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.
Fisher Controls International, Inc. 1995-2000. All rights reserved.
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
Table of Contents
(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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FloBoss 407 Instruction Manual
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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FloBoss 407 Instruction Manual
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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FloBoss 407 Instruction Manual
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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FloBoss 407 Instruction Manual
♦ 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.
AM
♦ 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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FloBoss 407 Instruction Manual
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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FloBoss 407 Instruction Manual
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
P
min
N/A 800 N/A 1200 1 N/A
P
max
P
min
P
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
P
min
P
max
P
min
P
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
P
SF
To convert P
24 volts.
to current consumption in amps (ISF), divide PSF by the system voltage (V), either 12 or
SF
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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FloBoss 407 Instruction Manual
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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FloBoss 407 Instruction Manual
+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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