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Gas Control Manager Program User Manual (FloBoss 107)
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Remote Automation Solutions Gas Control Manager Program User Manual (FloBoss 107) Manuals & Guides

Part D301749X012
August 2016
Gas Control Manager Program User Manual (for FloBoss™ 107)
Remote Automation Solutions
Page
Revision
All Pages
August-2016
Initial release
August-2014
Revision Tracking Sheet
August 2016
This manual may be revised periodically to incorporate new or updated information. The revision date of each page appears at the bottom of the page opposite the page number. A change in revision date to any page also changes the date of the manual that appears on the front cover. Listed below is the revision date of each page (if applicable):
ii Revised Aug-16
Contents
Chapter 1 – Introduction 1
1.1. Scope and Organization ................................................................................................................. 1
1.2. Product Overview ........................................................................................................................... 1
1.2.1. EFM Applicatio n s ............................................................................................................. 2
1.2.2. Cause and Effect .............................................................................................................. 2
1.2.3. Flow Summation............................................................................................................... 2
1.3. Program Requirements .................................................................................................................. 2
Chapter 2 – Installation 5
2.1. Installing the License Key ............................................................................................................... 5
2.2. Downloading the Program .............................................................................................................. 6
Chapter 3 – Configuration 11
3.1. EFM Applicatio n s .......................................................................................................................... 11
3.1.1. Run Switching – Run Switch Tab: Station Settings ....................................................... 12
3.1.2. Run Switching – Run Switch Tab: Tube Settings .......................................................... 17
3.1.3. Run Switching – Run Switch Operate Tab ..................................................................... 20
3.1.4. Run Switching – Proportional Output Tab ...................................................................... 21
3.1.5. Run Switching – Total Accum Tab ................................................................................. 22
3.1.6. About Open and Close DO ............................................................................................ 23
3.2. Cause and Effect .......................................................................................................................... 23
3.2.1. Effect Configuration Settings .......................................................................................... 25
3.2.2. Cause Configuration Settings ........................................................................................ 27
3.2.3. Cause and Effect Operate Display ................................................................................. 32
3.2.4. Configuration Examples ................................................................................................. 33
3.3. Flow Summation ........................................................................................................................... 41
3.3.1. Flow Sum ....................................................................................................................... 42
3.3.2. Examples ........................................................................................................................ 44
Chapter 4 – Reference 46
4.1. Point Type 22: Cause Configuration ............................................................................................ 47
4.2. Point Type 23: Effect Configuration .............................................................................................. 53
4.3. Point Type 35: Run Switching ...................................................................................................... 56
4.4. Point Type 36: Flow Sum ............................................................................................................. 66
Appendix A – Sample Cause and Effect Diagram 69
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iv Revised Aug-16

Chapter 1 – Introduction

Caution
When implementing control using this product, observe best industry practices as suggested by applicabl e and appropriate environmental, health, and safety organizations. While this product can be used as A safety component in a system, it is NOT intended o r designed to be the ONLY safety mechanism in that system.
This chapter describes the structure of this manual and presents an overview and installation instructions of the Gas Control Manager Program for the FloBoss 107 (FB107).

1.1. Scope and Organization

This document is the user manual for the Gas Control Manager Program for use in the FB107.
This manual describes how to download and configure this program (referred to as the “Gas Control Manager Program” or “the program” throughout the rest of this manual). You access and configure this program using ROCLINK™ 800 Configuration Software (version 2.20 or greater) loaded on a personal computer (PC) running Windows XP (with Service Pack 3), Windows Vista™ (32-bit), Windows 7 (32-bit and 64-bit), or Windows 8 (32-bit and 64-bit).
The sections in this manual provide information in a sequence appropriate for first-time users. Once you become familiar with the procedures and the software running in a FB107, the manual becomes a reference tool.
This manual has the following major sections:
Chapter 1 – Introduction Chapter 2 – Installation Chapter 3 – Configuration Chapter 4 – Reference
This manual assumes that you are familiar with the FB107 and its configuration. For more information, refer to the following manuals:
FloBoss 107 Flow Manager Instruction Manual (D301232X012) ROCLINK 800 Configuration Software User Manual (for FB107)

1.2. Product Overview

The Gas Control Manager Program has two major components: EFM Applications and Cause and Effect. This manual describes both
components, as well as an additional feature, Flow Summation.
(D301249X012)
Revised Aug-16 1
1.2.1. EFM Applications
The Gas Control Manager program enables you to configure the FB107 to perform common gas measurement (EFM) functions, including station emergency shutdown, output of a 4-20 mA signal proportional to an input or calculation, reset total meter accumulators for volume/energy, and run switching. Normally, you would have to write a series FSTs to accomplish these tasks; the program simplified the management of these and other EFM-related tasks.
1.2.2. Cause and Effect
The program supports 16 causes and 8 effects, enabling you to perform logical operations without writing FSTs. Typically, a cause monitors a selected point that the program logically evaluates against a setpoint you define. Any tripped cause linked to an effect forces the action defined in that effect. The design of the configuration screens enables you to configure this logic using a Cause & Effect matrix. In many cases you can input the effects and causes line by line through the entire matrix. Each cause configuration screen and effect configuration screen applies to a tag line in your Cause & Effect matrix.
1.2.3. Flow Summation
An additional feature of the Gas Control Management program is the ability to sum station values, totalizing any selected meter runs into flow or volume results for station 1 or 2. You can then place volume and energy results into softpoint tables or access those values directly through their TLPs. Resettable total station accumulators are available according to the totalization selections as well for station 1 or 2.
Station Total Accumulators for volume and energy accumulate selected meter runs as totalized amount until you manually reset the accumulators. The point parameters used accumulate to a huge number, and (for all practical purposes) will never reach a roll-over point.

1.3. Program Requirements

You download the Gas Control Manager Program to the Flash and RAM memory on the FB107 with firmware version 1.60 (or greater). Download and configure the program using ROCLINK 800 Configuration software version 2.20 (or greater).
The downloadable program is:
File Name
Target Unit/
Version
User Defined Points (UDP)
Flash Used
(in bytes)
DRAM Used
(in bytes)
ROCLINK 800
Version
Display
Number
GasControlMgr_
v305_02_1.bin
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FB107 1.60 22, 23, 35, 36 40260 16384 2.20
21, 22, 23,
35, 36
Note: You must connect a PC to the FloBoss’s LOI port before starting
the download.
For information on viewing the memory allocation of user programs, refer to the ROCLINK 800 Configuration Software User Manual (for FB107) (D301249X012).
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Chapter 2 – Installation

This section provides instructions for installing the Gas Control Manager Program into the FB107. Read Section 1.3 of this manual for program requirements.
Note: The program and license key can be installed in any order. The
manual shows the installation of the license key first.

2.1. Installing the License Key

A license key is required to use the Gas Control Manager Program. To install a USB key-based license on the FB107:
1. Insert the USB license key in a USB port on your PC.
2. Select Utilities > License Key Administrator > Transfer Between
Device and Key from the ROCLINK 800 menu bar. The Transfer Licenses Between a Device and a Key screen displays.
Figure 1. Transfer Licenses Between a Device and a Key
Note: This screen has three sections. The upper portion (Licenses on
Device) shows any software licenses installed on the FB107. The middle portion (Licenses on Key) shows software licenses on the license key. The lower portion of the screen (License Key Event Log) provides a rolling log of the last eight events related to this license key.
Revised Aug-16 5
3. Select the key-based license you want to transfer to the FB107 (Read
Only Port, as shown in Figure 1).
4. Click Move to Device. ROCLINK moves one instance of the license
from the key to the FB107 and updates the screen.
Note: An FB107 can hold up to six different licenses, although you
can install only one instance of each license on the FB107. When you click Move to Device, ROCLINK 800 moves only one instance of the license onto the FB107 and automatically decreases the license quantity on the USB key by one.
5. Verify the license name displays in the Licenses on Device section of
the screen. Proceed to Section 2.2 to download the user program.

2.2. Downloading the Program

This section provides instructions for installing the user program into FloBoss memory.
Note: Connect a PC to the FloBoss’s LOI port before starting the
download.
To download the user program:
Figure 2. License Installed
1. Start and logon to ROCLINK 800.
2. Select ROC > Direct Co n nect to connect to the FloBoss unit.
6 Revised Aug-16
3. Select Utilities > User Program Administrator from the ROCLINK
menu bar. The User Program Administrator screen displays (see
Figure 3):
Figure 3. User Program Administrator
4. Click Browse in the Download User Program File frame. The Select
User Program File screen displays (see Figure 4).
5. Select the path and user program file to download from the CD-ROM.
(Program files are typically located in the Program Files folder on the CD-ROM). As Figure 4 shows, the screen lists all valid user program files with the .BIN extension:
Figure 4. Select User Program File
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6. Click Open to select the program file. The User Program
Administrator screen displays. As shown in , note that the Download User Program File frame identifies the selected program and that the Download & Start button is active:
Figure 5. User Program Administrator
7. Click Download & Start to begin loading the selected program. The
following message displays:
Figure 6. Confirm Download
Note: For the FB107, ROCLINK 800 assigns program positions
based on memory allocations.
8. Click Yes to begin the download. During the download, the program
performs a warm start, creates an event in the event log, and—when the download completes—displays the following message:
8 Revised Aug-16
Figure 7. ROCLINK 800 Download Confirmation
9. Click OK. The User Program Administrator screen displays (see
Figure 8). Note that:
The User Programs Installed in Device frame identifies the loaded
program.
The Status field indicates that the program is running.
Figure 8. User Program Administrator
10. Click Close and proceed to Chapter 3 to configure the program.
Note: Installing a user program without a license key allows you only
to view the program screens (that is, the program outputs no data). Installing the license key enables the program to read from the meter and output data.
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10 Revised Aug-16

Chapter 3 – Configuration

After you download and start the Gas Control Manager Program, configure the program using ROCLINK 800 software. To do this, use the program-specific Gas Control Manager Program screen.
Figure 9. ROCLINK 800

3.1. EFM Applications

Once you have successfully loaded the Gas Control Manager program into the FloBoss, you can access the Gas Control Manager screens. To start the EFM Applications:
1. Double-click an FB107 device or click the D ir ect C on n ect icon in the
toolbar.
2. The device window opens. Select User Program > Gas Control Mgr
in the ROCLINK configuration tree.
3. Double-click Display #35, Run Switching.
4. You will see a display for each station. Double-click a station to see
the Run Switching window for that station.
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Figure 10. Run Switch tab – Run Switching screen
The Run Switch tab is divided into two main sections: Station Configuration and Tube Configuration:
Station Configuration. Use this section to configure global settings
that affect all tubes in the station. Two run switching stations are available.
Tube Configuration. Use this section to configure switching for up to
four runs. You define your input and output points, set high and low points, and choose when to open and close runs.
3.1.1. Run Switching – Run Switch Tab: Stati on S ett ings
Use this section to configure global settings that affect all tubes in the station. Two run switching stations are available.
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Field
Description
Figure 11. Station settings of the Run Switch tab
1. Review the values in the following fields:
Station Tag
Status
Status Message Display
Use this field to name your station. The default value is Station1.
The first number reflects the total number of runs (flow tubes) that the program believes is currently open. The next four fields show the status of each of the four tubes. The values are 1 (open) or 0 (closed). The blue box frames the tube that is in focus or control.
Provides information for the following run switching conditions:
0 = Status OK 1 = Station ESD 2 = PV Type Not Selected 3 = Invalid Open DO Type 4 = Invalid Open DO Param 5 = Invalid Close DO Type 6 = Invalid Close DO Param 7 = Invalid Open DI Type 8 = Invalid Open DI Param 9 = Invalid Close DI Type 10 = Invalid Close DI Param 11 = Illegal Flow Tube 1 12 = Illegal Flow Tube 2 13 = Illegal Flow Tube 3 14 = Illegal Flow Tube 4 15 = Illegal DI Tube 1 16 = Illegal DI Tube 2 17 = Illegal DI Tube 3 18 = Illegal DI Tube 4
Revised Aug-16 13
Delays
Use the Spike and Settling delays to set how long the system waits before taking action.
Field
Description
Spike Delay
Settling Delay
Switch Mode
Sets, in seconds, a delay time. The program examines this field whenever a run’s Input TLP value goes above or below its high or low set point. The condition must remain in effect for the number of seconds specified in this field before any run-switching executes. The delay provides a filter for the process variables. The Spike Delay time is also used when switching down to a lower tube that has been closed or up from a lower tube that will be closed (this happens when “Leave Open After Opening Next Tube” is unchecked). Before the program closes that tube, it must see flow (a PV value greater than the PV Cutoff Value) for the tube just opened, for the amount of time specified in the Spike Delay. Maximum value is 255 seconds.
Sets, in seconds, a delay time. This delay goes into effect immediately after a run switches. During the delay, the new focus run remains in focus, so no comparisons occur for any more possible switching. This allows process conditions to stabilize after the previous change before any more decisions are made. Maximum value is 255 seconds.
Indicates how the tubes are monitored.
Monitor All
Monitor Last Opened
Monitors all passed switch points. For example, if all four tubes had been opened, choosing this option causes the system to monitor the switch points in all four tubes.
Monitors only the switch point that was last activated. For example, if all four tubes had been opened, choosing this option causes the system to monitor the switch points in tube 4 only.
Solenoid Mode
14 Revised Aug-16
Selects a method for controlling the run switching valve activations. The selected mode applies to all valves, and impacts status messages that notify whether relevant selections for digital outputs and digital inputs have been made. Valid values are:
Single Solenoid Latch
The Open DO selection is defined for each valve used which opens and closes the valve by energizing or de­energizing a solenoid. The Open and Close DI selections can be defined and monitored to verify valve travel if needed.
Field
Description
Dual Solenoid Latch
Dual Solenoid Latch with DI Reset
Dual Solenoid Momentary
The Open DO selection defines the output signal to open the valve. The program will hold this state until a signal to close is issued. The Close DO selection will define the output signal to close the valve. One or the other solenoids will always be on. The Open and Close DI selections can be defined and monitored to verify valve travel if needed.
In this mode the outputs behave as a Dual Solenoid Latch, but the solenoid resets or releases after the valve travels and the valve DI limit switches detect that valve position.
In this mode, selections are made for an open and close DO that turn on momentarily while the valve travels and then turn off. The FloBoss Point I/O Time On setting for that DO determines the duration of the momentary pulse. The Open and Close DI selections can be defined and monitored to verify valve travel if needed.
Focus Run Verification
PV Cutoff Value
Verifies the focus (control) tube by continually monitoring the verification method of each enabled tube. The highest number tube that is verified to be flowing is set as the focus tube. This feedback causes the proper DO state to be asserted to establish proper focus. Valid values are:
Disable PV Flow
Sensing
DI State
Defines a threshold for a valid flow sensing condition using the low flow cutoff value. The program also uses this value to establish a valid flow for the Action On Failure mode Illegal PV Flow.
No Run Verification Compares Input PV to the PV Cutof f
Value to determine whether a flow condition exists for that tube. The highest number tube that is flowing becomes the focus tube.
Examines the state of the digital inputs for each tube to determine the focus tube. The highest number tube with its digital inputs indicating “valve open” becomes the focus tube. If these DI points are “Undefined,” this evaluation is not made.
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Field
Description
Station ESD
ESD TLP
Action On Failure
Configures the Emergency Shutdown feature. If you leave this field “Undefined” the ESD is not activated. This feature can also be used for routine station shut-in. When tripped, an ESD closes all run switching valves to provide positive shut-in. A Set conditi on is logge d to the alar m log. The program restores the run switching function when the ESD condition clears, and sends a Clear condition to the alarm log.
Defines the TLP the program monitors for emergency shutdown.
Verifies tube flowing conditions or DI states relative to the focus tube depending on the selected Failure Type. Various actions are possible based on the selection. No evaluations are made until after the Failure Delay counter to allow run switching to stabilize before applying any actions are applied. Valid values are:
Type: None
Type: Illegal PV Flow
Type: Illegal DI State
Action: Status Only
Action: Alarm Log
Action: Disable Tube & Alarm Log
Disables any failure evaluation.
Evaluates valid tube flow by using the PV Cutoff Value in the Focus Run Verification section, which determines if a tube is actually open or closed.
Uses digital input states to determine if a tube is actually open or closed.
Generates a status message code to indicate a Failure condition.
Sends a Failure condition to the alarm log that contains the status message code number.
Disables the tube where the Failure condition is identified and logs that tube as OFF in the alarm log. If this tube was not the last tube enabled, run switching skips the disabled tube and uses the next tube for control.
16 Revised Aug-16
Failure Delay (Sec)
All Action On Failures are performed after the Settling Delay plus the Failure Delay setting in seconds. Maximum value is 255 seconds.
2. Click Apply to save your changes.
3. Proceed to Section 3.1.2, Run Switching – Run Switch Tab: Tube
Settings.
Focus Run Verification methods can be used to assure the run switching program’s focus tube is what is actually happening. An example of this is a valve with momentary solenoids that do not change state when the output is pulsed. If this were to occur, the program would switch focus and lose sight of the actual valve states. This may be most useful for dual
solenoids that do not hold their states such as Momentary or DI Reset modes.
An example of what happens in the event of a valve switch failure: Tube 3 has just pulsed to close because of low DP. Ordinarily tube 2 becomes the focus run. But as long as flow is still sensed in tube 3, it remains the focus run. After the settling time expires (default 30 seconds), if tube 3 still has low DP, the program will pulse to close tube 3 again and wait another settling period.
3.1.2. Run Switching – Run Switch Tab: Tube S e t t ings
Use this section to configure switching for up to four runs. You define your input and output points, set high and low points, and choose when to open and close runs.
In the Run Switching section, you can configure switching for up to four runs, using various types of input and output points. The program supports both non-latching and latching (such as Versa® Valve or Magna-Latch) solenoids and has configurable high and low switch points, and the option of closing the previous run when opening another.
Figure 12. Station settings of the Run Switch tab
Notice that the Run 1 configuration has no Lo SwitchPt field. This is because the Lo SwitchPt field triggers a run to be closed and closing Run 1 would result in no flow at the station. Conversely, notice that the Run 4 configuration has no Hi SwitchPt or Leave Open fields. This is because there is no Run 5 to be opened after Run 4.
1. Review the values in the following fields:
Revised Aug-16 17
Field
Description
Tag
Enabled
Input PV TLP
A 10-character field that identifies the meters that makes up the run-switching scheme. This tag is useful for documentation purposes (screen prints, etc.).
Select this checkbox to enable a run for the run­switching scheme. You must enable at least two runs in order to do run-switching. If only one of the four runs is enabled, no action is done. The left-most run (Run 1) is the primary run (open during lowest/all flow conditions). The focus starts on the left and moves to the right. Normally, at least Run 1 and Run 2 would be enabled to do run-switching with two meters. However, the program allows you to skip runs (taken out of service) so the run-switching functionality is still valid even with Run 1 disabled (as long as you have enabled two or more other runs).
Specifies the points in the FB107 that are defined as variable inputs to the run-switching function. For orifice measurement, these are typically differential pressures (DPs) which are the “Meter Input” parameter used in flow calculations. For linear measurement, actual uncorrected flow is typically selected. If you leave this field “Undefined” the program displays a PV Type Not Selected status message. The field shown as PV displays the current value of the selected Input PV.
Open DO TLP
Close DO TLP
Energize to Open
Specifies the points in the FB107 that are wired to the valve solenoids. These should be digital output points. They can be wired to either non-latching solenoids (energized/de-energized) or latching solenoids (such as Versa Valves or Magna-Latches). All enabled tubes must use an Open DO with the exception of the base tube (the first enabled tube), which is optional. If the base tube has no actuated switching valve, the DO will be “Undefined”.
Specifies the points in the FB107 that are wired to the valve solenoids. These are the digital output points. They can be wired to either non-latching solenoids (energized/de-energized) or latching solenoids (such as Versa Valves or Magna-Latches). If the single solenoid mode is selected (such that a single solenoid both opens and closes the valve), or the base tube has no actuated switching valve, then the Close DO TLP is unused, and is left “Undefined”.
For more information about open and close DO, refer to Section 3.1.6. About Open and Close DO.
Energizes the Open DO to open the valve and open the run. If this box is not selected, the program turns off the Open DO to open the valve.
18 Revised Aug-16
Field
Description
Open DI TLP
Close DI TLP
Lo Switch Pt
Selects the Open DI from available points on the FB107. The TLP automatically uses the STATU S parameter regardless of what parameter is selected. This selection is mandatory only for the Solenoid Mode Dual Solenoid Latch – DI Reset. Otherwise the point can be used for monitoring purposes or left as “Undefined” if the valve has no limit switches.
Selects the Close DI from available points on the FB107. The TLP automatically uses the STATUS parameter regardless of what parameter is selected. This selection is mandatory only for the Solenoid Mode Dual Solenoid Latch – DI Reset. Otherwise the point can be used for monitoring purposes or left as “Undefined” if the valve has no limit switches.
Indicates the low value that the program compares to the value of the Input TLP for each run. In the run­switching function the right-most (furthest to the right) run open is the focus run. When the value of the focus run’s “Input TLP” is less than or equal to its low set point for a certain amount of time (spike delay), the run closes. When using “Monitor All Passed SwitchPts,” if any of the runs is below its low set point, the focus run closes and focus shifts to the next enabled run to the left.
Note: The units of this field are actual Engineering
Units (not percentages).
Hi Switch Pt
Leave Open After Opening Next Tube
Indicates the high value that the program compares to the value of the Input TLP for each run. In the run­switching function the right-most (furthest to the right) run open is the focus run. When the value of the focus run’s “Input TLP” is greater than or equal to its high set point for a certain amount of time (spike delay), the next enabled run to the right opens. When using “Monitor All Passed SwitchPts,” if any of the runs is above its high set point, the next enabled run to the right of focus opens and focus shifts to that run. Notice that Run4 has no “Hi Switch Pt” field as there is no openable run to its right (all available runs are already open).
Note: The units of this field are actual Engineering
Units (not percentages).
Select this checkbox if, during expansion, each run remains open when focus shifts to the next enabled run to the right. If you do not select this checkbox, each run opens only when it is the focus run (there is only one run open at all times). When a run loses focus it remains open while monitoring the new focus run (to either the left or right). When flow is detected on the new focus run (Input TLP value is greater than one, for the spike delay time), the previous focus closes.
Revised Aug-16 19
2. Click Apply to save your changes.
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