitors current loop or voltage output devices. The module provides a regulated 10-volt source for powering a device, usually a low power transmitter, and uses a scaling resistor for converting loop current to input voltage.

3.2.3 Analog Output Source Module

The Analog Output Source (AO Source) module provides both a current and a voltage output for powering analog devices. These outputs are isolated from each other and can be used simultaneously. A scaling resistor is provided for setting the minimum loop resistance of the current loop to 0 ohms (installed) or 220 ohms (removed).

3.2.4 Discrete Input Source and Isolated Modules

The Discrete Input Source (DI Source) and Discrete Input Isolated (DI Isolated) modules monitor the status of relays, solid-state switches, or other two-state devices. Each module can accommodate one discrete input.

Both types of modules provide an LED that lights when the input is active and use a scaling resistor for scaling the input range. Functions supported by both modules are: discrete latched input, discrete status input, and time-duration input.

The source module provides a source voltage for dry relay contacts or for an open-collector solid-state switch. The isolated module accepts an external voltage from a powered two-state device and provides electrical isolation from the ROC power supplies.

3.2.5 Discrete Output Source and Isolated Modules

The Discrete Output Source (DO Source) and Discrete Output Isolated (DO Isolated) modules provide two-state outputs to energize relays and power small electrical loads. Each module provides one discrete output.

Both types of modules use an LED to show the status of the output and are fused for protection against excessive current. Functions supported by both modules are: sustained discrete output, momentary discrete output, slow pulse-train output, and time-duration discrete output.

The source module supplies switched current-limited power to small loads. The isolated module acts as a solid-state normally-open switch for activating externally powered devices. The solid-state switch is optically isolated from the power supplies in the ROC/FloBoss.

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3.2.6 Discrete Output Relay Module

The Discrete Output Relay (DO Relay) module provides two sets of “dry” relay contacts to switch voltages of up to 250 volts ac. One set of contacts is normally open and the other set is normally closed. Two types of relay modules are available, one with a 12 volts dc energizing coil and the other with a 24 volts dc energizing coil.

An LED shows the status of the output. Functions supported by the module include: sustained discrete output, momentary discrete output, slow pulse-train output and time-duration discrete output. The module contacts are isolated from the ROC/FloBoss power supplies.

3.2.7 Pulse Input Source and Isolated Modules

The Pulse Input Source (PI Source) and Pulse Input Isolated (PI Isolated) modules count pulses from pulse-generating devices. Each module can accommodate one pulse input.

Both types of modules use an LED to show when the input is active and use a scaling resistor for scaling the input range. Input pulses are counted by a 16-bit counter capable of storing up to 6.5 seconds of pulse counts for a 10-KHz input signal. Functions supported by both modules are: slow-counter input, slow rate input, fast counter input, and fast rate input.

The source module provides a source voltage for dry relay contacts or for an open-collector solid-state switch. The isolated module accepts an external voltage from a powered device and provides electrical isolation from the ROC/FloBoss power supplies.

3.2.8 Slow Pulse Input Source and Isolated Modules

The Slow Pulse Input Source (SPI Source) and Slow Pulse Input Isolated (SPI Isolated) modules count the changes in the status of relays, solid-state switches, or other two-state devices. Each module can accommodate one pulse input.

The modules provide an LED that lights when the input is active and use a scaling resistor for scaling the input range. Functions supported are controlled by the ROC/FloBoss firmware. For example: raw pulse accumulation, rate in engineering units (EUs), today’s total in EUs, or rate alarm.

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3.2.9 Low-Level Pulse Input Module

The Low-Level Pulse Input module counts pulses from pulse-generating devices having a voltage range of 30 millivolts to 3 volts peak-to-peak. The module can accommodate one pulse input.

Input pulses are counted by a 16-bit counter that is capable of storing up to 22 seconds of pulse counts for a 3 KHz input signal. The module provides electrical isolation between the input pulses and the ROC/FloBoss power supplies.

3.2.10 RTD Input Module

The Resistance Temperature Detector (RTD) module monitors the temperature signal from an RTD source. The module can accommodate one input from a two-, three-, or four-wire RTD source.

The active element of an RTD probe is a precision, temperature-dependent resistor, made from a platinum alloy. It has a predictable positive temperature coefficient, meaning its resistance increases with temperature. The RTD input module works by supplying a small current to the RTD probe and measuring the voltage drop across it. Based on the voltage curve of the RTD, the signal is converted to temperature by the ROC/FloBoss firmware.

3.2.11 HART Interface Module

The HART Interface Module provides communications between a ROC/FloBoss and other devices using the Highway Addressable Remote Transducer (HART) protocol. The module has its own microprocessor and mounts in the I/O module sockets of a ROC/FloBoss.

The HART Interface Module communicates digitally to HART devices through the I/O termination blocks associated with the module position. Each HART module contains two separate channels. Each channel polls all HART devices connected to it before the other channel is polled. Each channel can be configured to operate in either the point-to-point mode or the multi-drop mode. In the point-to-point mode, each module channel supports one HART device.

In the multi-drop mode, each channel can support up to five HART devices for a total of ten devices for each module. By using the multi-drop mode with multiple HART modules, up to 32 HART devices (limited by the software) can be supported by a single ROC/FloBoss.

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3.3 INITIAL INSTALLATION AND SETUP

Each I/O module installs in the ROC/FloBoss in the same manner. Any I/O module can be installed into any I/O module socket. To install a module on a ROC/FloBoss that is not in service, perform the following steps. For an in-service ROC/FloBoss, refer to Section 3.6.

CAUTION

Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.

CAUTION

When preparing a unit for installation into a hazardous area, change components in an area known to be non-hazardous.

CAUTION

Units used for Measurement Canada installations must not employ I/O modules to supply flow measurement inputs.

1. Install I/O module by aligning the pins with the desired I/O module socket and pressing gently, but firmly straight down.

2. Tighten the module retaining screw.

3. Make sure a field wiring terminal block is installed in the socket adjacent to where the I/O module was installed. If a Lightning Protection Module is to be installed for this I/O channel, refer to Appendix A.

3.3.1 Calibrating an I/O Module

After an I/O module is installed, configure and calibrate the associated I/O channel as needed by using the ROCLINK Configuration Software.

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3.4 CONNECTI NG THE I/O MODULES TO WIRING

Each I/O module is electrically connected to field wiring by a separate plug-in terminal block. In addition, the ROC/FloBoss enclosures provide a ground bus bar for terminating the sheath on shielded wiring. The following paragraphs provide information on wiring field devices to each type of I/O module.

CAUTION

The sheath surrounding shielded wiring should never be connected to a signal ground terminal or to the common terminal of an I/O module. Doing so makes the I/O module susceptible to static discharge, which can permanently damage the module. Connect the shielded wiring sheath to a suitable earth ground only.

3.4.1 Analog Input Loop Module

The Analog Input Loop module monitors either loop current or output voltage from field devices. The module provides source power at terminal A for the loop. The AI Loop module operates by measuring the voltage at terminals B and C. For current loop monitoring, scaling resistor R1 generates a voltage across terminals B and C that is proportional to the loop current (I). A 250-ohm scaling resistor (R1) is supplied by the factory (0.1%, 1/8W) to accommodate either 0-to-20 milliamp or 4-to-20 milliamp current loop transmitters. This translates to a maximum operating input voltage of 5 volts dc, which is the upper limit of the module.

When using a transmitter with a maximum current requirement different than 20 milliamps, R1 should be scaled to achieve full scale deflection at 5 volts dc. The formula for determining a new value of R1 is given in Figure 3-2, where “I Maximum” is the upper end of the operating current range (such as

0.025 amps for a 0 to 25 milliamp device).

ROC-POWERED CURRENT LOOP DEVICE

TO SELECT PROPER VALUE OF R1:

= SOURCE VOLTAGE FROM MODULE = 11 TO 30 VDC, 25 mA MAX

5 VOLTS

R1 =

I MAXIMUM

A B

R1=250

+ –

AI LOOP

I LIMIT

DOC0153J

Figure 3-2. AI Loop Module Field Wiring for Current Loop Devices

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Figure 3-3 shows a typical voltage signal input. Terminal B is the “+” signal input and terminal C is the “-” signal input. These terminals accept a voltage signal in the 0 to 5 volt range. Since terminal C connects to a signal ground (non-isolated), the analog input must be a single-ended. Ensure that no scaling resistor (R1) is installed when the module is used to sense a voltage signal.

SELF-POWERED VOLTAGE DEVI CE

Figure 3-3. AI Loop Module Field Wiring for Voltage Devices

SIGNAL = 1 TO 5 VDC

R1=OPEN

AI LOOP

+T +

I LIMIT

DOC0153A (modified)

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3.4.2 Analog Input Differential Module

A schematic representation of the field wiring connections to the input circuit of the Analog Input Differential module is shown in Figure 3-4, Figure 3-5, and Figure 3-6.

The Analog Input Differential module measures either output voltage (V

or loop current (I) from

)

externally-powered devices only. The module operates by measuring the voltage between field wiring terminals B and C. The module input is semi-isolated from the ROC/FloBoss power supply and signal commons.

When connecting voltage devices, the 5-volts input voltage limit of the module must not be exceeded. If the output of the field device is in the range of 0 to 5 volts dc, do not use a scaling resistor; ensure that the supplied 250-ohm scaling resistor is removed. Refer to Figure 3-4 for connecting field devices with outputs of 5 volts dc or less.

For field devices with output voltages that exceed 5 volts dc, two scaling resistors, R1 and R2, are required (not supplied). Figure 3-5 shows how to connecting field devices with outputs exceeding 5 volts dc and where to install scaling resistors (at least 1%, 1/8W). The equation for determining values of scaling resistors R1 and R2 is given in Figure 3-5. For example, if VO = 10 volts, and R1 = 250 ohms, then R2 = 250 ohms. Note that R1 must be less than 4.5K ohms.

SELF-POWERED ANALOG VOLTAGE DEVICE

R1 = OPEN

N/C

V = VOLTAGE FROM ANALOG DEVICE = 0 TO 5 VDC

AI DIFF

200K 200K

DOC0155A

Figure 3-4. AI Differential Module Field Wiring for Low Voltage Devices

SELF-POWERED ANALOG VOLTAGE DEVICE

TO SCALE R1 AND R2 FOR:

V = VOLTAGE FROM ANALOG DEVICE = 5 TO 100 VDC

R1 MUST BE LESS THAN 4.5K OHM (1.0K OHM TYPICAL)

R2 =

R1(V - 5)

N/C

AI DIFF

200K 200K

DOC0156A

Figure 3-5. AI Differential Module Field Wiring for Higher Voltage Devices

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For current loop devices, scaling resistor R1 generates a voltage across terminals B and C that is proportional to the loop current. When connecting current loop devices, the value of R1 must be selected such that the 5-volt input limit of the module is not exceeded under maximum operating current conditions. For 0 to 20 milliamp or 4 to 20 milliamp devices, the value of R1 would be 250 ohms. In this case, you can use the 250-ohm (0.1%, 1/8W) scaling resistor supplied by the factory. The formula for determining the value of R1 is given in Figure 3-6, where “I Maximum” is the upper end of the operating current range (such as 0.025 amps for a 0 to 25 milliamp device).

N/C

SELF-POWERED CURRENT LOOP DEVICE

–

TO SELECT PROPER VALUE FOR R1:

V = VOLTAGE FROM ANALOG DEVICE = 0 TO 5 VDC

5 VOLTS

R1 =

I MAXIMUM

–

Figure 3-6. AI Differential Module Field Wiring for Current Loop Devices

AI DIFF

200K 200K

DOC0154A

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3.4.3 Analog Input Source Module

A schematic representation of the field wiring connections to the input circuit of the Analog Input Source module is shown in Figure 3-7 and Figure 3-8. The AI Source module is normally used to monitor the voltage output of low-voltage transmitters, but it can be used for monitoring loop current. The module provides source power at terminal A for the loop. The Analog Input Source module operates by measuring the voltage across terminals B and C. The module accepts a maximum input voltage of 5 volts dc, which is the upper operating limit of the module.

Figure 3-7 shows a typical voltage signal input. Terminal B is the positive (+) signal input and terminal C is the negative (-) signal input. These terminals accept a voltage signal in the 0 to 5 volt range. Since terminal C connects to common, the analog input can only be a single-ended input. Make sure no

scaling resistor is installed when wiring the module for a voltage signal.

I SRC

ROC-POWERED VOLTAGE DEVICE

+10Vdc +

SIGNAL = 0 TO 5 Vdc

A B C

+10Vdc +

V SRC

Figure 3-7. AI Source Module Field Wiring for Voltage Devices

The AI Source module can be used for monitoring loop current as shown in Figure 3-8. For current loop monitoring, scaling resistor R1 generates a voltage across terminals B and C that is proportional to the loop current (I). For example, a 250-ohm scaling resistor would accommodate either 0 to 20 milliamp, or 4 to 20 milliamp current loop transmitters (the transmitter must be able to operate on 10 volts dc or be powered from another source). This translates to a maximum operating input voltage of 5 volts dc, which is the upper limit of the module. When using a transmitter with a maximum operating current requirement different than 20 milliamps, R1 should be sized to achieve full scale deflection at 5 volts. The formula for determining a new value of R1 is given in Figure 3-8.

ROC-POWERED CURRENT LOOP DEVICE

TO SELECT PROPER VALUE OF R1: Vs = SOURCE VOLTAGE FROM MODUL E = 10 Vdc, 20 mA MAX

5 VOLTS

R1 =

I MAXIMUM

A B C

+10 Vdc

V SRC

I SRC

Figure 3-8. AI Source Module Field Wiring for Current Loop Devices

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3.4.4 Analog Output Source Module

A schematic representation of the field wiring connections to the output circuit of the Analog Output Source module is shown in Figure 3-9 and Figure 3-10. The AO Source module can provide either loop current or output voltage to non-powered field devices. The Analog Output Source module provides a 0- to 5.5-Volt output at terminal A, and a 0 to 30 milliamp current source output at terminal B. Terminal C is referenced to the ROC/FloBoss common.

Resistor R1 (0-ohm resistor supplied) helps keep the loop resistance within the operating range of the module. Remove the 0-ohm resistor when the loop resistance between terminals B and C is less than 100 ohms.

Terminals A and B are both active at the same time. Figure 3-9 shows wiring for a ROC/FloBosspowered current loop device, and Figure 3-10 shows wiring for an output voltage to non-powered field devices.

AO SRC

LEVEL

DOC0158A (Modified)

R1=0

220

+I COM

REMOVE RESISTOR R1 WHEN LOOP RESISTANCE IS LESS THAN 100 OHMS

I = 30 mA MAX

B C

ROC-POWERED LOOP DEVICE

Figure 3-9. Analog Output Source Module Field Wiring for Current Loop Devices

AO SRC

LEVEL

DOC0159A

R1=0

220

COM

V = OUTPUT VOLTAGE FROM MODULE = 0 TO 5 VDC, 5 mA

ROC-POWERED VOLTAGE DEVICE

Figure 3-10. Analog Output Source Module Field Wiring for Voltage Devices

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3.4.5 Discrete Input Source Module

A schematic representation of the field wiring connections to the input circuit of the Discrete Input Source module is shown in Figure 3-11.

CAUTION

The Discrete Input Source module is designed to operate only with non-powered discrete devices such as “dry” relay contacts or isolated solid-state switches. Use of the module with powered devices may cause improper operation or damage.

The Discrete Input Source module operates by providing a voltage across terminals B and C that is derived from internal voltage source Vs. When a field device, such as a set of relay contacts, is connected across terminals B and C, the closing of the contacts completes a circuit which causes a flow of current between Vs and ground at terminal C. This current flow is sensed by the DI module, which signals the ROC/FloBoss electronics that the relay contacts have closed. When the contacts open, current flow is interrupted and the DI module signals the ROC/FloBoss electronics that the relay contacts have opened.

A 10-ohm scaling resistor (R1) is supplied by the factory and accommodates a source voltage (Vs) of 11 to 30 volts dc. The source voltage is the input voltage to the ROC/FloBoss. However, it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage. The formula for determining the value of R1 is given in Figure 3-11. For optimum efficiency, R1 should be scaled for a loop current (I) of 3 milliamps.

R1=10

DI SRC

ROC-POWERED PULSE DEVICE

TO OPTIMIZE SCALING RESISTOR R1:

VS – 1

R1 = R1 + R

I = LOOP CURRENT = 3 mA TYPICAL R

VS = SOURCE VOLTAGE FROM MODULE = 11 TO 30 VDC

+ 3.3K = LOOP RESISTANCE = 4.5K OHMS MAX

= RESISTANCE OF FIELD WIRING

– R

– 3.3K

N/C

–

3.3K

DOC0143A Modified

Figure 3-11. Discrete Input Source Module Field Wiring

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3.4.6 Discrete Input Isolated Module

A schematic representation of the field wiring connections to the input circuit of the Discrete Input Isolated module is shown in Figure 3-12.

NOTE

The Discrete Input Isolated module is designed to operate only with discrete devices having their own power source such as “wet” relay contacts or two-state devices providing an output voltage. The module is inoperative with non-powered devices.

The Discrete Input Isolated module operates when a field device provides a voltage across terminals B and C of the module. The voltage sets up a flow of current sensed by the module which, in turn, signals the ROC/FloBoss electronics that the field device is active. When the field device no longer provides a voltage, current stops flowing and the DI module signals the ROC/FloBoss electronics that the device is inactive.

A 10-ohm scaling resistor (R1) is supplied by the factory and accommodates an external voltage (Vo) of 11 to 30 Volts dc. However, it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage. The formula for determining the optimum value of R1 is given in Figure 3-12. For best efficiency, R1 should be scaled for a loop current (I) of 3 milliamps.

SELF-POWERED DISCRETE DEVICE

VO – 1

RW – 3.3KR1 =

–

TO OPTIMIZE SCALING RES ISTOR R1:

R1 + RW + 3.3K = LOOP RESISTAN CE = 4.5K OHMS MAX I = LOOP CURRENT = 3 m A TY PICAL R

= RESISTANCE OF FIELD WI RI NG

= VOLTAGE FROM DISCRETE DEVICE = 11 TO 30 VDC

R1=10

N/C

B C

DI ISO

3.3K

DOC0144A

Figure 3-12. Discrete Input Isolated Module Field Wiring

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3.4.7 Discrete Output Source Module

A schematic representation of the field wiring connections to the output circuit of the Discrete Output Source module is shown in Figure 3-13.

CAUTION

The Discrete Output Source module is designed to operate only with non-powered discrete devices such as relay coils or solid-state switch inputs. Using the module with powered devices may cause improper operation or damage to occur.

The Discrete Output Source module provides a switched voltage across terminals B and C that is derived from internal voltage source Vs. A field device, such as a relay coil, is energized when the ROC/FloBoss electronics provides a voltage at terminals B and C. When Vs is switched off by the ROC/FloBoss electronics, the field device is no longer energized.

CAUTION

When using the Discrete Output Source module to drive an inductive load such as a relay coil, a suppression diode should be placed across the input terminals to the load. This protects the module from the reverse EMF spike generated when the inductive load is switched off.

1 Amp

N/C + –

B C

–

ROC-POWERED DISCRETE DEVICE

DO SRC

+5V

CONTROL

I LIMIT

DOC0145A

Figure 3-13. Discrete Output Source Module Field Wiring

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3.4.8 Discrete Output Isolated Module

A schematic representation of the field wiring connections to the output circuit of the Discrete Output Isolated module is shown in Figure 3-14.

NOTE

The Discrete Output Isolated module is designed to operate only with discrete devices having their own power source. The module is inoperative with non-powered devices.

The Discrete Output Isolated module operates by providing a low or high-output resistance to a field device. When the field device provides a voltage across terminals A and B of the module, current either flows or is switched off by the DO Isolated module. The switching is controlled by the ROC/FloBoss electronics.

DO ISO

+5V

CONTROL

DOC0146A (Modified)

1 Amp

+ – N/C

A B C

VO = VOLTAGE FROM DISCRETE DEVICE = 11 TO 30 VDC, 1.0 A MAX

SELF-POWERED DISCRETE DEVICE

–

Figure 3-14. Discrete Output Isolated Module Field Wiring

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3.4.9 Discrete Output Relay Module

A schematic representation of the field wiring connections to the output circuit of the Discrete Output Relay module is shown in Figure 3-15.

NOTE

The Discrete Output Relay module is designed to operate only with discrete devices having their own power source. The module will be inoperative with non-powered devices.

The Discrete Output Relay module operates by providing both normally-closed and normally-open contacts to a field device. Normally-closed contacts use terminals B and C, and normally-open contacts use terminals A and B. The status of the contacts (open or closed) is controlled by the ROC/FloBoss software.

There are two versions of the relay module. The 12-volt version (which has a 12-volt energizing coil) must be used when the ROC/FloBoss input voltage is a nominal 12 volts dc, and the 24-volt version (which has a 24-volt energizing coil) must be used when the ROC/FloBoss input voltage is a nominal 24 volts dc.

DO RLY

CONTROL

DOC0147A

COM

TERMINAL A CONNECTION TO BE MADE FOR NORMALLY OPEN APPLICATIONS TERMINAL B IS COMMON TERMINAL C CONNECTION TO BE MADE FOR NORMALLY CLOSED APPLICATIONS

= VOLTAGE FROM DISCRETE DEVICE = 0 TO 30 VDC OR 0 TO 115 VAC, 5 A MAX

Figure 3-15. Discrete Output Relay Module Field Wiring

SELF-POWERED DISCRETE DEVICE

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3.4.10 Pulse Input Source Module

A schematic representation of the field wiring connections to the input circuit of the Pulse Input Source module is shown in Figure 3-16.

CAUTION

The Pulse Input Source module is designed to operate only with non-powered discrete devices such as “dry” relay contacts or isolated solid-state switches. Use of the module with powered devices may cause improper operation or damage to occur.

The Pulse Input Source module provides a voltage across terminals B and C that is derived from internal voltage source Vs. When a field device, such as a set of relay contacts, is connected across terminals B and C, the opening and closing of the contacts causes current to either flow or not flow between Vs and ground at terminal C.

This interrupted, or pulsed current flow is counted and accumulated by the PI Source module which provides the accumulated count to the ROC/FloBoss electronics upon request.

A 10-ohm scaling resistor (R1) is supplied by the factory and accommodates a source voltage (Vs) of 11 to 30 volts dc and a pulse source with a 50% duty cycle. The source voltage is the input voltage to the ROC/FloBoss. However, it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage. The formula for determining the value of R1 is given in Figure 3-16. For optimum efficiency, R1should be scaled for a loop current (I) of 5 milliamps.

R1=10

PI SRC

ROC-POWERED PULSE DEVICE

TO OPTIMIZE SCALING RESISTOR R1:

VS – 1

R1 = R1 + R

I = LOOP CURRENT = 5 mA TYPICAL R

VS = SOURCE VOLTAGE FROM MODULE = 11 TO 30 VDC

+ 2.2K = LOOP RESISTANCE = 3.4K OHMS MAX

= RESISTANCE OF FIELD WIRING

– R

– 2.2K

N/C

–

2.2K

Figure 3-16. Pulse Input Source Module Field Wiring

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3.4.11 Pulse Input Isolated Module

A schematic representation of the field wiring connections to the input circuit of the Pulse Input Isolated module is shown in Figure 3-17.

NOTE

The Pulse Input Isolated module is designed to operate only with discrete devices having their own power source such as “wet” relay contacts or two-state devices providing an output voltage. The module is inoperative with non-powered devices.

The Pulse Input Isolated module operates when a field device provides a voltage across terminals B and C of the module. The voltage sets up a flow of current sensed by the module. When the field device no longer provides a voltage, current stops flowing.

This interrupted, or pulsed current flow is counted and accumulated by the PI module which provides the accumulated count to the ROC/FloBoss electronics upon request.

A 10-ohm scaling resistor (R1) is supplied by the factory, which accommodates a field device with pulse amplitude (Vo) of 11 to 30 volts dc and a duty cycle of 50%. However, it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to amplitudes greater than 30 volts dc. The formula for determining the value of R1 is given in Figure 3-17. For optimum efficiency, R1 should be scaled for a loop current (I) of 5 milliamps.

SELF-POWERED PULSE DEVICE

TO OPTIMIZE SCALING RESISTOR R1:

R1 = R1 + R

I = LOOP CURRENT = 5 mA TYPICAL RW = RESISTANCE OF FIELD WIRING

= VOLTAGE FROM PULSE DEVICE = 11 TO 30 VDC

VO – 1

+ 2.2K = LOOP RESISTANCE = 3.4K OHMS MAX

– R

– 2.2K

R1=10

N/C

–

PI ISO

2.2K

DOC0149A

Figure 3-17. Pulse Input Isolated Module Field Wiring

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3.4.12 Slow Pulse Input Source Module

A schematic representation of the field wiring connections to the input circuit of the Slow Pulse Input Source module is shown in Figure 3-18.

CAUTION

The Slow Pulse Input source module is designed to operate only with non-powered discrete devices such as “dry” relay contacts or isolated solid-state switches. Use of the module with powered devices may cause improper operation or damage to occur.

The Slow Pulse Input source module operates by providing a voltage across terminals B and C that is derived from internal voltage source Vs. When a field device, such as a set of relay contacts, is connected across terminals B and C, the closing of the contacts completes a circuit, which causes a flow of current between Vs and ground at terminal C.

This current flow is sensed by the SPI module, which signals the ROC/FloBoss electronics that the relay contacts have closed. When the contacts open, current flow is interrupted and the SPI module signals the ROC/FloBoss electronics that the relay contacts have opened. The ROC/FloBoss software counts the number of times the contacts switch from open to closed, and stores the count. The software checks for the input transition every 50 milliseconds.

A 10-ohm scaling resistor (R1) is supplied by the factory that accommodates a source voltage (Vs) of 11 to 30 volts dc. The source voltage is either the input voltage to the ROC/FloBoss or the output voltage of the I/O converter card if one is installed (ROC364 only). However, it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage. The formula for determining the value of R1 is given in Figure 3-

18. For optimum efficiency, R1 should be scaled for a loop current (I) of 3 milliamps.

R1=10

SPI SRC

ROC-POWERED DISCRETE DEVICE

TO OPTIMIZE SCALING RESISTOR R1:

V - 1

R1 =

R1 + Rw + 3.3K = LOOP RESISTANCE = 4.5K OHMS I = LOOP CURRENT = 3 mA TYPICAL R = RESISTANCE OF FIELD

V = SOURCE VOLTAGE FROM MODULE = 11 TO 30 VDC

- R - 3.3K

N/C

3.3K

DOC0151 Modified

Figure 3-18. Slow Pulse Input Source Module Field Wiring

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3.4.13 Slow Pulse Input Isolated Module

A schematic representation of the field wiring connections to the input circuit of the Slow Pulse Input Isolated module is shown in Figure 3-19.

NOTE

The Slow Pulse Input isolated module is designed to operate only with discrete devices having their own power source such as “wet” relay contacts or two-state devices providing an output voltage. The module is inoperative with non-powered devices.

The Slow Pulse Input isolated module operates when a field device provides a voltage across terminals B and C of the module. The voltage sets up a flow of current sensed by the module, which signals the ROC/FloBoss electronics that the field device is active. When the field device no longer provides a voltage, current stops flowing and the SPI module signals the ROC/FloBoss electronics that the device is inactive. The ROC/FloBoss software counts the number of times the current starts flowing, and stores the count. The software checks for the input transition every 50 milliseconds.

A 10-ohm scaling resistor (R1) is supplied by the factory, which accommodates an external voltage (Vo) of 11 to 30 volts dc. However, it is desirable to optimize the value of R1 to reduce the current drain from the source or reduce the heat generated in the module due to high source voltage. The formula for determining the value of R1 is given in Figure 3-19. For optimum efficiency, R1 should be scaled for a loop current (I) of 3 milliamps.

SELF-POWERED DISCRETE

DEVICE

TO OPTIMIZE SCALING RESISTOR R1:

V - 1

R1 =

R1 + R + 3.3K = LOOP RESISTANCE = 4.5K OHMS MAX I = LOOP CURRENT = 3 mA TYPICAL R = RESISTANCE OF FIELD

V = VOLTAGE FROM DISCRETE DEVICE = 11 TO 30 VDC

R1=10

N/C

- R - 3.3K

SPI ISO

3.3K

DOC0152A

Figure 3-19. Slow Pulse Input Isolated Module Field Wiring

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–

3.4.14 Low-Level Pulse Input Module

A schematic representation of the field wiring connections to the input circuit of the Low-Level Pulse Input module is shown in Figure 3-20. The field wiring connections are made through a separate terminal block that plugs in next to the module allowing replacement of the module without disconnecting field wiring.

NOTE

The Low-Level Pulse Input module is designed to operate only with pulsegenerating devices having their own power source. The module does not work with non-powered devices.

The low-level pulse input module operates when a field device provides a pulsed voltage between 30 millivolts and 3 volts peak-to-peak across terminals B and C of the module. The pulsed voltage is counted and accumulated by the module, which provides the accumulated count to the ROC/FloBoss electronics on request.

SELF-POWERED PULSE DEVICE

Figure 3-20. Low-Level Pulse Input Module Field Wiring Schematic

PI LL

N/C

B C

200K 200K

DOC0150A

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3.4.15 RTD Input Module

The RTD input module monitors the temperature signal from a resistance temperature detector (RTD) sensor or probe. The RTD module is isolated, reducing the possibility of lightning damage. A lightning protection module (LPM) will not protect the RTD, but it helps protect the rack in which the module is installed.

The RTD module needs to be calibrated while disconnected from the RTD probe; therefore, it may be more convenient to perform calibration before connecting the field wiring. However, if the field wiring between the ROC/FloBoss and the RTD probe is long enough to add a significant resistance, then calibration should be performed in a manner that takes this into account.

3.4.15.1 Calibrating the RTD Module

The following instructions describe how to manually calibrate an RTD input channel for use with an RTD probe having an alpha value of either 0.00385 or 0.00392 ohms/ohm/degree C. This procedure requires a resistance decade box with 0.01 ohm steps and an accuracy of ±1%. You also need a personal computer running the ROCLINK Configuration Software.

NOTE

For a more automated procedure, you may instead use the Calibrate pushbutton associated with the Analog Input configuration, as described in Section 4 of the ROCLINK user manual.

WHTC

WHT

A4464821

RTD

RED A

DECADE BOX

ABC

Figure 3-21. Calibration Setup

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Table 3-1. Calibration Resistance Values

ALPHA -50º C 100º C

0.00385 80.31 OHMS 138.50 OHMS

0.00392 79.96 OHMS 139.16 OHMS

Note: Resistance values for RTD probes with other alpha values can be found in the temperature-to-resistance conversion table for that probe.

1. Connect the decade box as shown in Figure 3-21 on Page 3-24.

2. Set the decade box to the -50° C resistance value corresponding to the RTD alpha value in Table 3-1.

3. Enter the value displayed for “Raw A/D Input” as the value for “Adj. A/D 0%” using the Analog Inputs configuration screen for the RTD input (in ROCLINK, see the Advanced Features for these parameters).

4. Set the decade box to the 100° C resistance value given in Table 3-1.

5. Enter the value displayed for “Raw A/D Input” as the value for “Adj. A/D 100%” using the Analog Inputs configuration screen for the RTD input.

6. Enter “-50” for “Low Reading EU”.

7. Enter “100” for the “High Reading EU”.

8. Press F8 to save the changes.

3.4.15.2 Connecting RTD Module Field Wiring

The RTD sensor connects to the RTD module with ordinary copper wire. To avoid a loss in accuracy, sensor wires should be equal in length, of the same material, and the same gauge. To avoid possible damage to the RTD module from induced voltages, sensor wires should be kept as short as possible (typically 100 feet or less). A schematic representation of the field wiring connections to the input circuit of the RTD input module is shown in Figure 3-22, Figure 3-23, Figure 3-24, and Figure 3-25.

Two-wire RTDs are connected to module terminals A and B. Terminal B must be connected to terminal C, as shown in Figure 3-22.

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RTD

ROC-POWERED 2-WIRE, 100 OHM RTD PROBE

RED

WHT

RED

WHT

I SRC

DOC4007A Modified

Figure 3-22. RTD Input Module Field Wiring for Two-Wire RTDs

Three-wire RTDs have an active element loop and a compensation loop. The active element loop is connected across terminals A and B. The compensation loop is connected across B and C. The compensation loop helps increase the accuracy of the temperature measurement by allowing the RTD module to compensate for the resistance of hookup wire used between the probe and RTD module.

In operation, the RTD module subtracts the resistance between terminals B and C from the resistance between terminals A and B. The remainder is the resistance of only the active element of the probe. This compensation becomes more important as the resistance of the hookup wire increases with distance between the probe and the ROC/FloBoss. Of course, in order to perform properly, the compensation loop must use the same type, size, and length of hookup wire as the active element loop.

The RTD module is designed for only one compensation loop, and this loop is not isolated from the active element loop because terminal B is common to both loops. In the 3-wire RTD, the wires are connected to module terminals A, B, and C, as shown in Figure 3-23.

It is important to match the color coding of the RTD probe wires to the proper module terminal, because the probe wire colors vary between manufacturers. To determine which leads are for the compensation loop and which are for the active element, read the resistance across the probe wires with an ohmmeter. The compensation loop reads 0 ohms, and the RTD element reads a resistance value matching the temperature curve of the RTD.

RTD

RED

WHT

I SRC

DOC0161A Modified

3-WIRE,100-OHM, RTD PROBE

RED

WHT

Figure 3-23. RTD Input Module Field Wiring for Three-Wire RTDs

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RTDs with 4 wires normally have the compensation loop separate from the active element loop to increase the accuracy of the probe. Various colors are used for the probe wires. For example, some probes have wire colors of red and white for the RTD element loop and black leads for the compensation loop, while other probes use two red leads for the active element loop and two white leads for the compensation loop.

The connections in Figure 3-24 connect a 4-wire RTD with compensation loop to the 3-wire RTD module. The RTD module designed for 3-wire use does not permit a 4-wire RTD to provide any additional accuracy over a 3-wire RTD.

RTD

RED

WHT

I SRC

DOC4008A

4-WIRE RTD WITH COMPENSATION LOOP

RED

WHT

Figure 3-24. RTD Input Module Field Wiring for 4-Wire RTD With Compensation Loop

Figure 3-25 shows the connections for a single-element, 4-wire RTD. The two leads for one side of the RTD are both red, and for the other side they are both white.

RTD

DOC4009A

4-WIRE RTD WITH SINGLE ELEMENT

RED

WHT

RED

WHT

I SRC

Figure 3-25. Field Wiring for 4-Wire, Single Element RTD

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3.4.16 HART Interface Module

The HART Interface module allows the ROC/FloBoss to interface with up to 10 HART devices per I/O slot. The HART module provides “loop source” power (+T) on terminal A and two channels for communications on terminals B and C. The +T power is regulated by a current limit. If the power required by all connected HART devices exceeds 40 milliamps (more than an average of 4 milliamps each), the total number of HART devices must be reduced.

The HART module polls one channel at a time. If more than one device is connected to a channel in a multi-drop configuration, the module polls all devices on that channel before it polls the second channel. The HART protocol allows one second per poll for each device, so with 5 devices per channel the entire poll time for the module would be ten seconds.

In a point-to-point configuration, only one HART device is wired to each HART module channel. In a multi-drop configuration, two to five HART devices are connected to a channel. In either case, terminal A (+T) is wired in parallel to the positive (+) terminal on all of the HART devices, regardless of the channel to which they are connected. Channel 1 (terminal B) is wired to the negative (-) terminal of a single HART device, or in parallel to the negative terminals of two to five devices. Likewise, channel 2 (terminal C) is wired to the negative (-) terminal of a single HART device, or in parallel to the negative terminals of a second group of two to five devices. Refer to Figure 3-26.

ROC-POWERED HART DEVICE 1

ROC-POWERED HART DEVICE 2

ROC-POWERED HART DEVICE 5

CHANNEL 1, MULTI-DROP MO DE CHANNEL 2, POINT-TO-POINT MODE

A B C

ROC-POWERED

HART DEVICE

Figure 3-26. Field Wiring for a HART Interface Module

MUX

HART MODULE

I LIMIT

MODEM

DOC0295A

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3.5 TROUBLESHOOTING AND REPAIR

The troubleshooting and repair help the technician identify and replace faulty modules. Faulty modules must be returned to your Fisher Representative for repair or replacement.

If an I/O point does not function correctly, first determine if the problem is with the field device or the I/O module as follows:

CAUTION

Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.

1. Isolate the field device from the ROC/FloBoss by disconnecting it at the I/O module terminal block.

2. Connect the ROC/FloBoss to a computer running the ROCLINK configuration software.

3. Perform the appropriate test procedure described in the following paragraphs.

A module suspected of being faulty should be checked for a short circuit between its input or output terminals and the ground screw on the termination card. If a terminal not directly connected to ground reads zero (0) when measured with an ohmmeter, the module is defective and must be replaced.

3.5.1 Analog Input Modules

Equipment Required: Multimeter

To determine if an Analog Input module is operating properly, its configuration must first be known. Table 3-2 shows typical configuration values for an analog input:

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Table 3-2. Analog Input Module Typical Configuration Values

PARAMETER VALUE CORRESPONDS TO:

Adj. A/D 0 % 800 1 volt dc across Rs (scaling resistor R1)

Adj. A/D 100 % 4000 5 volts dc across R Low Reading EU 0.0000 EU value with 1 volt dc across R High Reading EU 100.0 EU value with 5 volts dc across R

Filtered EUs xxxxx Value read by AI module

When the value of Filtered Engineering Units (EU) is -25% of span as configured above, it is an indication of no current flow (0 mA), which can result from open field wiring or a faulty field device.

When the value of Filtered EUs is in excess of 100% of span as configured above, it is an indication of maximum current flow, which can result from shorted field wiring or a faulty field device.

When the value of Filtered EUs is between the low and high readings, you can verify the accuracy of the reading by measuring the voltage across scaling resistor Rs (Vrs) with the multimeter. To convert this reading to the filtered EUs value, perform the following:

Filtered EUs = [((Vrs - 1)/4) × Span] + Low Reading EU, where Span = High Reading EU - Low Reading EU

This calculated value should be within one-tenth of one percent of the Filtered EUs value measured by the ROC/FloBoss. To verify an accuracy of 0.1 percent, read the loop current with a multimeter connected in series with current loop. Be sure to take into account that input values can change rapidly, which can cause a greater error between the measured value and the calculated value.

If the calculated value and the measured value are the same, the AI module is operating correctly.

3.5.2 Analog Output Modules

The Analog Output module is a source for current loop or voltage devices. Two test procedures are provided to verify correct operation. Use the first procedure to check current loop source installations and the second procedure to check voltage source installations.

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3.5.2.1 Check Current Loop Source Installations

Equipment Required: Multimeter

Personal Computer running ROCLINK Software

1. Taking appropriate precautions, disconnect the field wiring going to the AO module terminations.

2. Connect a multimeter between the B and C terminals of the module and set the multimeter to measure current in milliamps.

3. Using the ROCLINK software, put the AO point associated with the module under test in Manual mode (scanning disabled).

4. Set the output to the high EU value.

5. Verify a 20-milliamp reading on the multimeter.

6. Calibrate the analog output high EU value as needed by increasing or decreasing the “Adj D/A 100% Units”.

7. Set the output to the low EU value.

8. Verify a 4-milliamp reading on the multimeter.

9. Calibrate the analog output low EU value by increasing or decreasing the “Adj D/A 0% Units” as needed.

10. Enable scanning for the AO point, remove the test equipment, and reconnect the field device.

11. If possible, verify the correct operation of the AO module by setting the high and low EU values as before (scanning disabled) and observing the field device.

3.5.2.2 Check Voltage Source Installations

Equipment Required: Multimeter

Personal Computer running ROCLINK Software

To check operation of the Analog Output module powering a voltage device, use the following procedure.

1. If the resistance value (R) of the field device is known, measure the voltage drop (V) across the device and calculate the output EU value using the following formula.

EU value = [((1000V/R - 4)/16) × Span] + Low Reading EU, where Span = High Reading EU - Low Reading EU

2. Compare the computed value to the output EU value measured by the ROC/FloBoss with the ROCLINK software. It is normal for the reading to be several percent off, depending on the accuracy tolerance of the device and how rapidly changes occur in the output value.

3. Calibrate the analog output EU values by increasing or decreasing the “Adj D/A % Units” as needed.

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4. If the analog output is unable to drive the field device to the 100% value, confirm the +V (1 to 5 volts) voltage is present at the field device.

♦ If the voltage is present and the device is not at the 100% position, the resistance value of the

device is too large for the +V voltage. A field device with a lower internal resistance should be used.

♦ If the voltage is not present at the field device, but it is present at field wiring terminal B,

there is excessive resistance or a break in the field wiring.

3.5.3 Discrete Input Source Module

Equipment Required: Jumper wire

Place a jumper across terminals B and C. The LED on the module should light and the status as read by the ROCLINK software should change to “1”. With no jumper on terminals B and C, the LED should not be lit and the status should be “0”. If the unit fails to operate, make sure a correct value for the module resistor is being used.

3.5.4 Discrete Input Isolated Module

Equipment Required: Voltage generator capable of generating 11 to 30 V dc

Personal Computer running ROCLINK Software

Supply an input voltage across terminals B and C. The LED on the module should light and the status as read by the ROCLINK software should change to “1”. With no input on terminals B and C, the LED should not be on and the status should be “0”. If the unit fails to operate, make sure a correct value for the module resistor is being used.

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3.5.5 Discrete Output Source Module

Equipment Required: Multimeter

Personal Computer running ROCLINK Software

Place the Discrete Output in manual mode using the ROCLINK configuration software. With the output status set to “0”, less than 0.5 volts dc should be measured across pins B and C. With the output status set to “1”, approximately 1.5 volts dc less than the system voltage (Vs-1.5) should be measured across terminals A and B. If these values are not measured, check to see if the module fuse is open, verify the module is wired correctly, and verify the load current requirement does not exceed the 57milliamp current limit value of the module.

3.5.6 Discrete Output Isolated Module

Equipment Required: Multimeter

Personal Computer running ROCLINK Software

Place the Discrete Output in manual mode using the ROCLINK configuration software. Set the output status to “0” and measure the resistance across terminals A and B. No continuity should be indicated. Set the output status to “1” and measure the resistance across terminals A and B. A reading of 15K ohms or less should be obtained.

3.5.7 Discrete Output Relay Module

Equipment Required: Multimeter

Personal Computer running ROCLINK Software

Place the Discrete Output in manual mode using the ROCLINK configuration software. Set the output status to “0” and measure the resistance across terminals B and C. A reading of 0 ohms should be obtained. Measure the resistance across terminals A and B. No continuity should be indicated. Set the output status to “1” and measure the resistance across terminals B and C. No continuity should be indicated. Measure the resistance across terminals A and B. A reading of 0 ohms should be obtained.

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3.5.8 Pulse Input Source and Isolated Modules

Equipment Required: Pulse Generator

Voltage Generator Frequency Counter Jumper wire

For both types of modules, there are two methods of testing. One method tests high-speed operation, and the other method tests low-speed operation.

NOTE

When checking the operation of the Pulse Input Source and Isolated modules, ensure the scan rate for the pulse input is once every 6.5 seconds or less as set by the ROCLINK software.

To verify high-speed operation, connect a pulse generator having sufficient output to drive the module to terminals B and C. Connect a frequency counter across terminals B and C. Set the pulse generator to a value equal to, or less than 10 KHz, and set the frequency counter to count pulses. Verify the count read by the counter and the count read by the ROC/FloBoss are the same using the ROCLINK software.

To verify low-speed operation of the source module, alternately jumper across terminals B and C. The module LED should cycle on and off, and the accumulated count should increase.

To verify low-speed operation of the isolated module, alternately supply and remove an input voltage across terminals B and C. The module LED should cycle on and off, and the total accumulated count should increase.

3.5.9 Slow Pulse Input Source Module

Equipment Required: Jumper wire

To verify low-speed operation of the source module, connect and remove a jumper across terminals B and C several times to simulate slow switching. The module LED should cycle on and off and the accumulated count should increase.

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3.5.10 Slow Pulse Input Isolated Module

Equipment Required: Jumper wire

To verify low-speed operation of the isolated module, alternately supply and remove an input voltage across terminals B and C. The module LED should cycle on and off and the total accumulated count should increase.

3.5.11 Low-Level Pulse Input Module

Equipment Required: Pulse Generator

Frequency Counter Personal Computer running ROCLINK software

NOTE

When checking the operation of the Low-Level Pulse Input module, ensure that the scan rate for the pulse input is once every 22 seconds or less as set by the ROCLINK software.

To verify operation, connect a pulse generator, with the pulse amplitude set at less than 3 volts, to terminals B and C. Then, connect a frequency counter across terminals B and C. Set the pulse generator to a value equal to, or less than 3 KHz, and set the frequency counter to count pulses. Verify that the count read by the counter and in the count read by the ROC/FloBoss are the same using the ROCLINK software.

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3.5.12 RTD Input Module

The RTD module is similar in operation to an AI module and uses the same troubleshooting and repair procedures. The RTD module can accommodate two-wire, three-wire, or four-wire RTDs. If two-wire RTDs are used, terminals B and C must be connected together. If any of the input wires are broken or not connected, the ROCLINK software indicates the “Raw A/D Input” value is either at minimum (less than 800) or maximum (greater than 4000) as follows:

♦ An open at terminal A gives a maximum reading. ♦ An open at terminal B gives a minimum reading. ♦ An open at terminal C gives a minimum reading.

To verify the operation of the RTD module, disconnect the RTD and connect a jumper between terminals B and C of the RTD module. Next, connect either an accurate resistor or decade resistance box with a value to give a low end reading across terminals A and B. The resistance value required can be determined by the temperature-to-resistance conversion chart for the type of RTD being used. Use ROCLINK software to verify that the “Raw A/D Input” value changed and reflects the 0% A/D value. Change the resistance to reflect a high temperature as determined by the temperature-to-resistance conversion chart. Verify that the “Raw A/D Input” value changed and reflects the 100% A/D value.

3.5.13 HART Interface Module

The HART Interface Module provides the source for the HART devices and uses two test procedures to verify correct operation. Use the first procedure to check the integrity of the loop power and the second to verify communications.

3.5.13.1 Verify Integrity of Loop Power

Equipment Required: Multimeter

1. Measure voltage between terminals A and B to verify channel 1.

2. Measure voltage between terminals A and C to verify channel 2.

The voltage read in both measurements should reflect the value of +T less the voltage drop of the HART devices. Zero voltage indicates an open circuit in the I/O wiring, a defective HART device, or a defective module.

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3.5.13.2 Verify Communications

Equipment Required: Dual-trace Oscilloscope

In this test, the HART module and the ROC/FloBoss act as the host and transmit a polling request to each HART device. When polled, the HART device responds. In this test, you use the oscilloscope to observe the activity on the two HART communication channels. Note that there is normally one second from the start of one request to the start of the next request.

1. Attach one input probe to terminal B of the HART module and examine the signal for a polling request and response for each HART device connected to this channel.

2. Attach the other input probe to terminal C and examine the signal for a polling request and response for each HART device connected.

3. Compare the two traces; signal bursts should not appear on both channels simultaneously.

Keep in mind that each device on one channel is polled before the devices on the other channel are polled. If a channel indicates no response, this could be caused by faulty I/O wiring or a faulty device. If the HART module tries to poll both channels simultaneously, this could be caused by a defective module, in which case the module must be replaced.

3.6 REM OV AL, ADDITION, AND REPLACEMENT PROCEDURES

3.6.1 Impact on I/O Point Configuration

When an I/O module is replaced with the same type of I/O module, it is not necessary to reconfigure the ROC/FloBoss. Modules which are treated as the same type are:

♦ Discrete input isolated and source modules ♦ Discrete output isolated, source, and relay modules ♦ Analog input loop, differential, and source modules, and RTD input modules ♦ Pulse input isolated and source modules ♦ Slow pulse input isolated and source modules

If a module is to be replaced with one of the same type (see above), but some of its configuration parameters need to be changed, you can use the ROCLINK software to make the changes off-line or on-line. If you want to minimize “down time,” before you replace the module, you can make the needed changes (except for ROC display and FST changes) off-line by first saving the ROC/FloBoss configuration to disk. Modify the disk configuration, replace the module, and then load the configuration file into the ROC/FloBoss.

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To make changes on-line, replace the module, proceed directly to the configuration display for the affected point, and modify parameters as needed. Remember to consider the impact on FSTs and other points that reference the affected point.

Any added modules (new I/O points) start up with default configurations. Even though adding a module, removing a module, or moving a module to a new position in the ROC/FloBoss does not directly affect the configuration of other I/O points, it can affect the numbering of I/O points of the same type. This, in turn, can impact an FST or higher-level point because the referencing of I/O points is done by a sequence-based point number. For example, if you have AI modules installed in slots A7, A10, and A11, adding another AI module in slot A8 changes the point numbers of the analog inputs for modules in slots A10 and A11.

CAUTION

If one or more FSTs, or higher level points such as a PID loop or AGA Flow, have been configured in the ROC/FloBoss, be sure to reconfigure them according to the changes in I/O modules. Operational problems will occur if you do not reconfigure the ROC/FloBoss.

3.6.2 Removing/Installing an I/O Module

Use the following procedure to remove/install an I/O module. The procedure is performed using the ROCLINK Configuration Software.

CAUTION

2.5.2. CAUTION

When working on units labeled for service in hazardous areas, ensure that the working environment is currently non-hazardous.

NOTE

For a Measurement Canada FloBoss 407, resealing of the case must be performed by authorized personnel only.

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FloBoss 407 Instruction Manual

Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.

During this procedure all power will be removed from the ROC/FloBoss and devices powered by the ROC/FloBoss. Ensure that all connected input devices, output devices, and processes remain in a safe state when power is removed from the ROC/FloBoss and when power is restored.

1. Refer to Section 2.5.2 concerning RAM backup procedures.

2. Disconnect the input power, such as by unplugging the 5-terminal connector.

3. Perform one of the following steps, depending on whether the module is to be removed or

installed:

CAUTION

a) If removing the module, loosen the module retaining screw and remove the module by

lifting straight up. It may be necessary to rock the module gently while lifting.

b) If installing the module, insert the module pins into the module socket. Press the module

firmly in place. Tighten the module retaining screw.

4. After the module is removed/installed, reconnect the input power.

5. Check the configuration data (including ROC displays) and FSTs, and load or modify them

as required. Load and start any user programs as needed.

6. Read Section 3.6.1 on I/O point configuration. If you increased or reduced the number of

HART modules or changed their relative position, perform a warm start to cause the HART program to recognize the changes. Configure the HART points accordingly.

7. Verify that the ROC/FloBoss performs as required.

8. If you changed the configuration, save the configuration data to permanent memory.

9. If you changed the configuration, including the history database, FSTs, and ROC displays,

save them to disk. See Section 2.5.2 for more information on saving files.

Rev 5/00 3-39

FloBoss 407 Instruction Manual

3.7 I/O MODULE SPECIFICATIONS

The specifications for the various I/O modules are given in the following order in sections 3.7.1 through

3.7.11:

♦ Analog Input Modules—Loop and Differential ♦ Analog Input Source Module ♦ Analog Output Source Module ♦ Discrete Input Modules—Source and Isolated ♦ Discrete Output Modules—Source and Isolated ♦ Discrete Output Relay Module ♦ Pulse Input Modules—Source and Isolated ♦ Slow Pulse Input Modules—Source and Isolated ♦ Pulse Input Module—Low Level ♦ RTD Input Module ♦ HART Interface Module

3.7.1 Analog Input Modules—Loop and Differential

Loop Module Specifications

FIELD WIRING TERMINALS

INPUT

Loop Power (+T)

Analog Input (+)

Common (-)

Single-ended, voltage sense.

Type:

Current loop with scaling resistor (R1).

Loop Current:

mum range. Actual range depends on scaling resistor used.

Voltage Sensing:

software configured.

Accuracy:

30 °C). 0.5% of full scale (-40 to 70 °C).

0 to 25 mA maxi-

0 to 5 Volts dc,

0.1% of full scale (20 to

INPUT (CONTINUED)

POWER REQUIREMENTS

ISOLATION

Impedance:

ohms (without scaling resistor).

Normal Mode Rejection:

@ 60 Hz.

Loop Source:

from ROC power supply or I/O converter card (V

Module:

maximum; -4.5 to -5.5 Volts dc, 2 mA maximum (supplied by ROC).

Not isolated. Terminal C tied to power supply common.

Greater than 400K

50 dB

25 mA maximum,

= 11 to 30 Vdc).

4.9 to 5.1 Volts dc, 6 mA

3-40 Rev 5/00

FloBoss 407 Instruction Manual

Differential Module Specifications

FIELD WIRING TERMINALS

INPUT

SCALING RESISTOR

SURGE WITHSTAND

RESOLUTION

Not used.

Positive Analog Input (+)

Negative Analog Input (-)

Voltage sense. Externally-

Type:

powered current loop sensing with scaling resistor (R1).

Voltage:

configured.

Accuracy:

to 30 °C). 0.5% of full scale (-40 to 70 °C).

0 to 5 Volts dc, software

0.1% of full scale (20

Common Specifications

250 ohm (supplied) for 0 to 20 mA full scale. 100 ohm for 0 to 50 mA (externally-powered only).

Meets IEEE 472/ANSI C37.90a.

12 bits.

INPUT (CONTINUED)

POWER REQUIREMENTS

INPUT ISOLATION

MECHANICAL SHOCK

CASE

Normal Mode Rejection:

60 Hz.

Impedance:

ohms (without scaling resistor).

4.9 to 5.1 Volts dc, 6 mA maximum;

-4.5 to -5.5 Volts dc, 2 mA maximum (supplied by ROC).

Greater than 400K ohms input to power supply common.

1500 Gs 0.5 mS half sine per MILSTD-202 method 213, condition F.

Solvent-resistant thermoplastic polyester, meets UL94V-0. Dimensions are 0.60 in. D by 1.265 in. H by

1.69 in. W (15 mm by 32 mm by 43 mm), not including pins.

Greater than 400K

50 dB @

FILTER

CONVERSION TIME

VIBRATION

WEIGHT

Rev 5/00 3-41

Single pole, low-pass, 40 millisecond time constant.

30 microseconds typical.

20 Gs peak or 0.06 in. double amplitude, 10 to 2,000 Hz, per MIL-STD-202 method 204 condition F.

1.3 ounces (37 grams).

ENVIRONMENTAL

APPROVALS

Meets the Environmental specifications of the ROC or FloBoss in which the module is installed, including Temperature and Transient Protection specifications.

Approved by CSA for hazardous locations Class I, Division 2, Groups A, B, C, and D.

FloBoss 407 Instruction Manual

3.7.2 Analog Input Source Module

Specifications

FIELD WIRING TERMINALS

INPUT

SOURCE POWER

POWER REQUIREMENTS

INPUT ISOLATION

SURGE WITHSTAND

10 Vdc

Analog Input

Common

Type:

Single-ended, voltage sense; can be current loop if scaling resistor (not supplied) is used.

Voltage:

configurable.

Resolution: Accuracy:

C); 0.5% of full scale (-40 to 65 °C).

Impedance:

(without scaling resistor).

Normal Mode Rejection:

Hz.

9.99 to 10.01 Vdc, 20 mA maximum.

4.9 to 5.1 Vdc, 6 mA maximum; -4.5 to -

5.5 Vdc, 2 mA maximum (all supplied by ROC).

Not isolated. Terminal C is tied to power supply ground.

Meets IEEE 472 / ANSI C37.90a.

0 to 5 Vdc, software

12 bits.

0.1% of full scale (20 to 30

Greater than 400 kil-ohms

50 db @ 60

FILTER

CONVERSION TIME

VIBRATION

MECHANICAL SHOCK

CASE

ENVIRONMENTAL

WEIGHT

APPROVALS

Single pole, low-pass, 40 msec time constant.

30 microseconds typical.

20 Gs peak or 0.06 in. double amplitude, 10 to 2,000 Hz, per MILSTD-202 method 204 condition F.

1500 Gs 0.5 mS half sine per MIL-STD202, method 213, condition F.

Solvent-resistant thermoplastic polyester, meets UL94V-0. Dimensions

0.6 in. D by 1.265 in. H by 1.690 in. W (15 mm by 32 mm by 43 mm), not including pins.

Meets the Environmental specifications of the ROC or FloBoss in which the module is installed, including Temperature and Transient Protection specifications.

1.3 ounces (37 grams).

Approved by CSA for hazardous locations Class I, Division 2, Groups A, B, C, and D.

3.7.3 Analog Output Source Module

Specifications

FIELD WIRING TERMINALS

VOLTAGE OUTPUT

3-42 Rev 5/00

Voltage Output

Current Output

Common

Type:

Voltage source.

Range:

overranging. 25 mA maximum.

Resolution:

1 to 5 Vdc with 0 to 5.25 Vdc

12 bits.

VOLTAGE OUTPUT (CONT’D)

Accuracy:

from 20 to 30 °C. 0.5% of full-scale output for -40 to 65 °C.

Settling Time: Reset Action:

percent output or last value (software configurable) on power-up (warm start) or on watchdog timeout.

0.1% of full-scale output

100 µs maximum.

Output goes to zero

FloBoss 407 Instruction Manual

Specifications (Cont’d)

CURRENT OUTPUT

POWER REQUIREMENTS

Current loop.

Type: Range:

overranging, adjusted by scaling resistor. A 0-ohm resistor is supplied.

Loop Source:

supplied by ROC for “+T” power (typically 24 Vdc).

Loop Resistance at 12 Vdc:

ohms minimum, 250 ohms maximum.

Loop Resistance at 24 Vdc:

ohms minimum, 750 ohms maximum.

Resolution: Accuracy:

from 20 to 30 °C. 0.5% of full-scale output for -40 to 65 °C.

Settling Time:

maximum.

Reset Action:

percent output or last value (software configurable) on pow er-up (warm start) or on watchdog timeout.

Module Alone: Module w/Current Loop:

@ 4 mA output to 590 mW @ 20 mA output.

4 to 20 mA with 0 to 22 mA

11 to 30 Vdc, as

200

12 bits.

0.1% of full-scale output

100 microseconds

Output goes to zero

24 mW typical.

400 mW

OUTPUT ISOLATION

SURGE WITHSTAND

VIBRATION

MECHANICAL SHOCK

WEIGHT

CASE

ENVIRONMENTAL

APPROVALS

Not isolated. Terminal C tied to power supply common.

Meets IEEE 472/ANSI C37.90a.

20 Gs peak or 0.06 in. double amplitude, 10 to 2,000 Hz, per MILSTD-202 method 204 condition F.

1500 Gs 0.5 ms half sine per MILSTD-202, method 213, condition F.

1.3 ounces (37 grams) typical.

Solvent-resistant thermoplastic polyester, meets UL94V-0. Dimensions are 0.6 in. D by 1.265 in. H by 1.69 in. W (15 mm by 32 mm by 43 mm), not including pins.

Meets the Environmental specifications of the ROC or FloBoss in which the module is installed, including Temperature and Transient Protection specifications.

Approved by CSA for h a zardous locations Class I, Division 2, Groups A, B, C, and D.

Rev 5/00 3-43

FloBoss 407 Instruction Manual

3.7.4 Discrete Input Modules—Source and Isolated

Source Module Specifications

Not used

FIELD WIRING TERMINALS

INPUT

Discrete device source/signal

Common

Contact sense.

Type: Range:

Active, 2 to 9 mA.

Source Voltage: Source Current:

source voltag e (Vs), loop resistance (Rl), and scaling resistor (Rs, 10 ohm supplied): I = (Vs - 1)/(3.3K + Rl + Rs)

Inactive, 0 to 0.5 mA.

11 to 30 Vdc. Determined by

POWER REQUIREMENTS

INPUT ISOLATION

SURGE WITHSTAND

Source Input:

maximum from ROC power supply or I/O converter card.

Module:

maximum (supplied by ROC).

Not isolated. Terminal C tied to power supply common.

Meets IEEE 472/ANSI C37.90a.

11 to 30 Vdc, 9 mA

4.9 to 5.1 Vdc, 1 mA

FIELD WIRING TERMINALS

INPUT

Isolated Module Specifications

Not used

Positive discrete input

Negative discrete input

Type: Range:

Active; 2 to 9 mA.

Current:

voltage (Vi), loop resistance (Rl), and scaling resistor (Rs, 10 ohm supplied): I = (Vi - 1)/(3.3K + Rl + Rs)

Maximum Voltage:

forward, 5 Vdc reverse.

Two-state current sense.

Inactive; 0 to 0.5 mA.

Determined by input

30 Vdc

POWER REQUIREMENTS

INPUT ISOLATION

4.9 to 5.1 Vdc, 1 mA maximum (supplied by ROC).

Isolation:

input to output, and input or output to case.

Voltage:

minimum, input to output.

Capacitance:

output.

100 megohm minimum,

4,000 Vac (RMS)

6 pF typical, input to

3-44 Rev 5/00

Emerson Fisher FLOBOSS 407 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Tracking Sheet

Table of Contents

SECTION 1 — GENERAL INFORMATION

Product Overview 1.3 1-2 Related Documents and Compatibility 1.3.1 1-4 Installation Guidelines 1.4 1-5

SECTION 2 — THE FLOBOSS 407 BASE UNIT

SECTION 3 — INPUT/OUTPUT MODULES