Floboss S600 Flow Manager: Instruction Manual

FLOBOSS S600™ FLOW MANAGER
Instruction Manual
Form A6115
August 2001
Flow Computer Division

D301150X012 (loose leaf)
FloBoss S600 Instruction Manual
Revision Tracking Sheet

August 2001
This manual is periodically to incorporate new or updated information. The date revision level of each
page is indicated at the bottom of the page opposite the page number. A major change in the content
of the manual also changes the date of the manual, which appears on the front cover. Listed below is
the date revision level of each page.
Page Revision
All Pages 8/01
Daniel and FloBoss are marks of one of the Emerson Process Management companies. The Emerson logo is a trademark and service mark
of Emerson Electric Co. All other marks are the property of their respective owners. This product may be covered under one or more
patents pending.
 Fisher Controls International, Inc. 2001. All rights reserved.
While this information is presented in good faith and believed to be accurate, we do not guarantee satisfactory results from reliance upon such information.
Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness or any other
matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. We reserve the right, without notice, to
alter or improve the designs or specifications of the products described herein.
Printed in the U.S.A.
ii 8/01
TABLE OF CONTENTS
SECTION 1 – OVERVIEW................................................................................................................1-1
1.1 Section Contents ........................................................................................................................1-1
1.2 Scope of Manual ........................................................................................................................1-1
1.3 FloBoss S600 Flow Computer...................................................................................................1-3
1.4 IPL 600 ......................................................................................................................................1-6
1.5 Config 600 Lite..........................................................................................................................1-6
1.6 Config 600 Professional.............................................................................................................1-6
SECTION 2 – INSTALLATION........................................................................................................2-1
2.1 Scope..........................................................................................................................................2-1
2.3 Preparing for Installation ...........................................................................................................2-1
2.4 Unpacking the FloBoss S600.....................................................................................................2-2
2.5 Environmental Considerations...................................................................................................2-2
2.6 Required Tools for Installation ..................................................................................................2-3
2.7 Installing the FloBoss S600 .......................................................................................................2-3
SECTION 3 – OPERATION ..............................................................................................................3-1
3.1 Scope..........................................................................................................................................3-1
3.3 Description.................................................................................................................................3-2
3.4 Keypad .......................................................................................................................................3-3
Display .............................................................................................................................................3-6
3.6 Data Pages..................................................................................................................................3-7
3.7 Status/ID Line ............................................................................................................................3-7
3.8 Display Matrix ...........................................................................................................................3-7
3.9 Using the FloBoss S600.............................................................................................................3-9
3.10 Entering Data ...........................................................................................................................3-12
3.11 Alarms......................................................................................................................................3-17
3.12 Printing.....................................................................................................................................3-19
3.13 Special Pages ...........................................................................................................................3-21
3.14 Summary of Operation.............................................................................................................3-22
SECTION 4 – MAINTENANCE........................................................................................................4-1
4.1 Scope..........................................................................................................................................4-1
4.3 Cold Start Procedure..................................................................................................................4-1
4.4 Reflash Firmware.......................................................................................................................4-3
4.5 Network Setup ...........................................................................................................................4-5
4.6 Factory Setup .............................................................................................................................4-5
4.7 Troubleshooting .........................................................................................................................4-6
SECTION 5 – SETUP AND WIRING ...............................................................................................5-1
8/01 Table of Contents iii

5.1 Scope ......................................................................................................................................... 5-1
5.2 Section Contents........................................................................................................................ 5-1

5.3 CPU Board ................................................................................................................................ 5-2
5.4 P144 I/O Board........................................................................................................................ 5-12
5.5 P154 Prover Board .................................................................................................................. 5-21
SECTION 6 – SOFTWARE INTERFACE ...................................................................................... 6-1
6.1 Scope ......................................................................................................................................... 6-1
6.2 Section Contents........................................................................................................................ 6-1
6.3 System Requirements................................................................................................................ 6-2
6.4 Software Installation Procedure ................................................................................................ 6-2
6.5 File Locations............................................................................................................................ 6-3
6.6 StartUp ...................................................................................................................................... 6-4
6.7 Connecting to the FloBoss S600 ............................................................................................... 6-4
APPENDIX A – TECHNICAL DATA............................................................................................. A-1
A.1 Scope ........................................................................................................................................ A-1
A.2 Section Contents....................................................................................................................... A-1
A.3 Mechanical and Environmental................................................................................................ A-2
A.4 Power Supply ........................................................................................................................... A-3
A.5 P152 CPU................................................................................................................................. A-4
A.6 P144 I/O ................................................................................................................................... A-7
A.7 P154 Prover ............................................................................................................................ A-13
A.8 Display-Keypad...................................................................................................................... A-16
A.9 Mezzanine Boards .................................................................................................................. A-17
APPENDIX B – ENGINEERING DRAWINGS ..............................................................................B-1
B.1 List of Engineering Drawings ...................................................................................................B-1
GLOSSARY........................................................................................................................................ G-1
INDEX ...................................................................................................................................................I-1
iv Table of Contents 8/01

SECTION 1 – OVERVIEW
1.1 Section Contents

This section includes the following information:
Information Section Page Number

Section Contents 1.1 1-1
Scope of Manual 1.2 1-1
Organization of Manual 1.2.1 1-1
FloBoss S600 Flow Computer 1.3 1-3
IPL 600 1.4 1-5
Config 600 Lite 1.5 1-6
Config 600 Professional 1.6 1-6
1.2 Scope of Manual

This manual introduces the FloBoss S600 Flow Computer, IPL 600 software (used to transfer
application programs to the FloBoss S600), and the CONFIG 600 software (used to develop FloBoss
S600 applications). This manual describes the installation procedure and shows how to operate the
system including entering and modifying data. Basic maintenance and troubleshooting information is
also provided.
1.2.1 Organization of Manual

The information in this manual is arranged as follows:
♦ Section 1 – Overview provides an overview of the FloBoss S600, including the IPL 600 and
Config 600 user interfaces.
♦ Section 2 – Installation provides instructions on installing the FloBoss S600 and includes
information on installation preparation, panel mounting procedures, and the installation and
removal of the plug-in boards and the front panel.
♦ Section 3 – Operation shows how to use the FloBoss S600. This includes keypad functions,
screen displays, system initialization, display navigation, data entry, and printing reports.
♦ Section 4 – Maintenance describes how to initiate a cold start and provides maintenance and
troubleshooting information, including the basic board-level test procedures.
♦ Section 5 – Setup and Wiring describes the use of the plug-in connector blocks, field wiring
configuration, and link and jumper setting for the plug-in board.
♦ Section 6 – Software Interface introduces the FloBoss S600 user interface and lists the system
requirements, software installation instructions, and file locations on the host PC.
8/01 Overview 1-1

♦ Appendix A – Technical Data contains a complete list of physical, performance, and

environmental specifications of the FloBoss S600 and add-in boards.
♦ Appendix B – Engineering Drawings includes pertinent installation and wiring drawings
along with the spare parts list.
♦ Appendix C – Glossary is a glossary of terms and abbreviations used in this manual.
The FloBoss S600 is a compact, microprocessor-based flow computer that has been designed and built
using proven design techniques and methodologies. The FloBoss S600 can function as a stand-alone
single/multi-stream flow computer, as a combined meter station and meter stream computer, or as a
slave to an external supervisory computer.
The FloBoss S600 is supplied with the IPL 600 program (which allows you to transfer applications to
the flow computer from a host PC), a standard application, and a download cable. Refer to Figure 1-1
for an illustration of the FloBoss S600 system, including the optional PC interface cable.
Figure 1-1. The FloBoss S600 System
1-2 Overview 8/01

1.3 FloBoss S600 Flow Computer

The FloBoss S600 accepts process input signals and provides process output and control signals to
instruments used for fiscal metering, custody transfer, batch loading, and meter proving.
The FloBoss S600 provides the following hardware features:

♦ Intel 32-bit 80486 DX2 CPU running at 50 MHz with built-in floating point math co-processor.
This configuration is supported by six processors on each I/O board.
♦ Capacity, database, and processing capabilities for up to ten mixed metering runs. The CPU can
communicate with up to seven plug-in expansion I/O modules. The panel-mounted case has
capacity for one CPU module and up to three I/O modules.
Figure 1-2. CPU Board
♦ Front panel display and keypad for local system operation and data entry. The FloBoss S600
includes a backlit LCD display, 29-button keypad, and an alarm status LED.
♦ The panel case is fabricated from rugged, spot welded zinc coated mild steel with the power
supply backplate mounted inside the case.
♦ Multiple communication interfaces include two RS232 serial ports for connection to a printer
or RTU, and three RS422/RS485 serial ports (up to 57.6 kBaud) for connection to a Modbus
SCADA data network or the DCS Supervisory System.
♦ Network connectivity through Ethernet 10baseT using FTP and TCP/IP protocols.
♦ Dedicated configuration port for connection to the CONFIG 600 user interface.
8/01 Overview 1-3

♦ Functions such as:

¾ stream and station totalization
¾ batch totalization and correction
¾ 3-term PID control
¾ flow balancing
¾ flow scheduling
¾ automatic proving sequence
¾ K-factor linearization
¾ valve monitor/control
¾ sampler control
♦ Prover operations can be configured to include compact, as well as bi-directional provers.
♦ Modular Intelligent Input/Output (I/O). The I/O can be configured to match most system
requirements including multiple streams, multiple products, and primary meters.
The I/O card can be configured for the measurement, control, and logic service functions as stated
Table 1-1.
Table 1-1. I/O Functions
Number Description
12 Analog Inputs
4 Analog Outputs
1 Raw Pulse Output (Proving)
3 4-wire RTDs
16 Digital Inputs
12 Digital Outputs
3 Frequency Inputs
2 Dual Pulse Inputs
4 Single Pulse Inputs
5 Programmable Pulse Outputs
For more details on the FloBoss S600 hardware, see Appendix A, Technical Data.
1-4 Overview 8/01

Figure 1-3. Intelligent I/O Board
The FloBoss S600 incorporates the following software features:

♦ Batches can be programmed using a quantity method, and individual batch-end warning and
end-reached alarms can be configured.
♦ Flow and time weighted averages are configurable for all input variables. These averages can
be used to generate correction factors based on daily totals and running batch totals.
♦ Supports up to 16 different alarm groups; typically, the three most commonly used are
Computer, System and Process Groups. The current alarm status displays via a single tri-color
LED on the front panel of the FloBoss S600. The alarms in the system can also be viewed and
accepted from the front panel.
♦ Up to 12 user-defined period reports can be configured. Maintenance, batch, and snapshot
(current data) reports are also available. Separate report formats are used for gas, liquid, and
proving. Reports can be printed locally.
♦ Each user can be allocated a password-enabled security level from a total of 10 security levels.
♦ Current limiting is provided on start-up in order to prevent large in-rush current spikes.
♦ PID flow control logic can be configured for each meter run as either flow or pressure control.
1.4 IPL 600

The IPL 600 software is the “Interactive Program Loader” (supplied with the FloBoss S600). The IPL
600 software is used to upload and download pre-developed configurations and applications.
Note: The FloBoss S600 will not operate until a configuration file has been downloaded from
the host PC.
8/01 Overview 1-5

1.5 Config 600 Lite

The Config 600 Lite software (optional) is a subset of the Config 600 Professional software that can be
used to upload and download pre-developed configurations and applications.
Note: Config 600 Lite is used to custom configure a new FloBoss S600 during installation.
Config 600 Lite allows you to perform the following functions from the Config 600 Professional list:
♦ Edit process configuration data, including orifice size, analog input scaling, alarm limits, and
keypad values.
♦ Build and customize Modbus slave maps, Modbus master polling sequences, front panel
displays, and period report formats.
♦ Customize the alarm system, including alarm groups, suppression, text, and inhibits.
♦ Configure system security by setting user names and passwords, and assigning access levels for
each data object.
♦ Reflash the CPU module firmware with software upgrades.
1.6 Config 600 Professional

The Config 600 Professional program (optional) allows you to configure the FloBoss S600 from a
portable or desktop PC running Windows 95, 98, or NT.
Note: The Config 600 Professional is used to create and develop new FloBoss S600
applications.
Config 600 Professional allows you to perform the following functions:

♦ Create a new application from base templates for a gas orifice, gas turbine, gas ultrasonic,
liquid turbine, or bi-directional prover system.
♦ Edit process configuration data, including orifice size, analog input scaling, alarm limits, and
keypad values.
♦ Upload data, such as the process configuration data.
♦ Build and customize Modbus slave maps, Modbus master polling sequences, front panel
displays, and period report formats.
♦ Specify the engineering units and totalization rollover value.
♦ Customize the alarm system, including alarm groups, suppression, text, and inhibits.
♦ Configure system security by setting user names and passwords, and assigning access levels for
each data object.
♦ Reflash the CPU module firmware with software upgrades.
For more details on using CONFIG 600 Lite and CONFIG 600 Professional software, refer to the
online help file provided with the program.
1-6 Overview 8/01

The online help is content-sensitive and accessible via the F1 key.
8/01 Overview 1-7

1-8 Overview 8/01

SECTION 2 – INSTALLATION
2.1 Scope
This section provides instructions on installing the FloBoss S600 including installation preparation,
panel mounting procedures, and the installation and removal of the plug-in boards, and the front panel.

This section includes:

Scope 2.1 2-1
Preparing for Installation 2.3 2-1
Unpacking the FloBoss S600 2.4 2-2
Environmental Considerations 2.5 2-2
Required Tools for Installation 2.6 2-2
Installing the FloBoss S600 2.7 2-2
Removing the Front Panel 2.7.1 2-2
Installing the Panel-Mounted Unit 2.7.2 2-2
Installation and Removal of the Boards 2.7.3 2-2
Installing Plug-In Boards 2.7.4 2-2
Reinstalling the Front Panel 2.7.5 2-2
2.3 Preparing for Installation

Installation of the FloBoss S600 must conform to all applicable local codes and regulations. All
installation procedures should be in accordance with normal practices of good workmanship.
Although the FloBoss S600 may not include all of the hardware options described in this manual, the
procedure for the basic installation of the unit remains the same.
Note: It is strongly recommended that you familiarize yourself with the procedures described
in this section before you begin to install the FloBoss S600.
The FloBoss S600 uses a modular design, providing maximum flexibility, and ease of installation. The
basic panel-mounted version consists of three major components:
♦ Fabricated metal case, complete with pre-installed PSU/backplate and four card slots for the
plug-in cards (comprising a dedicated CPU slot and three I/O slots).
8/01 Installation 2-1

♦ Removable front panel comprising the LCD display and keypad assembly.
♦ Plug-in boards, one CPU board and one I/O board are supplied for a basic configuration (two
blanking plates are supplied to cover the unused slots).
Figure 2-1 shows the FloBoss S600 system components with the appropriate user-provided tools.
Figure 2-1. All Parts of the Basic FloBoss S600 System
2.4 Unpacking the FloBoss S600

Unpack the FloBoss S600 carefully and inspect all parts for visual damage. All parts should then be
checked off against the purchase order.
Note: Do not discard any packaging material until all pieces of the shipment have been
identified and you are confident that all parts are working correctly.
2.5 Environmental Considerations

The FloBoss S600 panel mount is designed for use within the control room and should be placed in a
position that provides ease of use, comfort, and safety for operators and maintenance personnel. The
optimum height for viewing and using the display and keypad is at operator eye level.
2-2 Installation 8/01

CAUTION
Where one or more units are installed in a confined space or with other heat producing
equipment, special attention should be given to the combined heating effect.
This combined heat could increase the environmental temperature beyond its acceptable
threshold impacting performance.
2.6 Required Tools for Installation

Before attempting any installation of the FloBoss S600 hardware, ensure you have the following tools:
♦ Small flat-blade screwdriver suitable for the slot headed captive screws on the rear of the case
that secure each plug-in board into the case.
♦ 5 mm hex or small adjustable crescent wrench for the front panel bosses.
♦ 2.5 mm Allen wrench suitable for the hex cap screw on the front face of the front panel to
secure the front panel molding to the case.
2.7 Installing the FloBoss S600

Refer to the following procedures for installing the various FloBoss S600 components, including the
front panel, panel-mounted unit, and plug-in boards.
2.7.1 Removing the Front Panel

To begin the installation process, first remove the front panel from the FloBoss S600 as follows:
1. Ensure the FloBoss S600 is switched off.
2. Use a 2.5 mm Allen wrench to remove the hex cap screw from the bottom center of the
front panel. Refer to Figure 2-2.

Figure 2-2. Removing the Front Panel
3. Carefully slide the FloBoss S600 face up 4 mm (0.15") to allow it to clear the retaining
groove at the top of the case, and then allow the face to come forwards to clear the panel
case completely. Refer to Figure 2-3.
Figure 2-3. Lift up Panel

4. Disconnect the ribbon cable from the back of the front panel, as it is easier to refit when
reconnecting the front panel. Refer to Figure 2-4.
CAUTION
Do not remove the ribbon cable from the FloBoss S600 board.
Disconnect
Here
Figure 2-4. Remove Connector
5. Remove the top and bottom bosses from the unit using a 5 mm hex wrench.
2.7.2 Installing the Panel-Mounted Unit

After removing the front panel, you can install the panel-mounted unit as follows:
1. Keeping the environmental considerations in mind, construct the framework of the cubicle
to support the operating panel.
Note: A standard 19" rack 12.25" high will accommodate up to five FloBoss S600 flow
computers.
2. Refer to drawing DE-20438 in Appendix A for position details for two 7 mm (0.276") holes
and a cutout. The panel cut out should be rectangular in shape, 150 mm (5.9") vertically by
66 mm (2.6") horizontally, for each FloBoss S600 unit. A tolerance of +/- 3 mm (0.12") is
allowed on each axis.

3. Panel thickness should be at least 3 mm to prevent distortion. Thinner panels can be used,
but these require the rear of the case to be supported. Refer to Figure 2-5.
CAUTION
It is recommended that a rear support or anchor is always used to prevent twisting and
other distortion effects during installation and maintenance.
Figure 2-5. Panel Mount
4. Place the front panel case against the rear of the prepared cutout.
5. Reinstall the top and bottom bosses, and tighten with a 5 mm hex wrench.
6. When the rear support is fitted, you should use a self-tapping screw to secure the case to the
rear support. The maximum depth of the screw inside the case should be 3 mm (0.12").

2.7.3 Installation and Removal of the Boards

The CPU board is dedicated to the left-most rear slot of the case.
The remaining slots can be populated with plug-in I/O boards, or they can be left blank and covered
with the blank plates designed for the purpose.
CAUTION
Ensure suitable electrostatic discharge precautions are taken prior to removing any of the
plug-in boards.
CAUTION
The terminals on some boards may be wired to electrical potentials sufficiently high to
cause electrical shock and injury. Make sure the power sources of any connected devices
are turned off and discharged before performing any installation or repairs.
Removal of the plug-in boards:

1. Ensure the FloBoss S600 is powered-down before attempting to extract a plug-in board.
2. Unscrew the retention screws before attempting to remove a board to avoid damage to the
pull tabs. Refer to Figure 2-6.
Figure 2-6. Unscrewing the Retention Screws

3. Remove the plug-in boards by using the pull-tabs for the appropriate board and pull the
board clear of the case. Some rocking of the board may be required to release the
connector. Refer to Figure 2-7, Figure 2-8, and Figure 2-9.
Figure 2-7. Preparing to use the pull tabs for board release
Figure 2-8. Using the Pull Tabs

Figure 2-9. Board Ready for Removal or Final Insertion
2.7.4 Installing Plug-In Boards

1. Install the plug-in boards with care by aligning them in the guides (located at top and
bottom of the case), and gently sliding the board until it mates fully with the appropriate
connector on the power supply backplate.
2. Each plug-in board has two “pull tabs” on the backplate. These should be pressed in
securely on insertion.
CAUTION
The insertion and location of the plug-in boards along the guides does not require
excessive force. Take care not to twist or otherwise distort the boards during
installation.
3. Secure the board in the case with the retention screws (two per board).
2.7.5 Reinstalling the Front Panel

The final stage of the installation process is to reinstall the front panel on the FloBoss S600 as follows:
1. Connect the ribbon cable (from the front of the case) to the socket on the front panel.

CAUTION
Observe the orientation of the connector with its mating keyway that will prevent
incorrect insertion. Do not to use excessive force to refit the cable.
2. Place the top of the front panel over the retaining groove on the top boss and slide
downwards.
3. To secure the front panel, place the hex socket screw into its recess in the bottom center of
the front panel.
4. Use a 2.5 mm Allen wrench to tighten the screw finger-tight.
CAUTION
Take care not to over-tighten the screw; otherwise, damage to the panel face may
occur.
5. Turn an additional 180 degrees to complete the installation.

SECTION 3 – OPERATION
3.1 Scope
This section shows how to use the FloBoss S600, including keypad functions, screen displays, system
initialization, data entry, and printing reports. Operation also shows how to navigate the display
matrix.

Scope 3.1 3-1
Description 3.3 3-2
Keypad 3.4 3-3
F Keys 3.4.1 3-3
Vector and Menu Keys 3.4.2 3-4
Alarm Light and Keys 3.4.3 3-4
Numeric Keys 3.4.4 3-5
Operation Keys 3.4.5 3-5
Display 3.5 3-6
Menus 3.5.1 3-6
Data Pages 3.6 3-7
Status/ID Line 3.7 3-7
Display Matrix 3.8 3-7
Using the FloBoss S600 3.9 3-9
Initialization 3.9.1 3-9
Navigating the Display 3.9.2 3-11
Entering Data 3.10 3-12
Changing a Value 3.10.1 3-12
Example Value 3.10.2 3-13
Changing Mode 3.10.3 3-14
Example Mode 3.10.4 3-15
Exponential Format 3.10.5 3-16
Security Code 3.10.6 3-16
8/01 Operation 3-1

Alarms 3.11 3-17

Alarm Light 3.11.1 3-17
View Alarm 3.11.2 3-18
Alarm Accept 3.11.3 3-18
Printing 3.12 3-19
Special Pages 3.13 3-21
Summary of Operation 3.14 3-22
3.3 Description
After the FloBoss S600 has been wired for power and external devices, it may be activated by
energizing the external 24 VDC power supply. When power is first applied, the unit displays the
message RESETTING. Unless LK13 (cold start jumper/link) is installed, the FloBoss S600 displays
the message RESTARTING. When the unit initializes properly, a menu appears. You may proceed
through the instructions in this section to gain familiarity with the unit. If the FloBoss S600 does not
properly initialize, proceed to Section 4 for cold start and configuration procedures.
The operation of the FloBoss S600 is through an operator interface comprising an LCD display and a
keypad. The layout of the FloBoss S600 front panel is shown in Figure 3-1.
3-2 Operation 8/01

Figure 3-1. Front Panel
3.4 Keypad
The layout of the front panel keypad has been designed to make it easy to use and to reduce the
possibility of error. The keys on the keypad are color-coded by type:
♦ Function – yellow
♦ Alarm – dark green
♦ Vector/Menu – dark green
♦ Numeric – light green
♦ Operation – dark green
3.4.1 F Keys
The top of the keypad has four function keys numbered F1 to F4. Each F key can be programmed as a
shortcut to a frequently used display page. To program a function key:
1. Go to the required display page.
2. Press the Decimal Point key.
3. Press the desired F key to which the display page is to be assigned.
8/01 Operation 3-3

Once programmed, an F key cannot be unassigned unless the SRAM is cleared or the FloBoss S600 is
cold started. Refer to Section 3.9. However, you can reassign an F key to a different display page.
3.4.2 Vector and Menu Keys

The 4-way directional arrow key is located just below the Menu key. The 4-way directional arrow key
allows you to navigate the display matrix and select parameters or data items to view or change.
On a data page, use the or keys to view the previous or next display, respectively. The number of
the current display is indicated after the decimal point on the Status/ID line.
When the display moves vertically to view another row, the data item shown is always the first display
cell of that row.
The key is also used as the delete/backspace key when entering or changing data.
Press the Menu key to return up one level of the display hierarchy. On a data page, this key returns
you to the parent menu. By pressing the Menu key followed by the key while on any menu page,
you return directly to the Main menu.
3.4.3 Alarm Light and Keys

Between the F keys and the MENU key is the Alarm light and two Alarm keys, View and Accept.
During normal operation, with no alarm activated, the Alarm light is green.
When an alarm is activated, the Alarm light flashes red until the cause for the alarm has been viewed
and acknowledged using the View and Accept keys, respectively.
Unacknowledged alarms are initially displayed with the date and time in inverse video. Once
acknowledged, the alarms display in normal video. Multiple alarms display in chronological order.
The Alarm light shows a solid red until the alarm has been cleared. A yellow Alarm light indicates
either a fault with the display or keypad, or alternatively, a communications failure between the front
panel and the CPU module.
3-4 Operation 8/01

3.4.4 Numeric Keys

The lower part of the keypad houses the numeric keys. The numeric keys offer the full number set (0-
9), decimal point (.), and a minus (-) key.
♦ Numeric 0 to 9 – Used to enter or change data and to navigate the display matrix.
♦ Minus – Used to define the default display on the FloBoss S600.
To define the default display:
1. Go to the required data display page.

2. Press the Minus key.
3. Press the Minus key again to confirm.
You cannot unassign a default display for a menu page. To unassign a default display, go to a menu
page and repeat steps 2 and 3.
You can also use the minus key to enter negative quantities and the decimal point when entering
fractional quantities. The decimal point is also used to define shortcuts to access frequently used
displays; see Section 3.4.1.
3.4.5 Operation Keys

The Operation keys are used in conjunction with the Numeric keys to perform a variety of tasks,
including:
Exponent – The Expt key is used to enter quantities in scientific notation. Where the value to be
entered exceeds the space available on the display (20 characters), it is necessary to express the
data in exponential terms.
Clear – The Clear key is used to cancel or exit from the current operation and return to the previous
data display. Clear is also used to activate the default display.
Display – The Disp key is used to enter the path of a required display. The path is shown on the
Status/ID line at the bottom of every page.
Print – The Print key is used to display the print menu, where commands can be requested for various
pre-configured reports or logs to a printer or computer terminal.
8/01 Operation 3-5

Change – The Chng key is used to edit a displayed database item. Only items marked with an asterisk
(*) are changeable. To enter the edit sequence:
1. Press the Chng key. If more than one asterisk is shown on a data display, the FloBoss S600
highlights the first object on the page. Use the and keys to move the highlight to the
required point.
2. Press the Chng key again to change the data values. The system automatically determines
whether your assigned security level allows you to change the selected data. In order to
prevent accidental re-configuration, certain essential data entry fields require confirmation.
While in Change mode, the key can be used to delete digits or characters by backspacing over the
displayed data. The Clear key can be pressed at any time to abort the current operation or task.
Enter – Used in combination with the numeric and Chng keys, the key is used to confirm the
data has been entered correctly and complete an operational sequence.
3.5 Display
The LCD display offers eight lines of information displayed as alphanumeric characters. An example
of a typical display is shown below.
1. OVOL FR
2. CVOL FR
3. MASS FR
4. ENERGY
Figure 3-2. LCD Display
3.5.1 Menus
All eight lines of the display are used to show the available menu options, which are arranged in a
hierarchical parent menu and sub-menu order. Each menu and associated sub-menu is allocated a
number between 1 to 8 and can be selected using the numeric keys.
If the menu displays more than eight options, press NEXT to display additional items.
The following characters are used after the option number to identify the type of sub-menu or data
page available:
♦ An asterisk (*) signifies a further menu display.
♦ A decimal point ( . ) signifies a data display.
3-6 Operation 8/01

3.6 Data Pages

Generally, each data display shows a single data item along with the associated text, units, and
description. Prompts and messages also appear when you enter or edit data items. For example, if you
press the Chng key, and are logged in at the required security level, the display prompts you with
either Enter New Value: or displays the available menu options.
Depending on the base configuration, not all data items can be modified. A changeable data item is
indicated by an asterisk (*) at the end of the display line.
3.7 Status/ID Line

On the bottom line of every data page is the Status/ID line. Refer to Figure 3-3.
P1.1 <of 2>
Figure 3-3. Status ID Line
On the left-hand side of the Status/ID line is the page reference number. For example, P12.5 followed
by the number of associated data pages that can be navigated using the and keys.
In addition, the Status/ID line indicates whether the flow computer is in Prove mode or Maintenance
mode by displaying the characters P or M, respectively, on the right-hand side.
3.8 Display Matrix

The FloBoss S600 software system is organized as a structured database of parameters, such as
TOTALS, I/O, and CALCULATIONS.
The database groups the parameters logically in a matrix of display cells. For example, most I/O
parameters are grouped in the same area of the matrix. Within these groups, related data items are
organized into rows. For example, for PRT INPUTS, the parameters for Measured, Keypad, and
Alarm Limits are all kept in one horizontal row. Refer to Figure 3-4.
8/01 Operation 3-7

PRT Input 1 PRT Input 1
I/001 PRT 01 I/001 PRT 01
In Use Value: Keypad Value:

30.124 Deg.C 25.000 Deg.C*
Mode Status: Measured Value:

MEASURED * 30.124 Deg.C
P55.1 <of4> P55.2 <of4>
PRT Input 1 PRT Channel 1
I/001 PRT 01 I/001 PRT 01
Limits (HH/H/L/LL): Resistance:

100.000 Deg.C* 111.72 ohms
95.000 Deg.C*
5.000 Deg.C*
0.000 Deg.C*
P55.3 <of4> P55.4 <of4>
Figure 3-4. Database Matrix
The PRT Input group is shown in Figure 3-4. The first cell in the row (page 1) displays the In Use
Value parameter. You can move one cell to the right, using the key, and the associated Keypad
Value and Measured Value parameters display. Press the key two further times and the display
changes to the Resistance parameter.
You can use the Print key and the configuration option to request a display dump of the whole display
matrix.
Note: The content of the display matrix is application-specific. Although details may vary
between different applications, the principle described is the same. Refer to the Application
Manual for details of parameters installed in your FloBoss S600.
3-8 Operation 8/01

3.9 Using the FloBoss S600

If you are already familiar with Spectra Flow Computers, you may find it useful to refer to Section
3.14, Summary of Operation, on page 3-22.
3.9.1 Initialization
The FloBoss S600 automatically performs an initialization sequence, including a self-test routine,
during startup. The startup screen is shown in Figure 3-5.
STARTUP COMPLETED
S/W Version 0.9.0

View Angle Setting 8
LCD Back Light ON
Alarm OFF
Figure 3-5. Startup Screen
Depending on the setting of the cold start bit-jumper (link) (LK13), located on the P152 plug in board,
and the contents of the SRAM, the FloBoss S600 starts up in one of two modes:
♦ Warm Start – If the FloBoss S600 has been previously configured and the cold start jumper is
not installed, the FloBoss restarts where it left off prior to being powered down. The Main
menu displays following a successful startup.
♦ Cold Start – If the FloBoss S600 is un-configured, has the cold start jumper installed or a
Clear SRAM command has been previously issued, the Startup menu displays.
Note: The default setting of the cold start jumper is “open” which results in a warm start.
When the FloBoss S600 is restarted in warm or cold start mode, the firmware is always copied from
Flash to RAM and subsequent operation uses RAM.
During a warm start, the configuration memory (SRAM) is not affected. The FloBoss S600 will
continue operation using the data stored in the configuration memory just before the restart occurred.
Any current accumulated values and online changes that have not been saved will be preserved. A
warm start is generally not required when online parameters are changed and accepted.
8/01 Operation 3-9

During a cold start, the configuration files are copied from Flash and replace any currently
accumulated totals, as well as any online changes made to the configuration files since the last
download from CONFIG 600. Therefore, a cold start is used to reflash a new configuration or to
recover from extreme situations, such as a corrupted database.
Note: When setting the cold start jumper, keep in mind that this setting will also be used when
the FloBoss S600 self starts for any reason, such as a low-voltage shutdown or recovery from a
malfunction. Ensure the cold start jumper setting is removed when not required; otherwise, an
unplanned restart could result in lost data.
The following descriptions of FloBoss S600 operations assume a warm start has been performed. For
information on operations after a cold start, refer to Section 4.
Following a successful warm start, the Main menu displays as in Figure 3-6.
1* FLOW RATES
2* TOTALS
3* OPERATOR
4* PLANT I/O
5* SYSTEM SETTINGS
6* TECH/ENGINEER
8* CALCULATIONS
Figure 3-6. Main Menu
The Main menu is the starting point or root of the display matrix. From the Main menu, you can
navigate the sub-menus to access the required data pages.
3-10 Operation 8/01

3.9.2 Navigating the Display

From the Main menu, select the option you require with the appropriate numerical key.
An asterisk (*) before a menu option indicates that further sub-menus are available. A decimal point
( . ) before the menu option shows there is no further sub-menu; selecting this option type displays the
first cell in a row of related parameters within the display matrix.
To navigate the PLANT I/O option, for example, proceed as follows:

1. Select the PLANT I/O option by pressing 4 from the Main menu (Figure 3-6) and the
available sub- menus display. Refer to Figure 3-7.
1* ANALOG INPUTS
2* PRT/RTD INPUTS
3* FREQUENCY INPUTS
4* PULSE INPUTS
5* DIGITAL I/OS
6* ANALOG OUTPUTS
7* PULSE OUTPUTS
Figure 3-7. Submenu
2. Select the ANALOG INPUTS option by pressing 1, and then select ADC - 06 by pressing 3.
Refer to Figure 3-8.
1. ADC 01 - ADC01
2. ADC 02 - ACD02
3. ADC 06 - ACD06
Figure 3-8. Analog Inputs
8/01 Operation 3-11

The data item In Use Value for I/O01 ADC 06 displays, which is the first cell in the row of
related analog input parameters.
As the configuration of your FloBoss S600 may differ from this example, try selecting options from
the menus offered in order to reach the parameter that you require.
The Status/ID line on the bottom of the display changes as you move left or right across the row of
related display pages.
An alternative method of selecting the required data page is to enter the unique page address using the
Disp key. If you know the location number of the parameter you wish to view, proceed as follows:
1. Press Disp followed by the location number in the format “column.row” such as 1.3.
2. Press Enter.
If you only enter a single number such as the column value, the first cell of the row displays.
To return to the parent menu, press the Menu key located above the arrow key; repeated pressing of
this key moves you up the display matrix to the Main menu.
Note: If you are on a menu or data page, you can return directly to the Main menu at any time
(except during a change sequence) by pressing the Menu key followed by the key.
If you have pressed the Chng key, the Menu key will not respond until either Clear (to abort the
change) or Enter (to complete the change) has been pressed.
3.10 Entering Data

Changing the value or mode of any displayed parameter is straightforward with the FloBoss S600.
You can modify both numeric values and calculation modes using the Chng key.
3.10.1 Changing a Value

Locate the parameter to be changed using one of the methods described in section 3.9.2.
If the value is changeable, the data is marked with an asterisk; if there is no asterisk, the data cannot be
modified.
To change the value of a parameter, proceed as follows:
Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required data
page.
1. Press Chng on the required data page.

2. Select the required parameter using the or keys.
3-12 Operation 8/01

3. Press Chng and the prompt ENTER CODE: displays.

4. Key in your Security Code and press Enter (the security code number does not display, but
each digit is indicated by a dot as you key it in).
5. At the prompt ENTER NEW VALUE: key in the new value in integer, numeric, or scientific
notation as appropriate (the current value and any entry limits associated with this parameter
are also shown).
6. Press Enter to confirm.
The change mode is automatically exited on accepting or rejecting the mode change if only one data
item is changeable on the data page.
If necessary, you can edit the new data as you key it in. Enter Change mode and use the key to
delete single figures or characters. If you wish to abort the change, press Clear.
Deleting or canceling the change to the parameter should be done before pressing Enter. The Enter
command confirms that you wish the revision to proceed.
3.10.2 Example Value

The following example shows how to change the alarm limits for the A/D Converter analog input.
1. Locate the page displaying the alarm limits (HH/H/L/LL) for the Channel 1 I/O01 parameter.
The display shows the location number and the asterisk indicates that the values are
changeable. Refer to Figure 3-9.
ADC CHANNEL 1
I/O01 ADC 01
Limits (HH/H/L/LL)
1000.000 barg*
95.000 barg*
5.000 barg*
0.0 barg*
1.0
P52.3 <of5>
Figure 3-9. Alarm Limits
8/01 Operation 3-13

2. Press Chng and highlight the HH value.

♦ Press Chng again and the display responds with the prompt ENTER CODE:.
♦ Key in your Security Code and press Enter.
♦ At the prompt ENTER NEW VALUE: key in the new value 100 and verify this on the
display.
3. Once you have verified the data, press Enter to confirm. The value in the display changes to
the new data and recalculates any linked parameters.
4. Repeat the above process for the H, L, and LL limits.
3.10.3 Changing Mode

To select a new calculation mode, the key sequence is similar to changing a value.
Locate the parameter to be changed using one of the methods described under Section 3.9.2
If the mode is changeable, the mode is marked with an asterisk; if there is no asterisk, the mode cannot
be modified.
Note: Steps 1 and 2 will be skipped if only one data item is changeable on the required data
page.
1. Press Chng on the required data page.

2. Select the required parameter using the or keys.
3. Press Chng and the prompt ENTER CODE: displays.
4. Key in your Security Code and press Enter (the security code number does not display but
each digit is indicated by a dot as you key it in).
5. At the prompt, select the required mode by using the appropriate numerical key (1 to 8).
6. A second mode change window displays asking for confirmation. Press 1 to accept or 2 to
reject the mode change.
The change mode is automatically exited on accepting or rejecting the mode change if only one data
item is changeable on the data page.
The Clear key enables you to cancel the mode change to the parameter, if necessary.
3-14 Operation 8/01

3.10.4 Example Mode

The following example shows how to change the standard density parameter to a calculated value from
a keypad-entered value.
1. Locate the page displaying the STR01 STANDARD DENS mode status. Refer to Figure 3-10.
STR01 STANDARD DENS
In Use Value:
10.000000 kg/m3
Mode Status:
KEYPAD *
P32.10 <of 21>
Figure 3-10. Standard DENS
2. Press Chng, key in your Security Code and press Enter.

3. Press 1 to select CALCULATED. Refer to Figure 3-11.
1. CALCULATED
2. KEYPAD
Figure 3-11. Calculated
8/01 Operation 3-15

Confirm
SET TO:
CALCULATED
1. YES
2. NO
Figure 3-12. Confirm
4. Press 1 to confirm. The display indicates the revised operational mode. Refer to Figure 3-12.
Note: If the change is not allowed, ‘Denied’ displays on the line you are changing and the
change is not implemented.
3.10.5 Exponential Format

The Expt key allows you to enter parameters in scientific notation. Where a value is smaller than
0.00000001 or greater than 10000000 (8 significant figures), you must use the Expt key to express the
value in exponential terms.
You can also use the exponential notation for entering numbers that are within the range of 8
significant figures; but the displayed value will be shown as a normal number.
To enter an exponential value:

1. Key in the value.
2. Press the Expt key (an E appears on the display) and then enter the required power.
3. Press the Enter key.
For example, to enter the figure 0.00000009 as an exponential value: Key in 9.0, press Expt, enter -8
to represent the power and press Enter to confirm.
3.10.6 Security Code

The security system allows up to 50 unique users. Each user is allocated two individual passwords;
one is numeric for access to the FloBoss S600 and the other is alphanumeric for access to the CONFIG
600 Software. In addition, each user is allocated a security level between 0 (highest) and 9 (lowest).
Note: Each user should have a unique FloBoss S600 security code and username. Level 0
cannot be set as a login level as it is used for totalizer values, measured values, and such.
3-16 Operation 8/01

The configuration parameters are assigned in predefined groups with common minimum-security level.
The security level can be modified for each user application from within CONFIG 600.
Please refer to your System Administrator for further information on your password settings and
security levels.
3.11 Alarms
The default alarm system installed in the FloBoss S600 is a latching, manual, common-accept system.
Alarms are triggered when measurements exceed the pre-set limits for a parameter or if there is a
malfunction. The alarm may be relayed to a terminal or siren (klaxon) in the Control Room. On the
panel of the FloBoss S600, a light indicates an alarm and the source of the alarm is shown on the
display.
3.11.1 Alarm Light

During normal operation, with no alarms present, the Alarm light is a constant green. When an alarm
is activated, the light flashes red until the cause for the alarm has been viewed and the Accept key has
been pressed. Refer to Section 3.11.3, Alarm Accept, on page 3-18.
Once acknowledged, the light shows a constant red until the alarm condition has been cleared.
8/01 Operation 3-17

3.11.2 View Alarm

Press the View key to display the parameters that have triggered the alarm.
The first line of the alarm display indicates the date and time of the alarm. While the alarm remains
unaccepted, this line is shown in inverse video. The second and third lines are used to describe where
the alarm has been activated and its nature. The total number of alarms, accepted and unaccepted, is
shown on the bottom line. Refer to Figure 3-13.
09/11/1999 13:05:00
STR01 CHROM MODE
TELEM
Alarm 1 of 9
Figure 3-13. Alarm Display
When there is more than one alarm to be viewed, the display can be cycled around all the alarms using
the or keys.
3.11.3 Alarm Accept

Press the Accept key to notify the FloBoss S600 that you have viewed all the alarms and are prepared
to acknowledge them all together. The inverse time and date on all the alarms then returns to normal
video.
Once an alarm condition is cleared, its alarm prompt is automatically cleared from the display. When
all the alarms in the system have cleared, the Alarm light resets to a constant green.
3-18 Operation 8/01

3.12 Printing
By default the FloBoss S600 is configured to output reports to a serial printer or a terminal. The Print
key is used to generate either a constant log or pre-configured reports.
The Print menu is Figure 3-14.
PRINT OPTIONS
1. HELP
2* CONFIGURATION
3* REPORTS
4* COMMUNICATIONS
5. CURRENT ALARMS
Figure 3-14. Print Options
Pressing 1 or 5 performs the action; 2, 3, or 4 go to the following submenus:
PRINT OPTIONS
1. CONSTANTS LOG
2. DISPLAY DUMP
3. SECURITY DUMP
4. ALL ALARMS
Figure 3-15. Print Options 2
8/01 Operation 3-19

PRINT OPTIONS
1. CURRENT REPORT
2. CONFIG REPORT
3. ARCHIVED REPORTS
Pressing 3 in the menu displayed in Figure 3-16 takes you to a submenu listing the reports that are
setup to archive reports. Choosing any of those will then display the available reports to print.
PRINT OPTIONS
1. MODBUS MAPS
The following reports can be requested:
Constants Log – Lists all the constant parameters and the in-use values that are available for change
from the display.
Display Dump – Lists the whole display matrix.
Security Dump – Lists the current security levels assigned to data items.
All Alarms – Lists all possible alarms that can be generated by the alarm system.
Current Report – Lists the meter run totals.
3-20 Operation 8/01

Config Report – Lists the configuration parameters, including the installed calculation sets.
Archived Reports – Includes all archived reports listed by time and date.
Current Alarms – Lists all the acknowledged and un-acknowledged alarms currently set in the flow
computer in separate chronological lists.
Modbus Maps – Lists the Modbus maps stored in the FloBoss S600 that are assigned to a telemetry
link.
3.13 Special Pages

The FloBoss S600 includes display pages to perform specific functions, which are located under the
TECH-ENGINEER/DISPLAY SETUP menu. Refer to Figure 3-18.
1. DISPLAY SETUP
2. CONTRAST
3. DATE & TIME
4. DISPLAY TEST
5. SECURITY
6. COMMUNICATIONS
Figure 3-18. Display Setup Menu
Display Setup – Includes the parameters associated with the display setup.
♦ Display T/O – The display timeout is the period of non-use before the default display is shown
(default 300sec).
♦ Logout T/O – The logout timeout is the period of non-use in change mode before the current
user is automatically logged out (default 20sec).
♦ Ident T/O – This is the timeout period of non-use in change mode before the display mode is
activated (default 120sec).
♦ Contrast – Used to set the LCD viewing angle.
Note: Some models have automatic temperature correction of viewing angle with no
manual adjustment provided.
Date & Time – Used to set the current date and time.
8/01 Operation 3-21

Display Test – Used to turn all the pixels on and off.
Security – Used to enable/disable keypad access and file transfer from the host PC.
Communications – Used to display the available COM ports and link status, and define the serial port
settings.
3.14 Summary of Operation

The following is a summary of the operational features available on the FloBoss S600.
Display Matrix – Data items are arranged logically in groups and are placed in cells and rows within a
display matrix. See your Application Manual for details of the parameters installed on your
FloBoss S600.
View Parameter – First, use the numerical keys to select the relevant menu and sub-menu option, and
then use the and keys to display the required parameter in the matrix row. Alternatively,
press the Disp key, enter the location number (row.column), and press Enter.
Return to Main menu – Press the Menu key to view the parent menu. Repeated pressing of this key
moves you to the Main menu. Alternatively, press the Menu key followed by the key while
viewing a menu or data display (but not during a change sequence) to return directly to the Main
menu.
Change Value – Select the display cell of the parameter to be changed. An asterisk indicates that the
value is changeable. Press Chng, enter Security Code, press Enter, enter new value, and press
Enter to confirm.
Change Mode – Select the display cell of parameter to be changed. An asterisk indicates that the
value is changeable. Press Chng, enter Security Code, press Enter, select the required mode from
option list, and press 1 to confirm.
Clear – Press Clear to abort the change sequence.
Scientific Notation – Use the Exponent key when a value exceeds 8 significant figures. Key in the
new value, press Expt, enter required power, and then press Enter to convert value to exponential
format.
Alarm – Alarms are indicated by a flashing red light. Display alarm details by pressing the View key.
Accept each alarm as it displays by pressing the Accept key. Once the fault conditions are
removed, the Alarm Light shows a constant green.
Print – Press the Print key to print a constant log or generate a report.
3-22 Operation 8/01

Default Display – Select data display page to be used as default, press the Minus key, and press the
Minus key again to confirm. Note you cannot assign a default display for a data entry or menu
page.
To select a different page to be used as the default, go to the desired page, press the Minus key,
and press the Minus key again to confirm.
To clear the default page function, go to any menu page, press the Minus key, and press the Minus
key again to confirm.
Program Function Keys – Go to the required display page, press the Decimal Point key, and then
press the required F key to which the display page is to be assigned.
8/01 Operation 3-23

3-24 Operation 8/01

SECTION 4 – MAINTENANCE
4.1 Scope
This section describes the procedure for initiating a Cold Start on the FloBoss S600. Maintenance also
provides instructions for maintaining and troubleshooting the FloBoss S600.

This section includes:

Scope 4.1 4-1
Cold Start Procedure 4.3 4-1
Run Mode 4.3.1 4-2
Reflash Firmware 4.4 4-2
Download and Reflash Config File 4.4.1 4-2
Cold Start 4.4.2 4-2
Network Setup 4.5 4-2
Factory Setup 4.6 4-2
Clear SRAM 4.6.1 4-2
RAM Disc Start 4.6.2 4-2
Format Flash 4.6.3 4-2
Troubleshooting 4.7 4-2
Initial Checks 4.7.1 4-2
Removing and Replacing Plug-in Boards 4.7.2 4-2
Changing the Fuse 4.7.3 4-2
Startup List 4.7.4 4-2
4.3 Cold Start Procedure

Normally, the FloBoss S600 would be requested to Warm Start. The FloBoss S600 will be unable to
Warm Start if:
♦ The FloBoss S600 has not been previously configured.
♦ The Cold Start jumper (LK13) installed.
♦ A Clear SRAM command has been issued.
8/01 Maintenance 4-1

CAUTION
Only a suitably qualified person should perform reprogramming of the FloBoss S600.
4.3.1 Run Mode

On a running FloBoss S600, prior to programming the Flash memory with the FloBoss S600 operating
system firmware, you must set the run mode to Cold Start, as follows:
1. Go to the SYSTEM SETTINGS menu.
2. Select the SYSTEM STATUS sub-menu.
Note: The sequence of keys to access the SYSTEM STATUS page may vary on customized
displays. This may also be true for any page in a customized system.
3. Press Chng and the prompt Enter Code: displays.

4. Key in your Security Code.
5. Press 1 to select Cold Start, and press 1 again to confirm.
6. Reboot the FloBoss S600 (power down, wait a minimum of five seconds, and then repower).
Once the FloBoss S600 has completed its start-up initialization sequence, the FloBoss S600 Startup menu
displays. Refer to Figure 4-1.
1. WARM START
2. COLD START
3. NETWORK SETUP
4. REFLASH FIRMWARE
5. REFLASH CONFIG
6.
7.
8. FACTORY SETUP
Figure 4-1. Startup Menu
The FloBoss S600 Startup menu options include:

♦ Warm Start – This selection restarts a previously configured FloBoss S600 where it left off prior
to being powered down.
♦ Cold Start – This is used to build a new metering database on the FloBoss S600 using the
configuration files stored in Flash memory.
♦ Network Setup – This is used to configure the TCP/IP, Gateway and Modbus addresses. If the
Modbus address has been changed, restart the FloBoss S600 for the change to take place.
4-2 Maintenance 8/01

♦ Reflash Firmware – This is used to reprogram the FloBoss S600 operating system firmware
stored in Flash memory.
♦ Reflash Config – This is used to copy the configuration files into Flash memory from the volatile
RAM disk.
♦ Factory Setup – This is used to perform a RAM Disc Start, Clear SRAM, and Format Flash.
4.4 Reflash Firmware

The Reflash Firmware option allows you to reprogram the Flash memory with new values for the
operating system components and the application firmware.
This option requires you to download a binary file from CONFIG 600 into the volatile RAM disk on the
FloBoss S600 prior to erasing and reprogramming the Flash memory. Refer to Section 5, PC Setup, for
PC software setup and use.
CAUTION
Under no circumstances should you allow the FloBoss S600 to be turned off while it is erasing
or reprogramming the Flash memory; otherwise, the FloBoss S600 will be rendered
unusable. Should this occur, the FloBoss S600 must be returned to the factory for system
reprogramming.
To reprogram the Flash memory:

1. Select the REFLASH FIRMWARE command from the FloBoss S600 Startup menu.
2. Press 1 to confirm, and the following message displays:
PERFORM CONFIG 600 FLASH COMMAND NOW
3. From CONFIG 600, enter the Transfer program, select the required vxworks.bin file and click on
Send Now to download it to the FloBoss S600.
4. The following message displays on the FloBoss S600:
RECEIVING BINARY FILE
Once the file has been successfully downloaded, the FloBoss S600 displays the message:
RECEIVED OK
Note: Do not proceed if the message FLASH FAILED displays. Remove the power connector for
5 seconds and the FloBoss S600 will Cold Start.
5. The FloBoss S600 proceeds to erase and reprogram the Flash memory, and displays the following
message:
RESETTING - PLEASE WAIT
The FloBoss S600 then restarts; if the FloBoss S600 has not restarted after 30 seconds, remove the
power connector for 5 seconds to initiate a Cold Start.

4.4.1 Download and Reflash Config File

To allow the FloBoss S600 to retain the configuration data indefinitely following a download from
CONFIG 600, the Reflash Config option is used to copy the configuration file into Flash memory from
the volatile RAM disc.
To reflash the configuration data from the RAM disc:

1. From the Config 600 software, select the Transfer Data option.
2. Choose the Com port connected to the FloBoss S600. Default parameters are 38,400 KB, 8 data
bits, 1 stop bit, and no parity.
Note: Configurations can also be transferred via Ethernet, as well as by the serial
communications port.
3. Select the configuration you require, then select the sections you desire to transfer to the FloBoss
S600.
4. Click on Send Now to download to the FloBoss S600.
5. Select the REFLASH CONFIG command from the FloBoss S600 Startup menu.
6. Press 1 to confirm, and the following message displays:
SAVING CONFIGURATION TO FLASH
Once completed, the FloBoss S600 Startup menu displays.
For further configurations, the data is automatically stored to flash memory when it has been transferred.
The user is not required to manually reflash the configuration.
4.4.2 Cold Start

Once the configuration file has been downloaded from the host PC, you can select the Cold Start option
to build a new metering database using the configuration data stored in the Flash memory of the FloBoss
S600.
Prior to any network communications, the necessary network settings should also be set. These
parameters can only be viewed or changed via the FloBoss S600 Startup menu. Refer to Network Setup,
Section 4.5.
To initiate a Cold Start of the FloBoss S600:

1. Select the COLD START command from the FloBoss S600 Startup menu.
2. Press 1 to confirm and the following message displays:
CONFIGURING - PLEASE WAIT
3. A new database is then built using the configuration files held in the Flash memory.
Once completed, the FloBoss S600 Main menu displays.

4.5 Network Setup

The Network Setup option allows you to define the TCP/IP Ethernet, Gateway, and Modbus network
addresses.
When any Modbus slave configuration builder has an address of zero specified, the Modbus port will be
configured with the address entered here. This is typically used when the same configuration file is loaded
into multiple FloBoss S600 flow computers on the same Modbus network; thus, giving each FloBoss S600
a unique node address.
These settings are kept in a separate area of the SRAM database and will be retained following a
configuration download.
These parameters can only be viewed or changed via the FloBoss S600 Startup menu.
To define the network addresses:

1. Select NETWORK SETUP from the FloBoss S600 Startup menu.
2. Select the required address option.
3. Enter the address value (for an Enron Modbus link, a maximum value of 247 is permitted).
4.6 Factory Setup

The Factory Setup options include RAM Disc Start, Clear SRAM, and Format Flash. These options,
with the exception of Clear SRAM, should only be used by factory personnel in the event of a problem.
4.6.1 Clear SRAM

The Clear SRAM option is used to clear out the FloBoss S600 by overwriting the SRAM area. All
battery-backed configuration data will be lost, including system configuration data, process configuration
data, metering totalizers, and network settings.
Generally, Clear SRAM is only used prior to a new application being downloaded to the FloBoss S600.
Following a Clear SRAM command, the FloBoss S600 will not be able to warm start again until a full
configuration download from PC Setup has been completed.
To clear the SRAM:

1. Select FACTORY SETUP from the FloBoss S600 Startup menu.
2. Select the CLEAR SRAM command.
3. Press 1 to confirm and the following message displays:
COMMUNICATIONS LINK FAILURE

4. Reboot the FloBoss S600 (power down, wait five seconds, and then repower). Once completed,
the FloBoss S600 Startup menu displays.
4.6.2 RAM Disc Start

The RAM Disc Start option provides an alternative means of creating a new metering database on the
FloBoss S600 via FTP transfer. Do not use this option. This option should only be used by factory
personnel.
To initiate a RAM Disc Start:

2. Select the RAM DISC START command.
3. Press 1 to confirm.
4. The existing SRAM database, including the totals, is deleted. A new database is then built using
the configuration files held on the SRAM disk. The following message displays:
CONFIGURING - PLEASE WAIT
Note: The RAM disk contents are volatile. Use the REFLASH CONFIG command to ensure the
new configuration is permanently saved.
4.6.3 Format Flash

The Format Flash option is used to reformat the Flash memory. Any data stored in Flash will be lost,
including the configuration data, report formats, display setting, and Modbus addresses. This option
should only be used by Flow Computer Division (Daniel) personnel.
To initiate a reformat of the Flash memory:

2. Select the FORMAT FLASH command.
3. Press 1 to confirm.
4.7 Troubleshooting
The troubleshooting techniques described here allow you to determine the nature of a problem and apply
the most applicable solution.

4.7.1 Initial Checks

Before contacting your sales/support agent with a problem, first check the following:
♦ Check that all the plug-in boards are seated correctly and the retaining screws are fastened.
♦ Check that all the field wiring is properly connected.
♦ Check the supply voltage.
If the power supply seems to be working correctly, but the startup routine does not appear on the display,
check the fuse for damage.
If the problem persists, and none of the checks appear to solve the problem, please contact your local sales
representative to return the unit.
Note: The whole machine, including the case, should be returned. On no account should the
circuit boards be extracted and returned separately.
4.7.2 Removing and Replacing Plug-in Boards

To remove or install a plug-in board from the FloBoss S600, refer to Section 2, Installation, for detailed
procedures.
4.7.3 Changing the Fuse

The fuse is located in a clip-in type holder on the CPU module.

FUSE
Figure 4-2. Fuse Location
To change a suspect fuse, proceed as follows:

1. Switch off power.
2. Unscrew and remove the CPU module.
3. Use only light pressure to extract the fuse.
4. Check the fuse and, if necessary, replace it with a 20 mm x 5 mm 2.5 Amp anti-surge fuse only.
The use of a fuse with a higher current rating invalidates the warranty on the FloBoss S600.
5. Replace the fuse and check it is secure before replacing the CPU module into the case.
6. Replace the plug connectors.
7. Switch on the power supply.
4.7.4 Startup List

The following table provides a list of possible solutions to problems that may be encountered during the
startup sequence.

Table 4-1. Startup List
Symptom Possible Solution

No Power Check fuse.
No Initial I/O Red Led After Power On Power down, remove and reseat I/O board, reapply power.
No Front Panel Backlight Check connector (J2) between front panel and main board.
Front Panel Led Is Permanently Orange Reboot the FloBoss S600; if problem remains, return FloBoss
S600 to factory.
No I/O Red Led Showing Depower, remove and reseat I/O board, reapply power.
Cold Start Menu Is Displayed Instead Of Check if cold start jumper (link) is fitted. Download configuration
Expected Warm Start Menu file.
I/O Fail Message Is Displayed Check I/O links (refer to Section 5, Setup and Wiring).


SECTION 5 – SETUP AND WIRING
5.1 Scope
This section includes information on plug-in connector blocks, field wiring configurations (ANIN,
PRT, and DPR signals), and link/jumper settings for the plug-in boards.
It is recommended that all wiring be made with stranded wire that is no larger than 16 AWG.
For the communication ports, wiring of 18 to 22 AWG is recommended. Power wiring is

recommended to be 16 AWG.
All local wiring practices and regulations should be observed.
CAUTION
Do not use a Megger or similar instrument to check for isolation or continuity between
signals on any of the connectors of the FloBoss S600. These instruments produce voltages
far in excess of design parameters and damage may occur. If any such instrument is used,
the warranty on the FloBoss S600 will be invalidated.


Scope 5.1 5-1
CPU Board 5.3 5-2
Power Supply 5.3.1 5-3
Watchdog Relay 5.3.2 5-3
RS232 Modem Port 5.3.3 5-3
RS422/485 Multidrop Port 5.3.4 5-3
Ethernet LAN Port 5.3.6 5-3
Front Panel Port 5.3.6 5-3
On-Board Battery Backup 5.3.7 5-3
Remote Display or PC 5.3.8 5-3
P152 CPU On-board Connectors 5.3.9 5-3
P152 CPU Berg Jumpers (Links) 5.3.10 5-3
P144 I/O Board 5.4 5-3
Analog Inputs 5.4.1 5-3
Digital Inputs 5.4.2 5-3
8/01 Setup and Wiring 5-1

Turbine Pulse Inputs 5.4.3 5-3

Frequency Inputs 5.4.4 5-3
PRT/RTD Inputs 5.4.5 5-3
Analog Outputs 5.4.6 5-3
Digital Outputs 5.4.7 5-3
Pulse Outputs 5.4.8 5-3
P144 I/O Berg Jumpers (Links) 5.4.9 5-3
P154 Prover Board 5.5 5-3
Digital Inputs 5.5.1 5-3
Turbine Pulse Inputs 5.5.2 5-3
Frequency Inputs 5.5.3 5-3
Digital Outputs 5.5.4 5-3
Pulse Outputs 5.5.5 5-3
P154 Prover Berg Jumpers (Links) 5.5.6 5-3
5.3 CPU Board

The P152 CPU board contains the host processor and associated peripherals, which form the heart of
the system.
Various plug-in connections are provided on the rear backplate of the CPU board. Additional
connectors and jumpers (links) are also used on the board, which are set at the factory prior to
shipping.
Refer to Figure 5-1 for a detailed illustration of the CPU board backplate.
5-2 Setup and Wiring 8/01

TB-1
POWER
COM 4
COM 3
COM 1-2
REMOTE I/O
TB-2
COM 5, 6, 7
RS 232/485
NETWORK
Figure 5-1. CPU Backplate
5.3.1 Power Supply

Power is supplied to the FloBoss S600 via the P152 CPU board. Connection is made by a plug-in,
standard 5-mm pitch screw terminal. The power supply connector is labeled TB-1.
The FloBoss S600 should be powered by a nominal 24 VDC power source capable of supplying 2
amps. The unit will operate between 20 and 32 VDC.
The startup in-rush current may draw 6 amps for approximately 100 milliseconds. This in-rush
becomes significant when multiple flow computers are connected to the same power supply.
An on-board anti-surge fuse (2.5 amp rating) protects the supply line should a fault occur within the
unit.
Fully regulated 15 and 24 VDC supplies are also available for applications such as powering loops or
pre-amplifiers. These outputs are protected by resettable thermal fuses.
The TB-1 pin connections are shown in Table 5-1.

Table 5-1. TB-1 Pin Connections
Pin Function
1 +24 VDC-INPUT
2 0 V (Return)-INPUT
3 +24 VDC-OUTPUT (500 mA)
4 +15 VDC-OUTPUT (100 mA)
5 0 V (Return)-OUTPUT
5.3.2 Watchdog Relay

A single pole, double throw relay with Normally Open or Normally Closed terminals provides the
watchdog status from pins 6, 7, and 8 of TB-1. A CPU failure causes the relay to de-energize.
Connection is made by a plug-in, standard 5 mm-pitch screw terminals.
Note: Contact is rated at 1A, 30 volts DC and 30 volts AC, and is a Form “C” contact.
The TB-1 pin connections display in Table 5-2.
Table 5-2. TB-1 Pin Connections
Pin Function
6 Normally Closed
7 Common
8 Normally Open
The relay is energized during normal operation.

5.3.3 RS232 Modem Port

Two RS232D communications ports are provided on the backplate of the CPU board. The ports use
FCC-68 RJ45 connectors and are labeled COM3 and COM4. Converters are commercially available
to configure either 9-way D type or 25-way D type connection.
The COM3 and COM4 pin connections are shown in Table 5-3.
Table 5-3. COM3 and COM4 Pin Connections
Pin Function
1 GND
2 DTR
3 RTS
4 TX
5 RX
6 CTS
7 DSR
8 DCD
Figure 5-2. Pin Connections
Maximum cable length is a function of the baud rate and quality of cable used. For example, a
maximum length of 15 m (50 feet) should be used at 19.2 kBaud using unscreened cable.
The ports should be connected to the peripheral devices using multi-conductor, shielded cable. It is
recommended that the cable screen be connected to protective earth, keeping signal ground separate,
particularly in noisy environments.

5.3.4 RS422/485 Multidrop Port

Three RS422/RS485 ports are located on the backplate of the CPU board and provide high speed/long
distance links of up to 57.6 kBaud and 1200 meters (4000 feet). The ports use the connector labeled
TB-2.
Note: For two-wire RS422/ RS485 installations, jumper TX+ to RX+ and TX- to RX- on P152
CPU board TB-2.
The COM5, COM6, and COM7 pin connections is shown in Table 5-4.
Table 5-4. COM5, COM6, and COM7 Pin Connections
Pin Port Function

1 COM5 RX-
2 COM5 RX+
3 COM5 TX-
4 COM5 TX+
5 COM6 RX-
6 COM6 RX+
7 COM6 TX-
8 COM6 TX+
9 COM7 RX-
10 COM7 RX+
11 COM7 TX-
12 COM7 TX+
13 COMPUTER GND
GROUND
5.3.5 Ethernet LAN Port

This port is for high-speed communications using an Ethernet local area network architecture. The
speed of data transfer is 10Mb/sec using a 10baseT twisted pair.
The port uses a FCC-68 RJ45 connector labeled Network on the backplate of the CPU.

5.3.6 Front Panel Port

This is an alternative connection for COM2 and is used with the CONFIG 600 program to transfer
configuration files.
Pinouts display in Table 5-5.
Table 5-5. COM2 Alternative Connections
Pin Function
1 RTS
2 TX
3 GND
4 GND
5 RX
6 CTS
Figure 5-3. COM2 Alternative Connections
5.3.7 On-Board Battery Backup

Two battery options are available. A simple check should be made to ensure which type has been
supplied:
♦ Rechargeable, board mounted, nickel metal hydride cell.
♦ Non-rechargeable, intrinsically safe cell.
Note: The status of this battery is monitored by a voltage sensing circuit. An alarm is raised if
the battery voltage drops below the predefined limit.
This is a factory-fitted option. Only one type of battery can be installed. Once the IS or 1/2AA cell is
installed, without line power to the FloBoss S600 unit, the battery life will become exhausted.

5.3.8 Remote Display or PC

The connector labeled COM1-2 on the backplate of the CPU board is used to connect the FloBoss
S600 to a remote display (COM1) or the host PC (COM2).
CAUTION
Do not reconfigure Com1 and Com2. They are for internal use only.
The COM1-2 pin connections display in Table 5-6.
Table 5-6. COM1-2 Pin Connections
Pin Function
1 GND
2 TX to R. Display
3 GND
4 SPEAKER OUT
5 N/C
6 TX to PC
7 RTS to PC
8 GND
9 RX from R. Display
10 CTS to R. Display
11 GND
12 N/C
13 N/C
14 RX from PC
15 CTS to PC
The COM1-2 port uses a standard 15-way D-type female connector.
Only shielded, multi-conductor cable should be used to connect to the COM1-2 port. It is
recommended, particularly in noisy environments, that the cable shield is connected to earth ground,
ensuring the signal ground is separate.
Note: The cable length should not exceed 15 meters (49 feet).

5.3.9 P152 CPU On-board Connectors

The miscellaneous device connectors provided on the P152 CPU module are shown in Table 5-7. This
information is for identification purposes only.
Table 5-7. Miscellaneous Device Connectors for the P152 CPU Module
Socket Description
J2 CPU cooling fan molex (12 VDC)
J3 PC/104 expansion bus (16- bit)
J4 Additional plug-in battery molex 3.6 VDC
J5 IDE Hard disk pin header
J6 Altera serial programming pin header (factory use only)
J7 Keyboard and mouse pin header
J8 Security bit link
J9 Optional communications LED backplate pin header

5.3.10 P152 CPU Berg Jumpers (Links)

The entries shown in boldface are the default configuration settings; however, these may not apply to
your specific configuration.
Table 5-8. Default Configuration Settings for the P152 CPU Berg Jumpers (Links)
Jumper (Link) Position Description

CPU & RADISYS
LK3 ON 3 volt operation
OFF
LK4 ON Internal RTC enabled
OFF
LK5 ON Internal keyboard & mouse enabled
OFF Enabled
LK6 ON 8 bit BIOS
OFF
LK7 ON 7 DMA channel operation
OFF
LK8 ON All interrupts available via MUX
OFF
LK9 ON EIDE supported
OFF
LK10 ON CS_USR1# supported
OFF
LK11 ON COM1, COM2 supported: data & RTS/CTS only
OFF
LK12 ON COMCLK enabled
OFF
LK13 ON Cold Start forced on power up
OFF
LK14 ON BIOS Monitor start enabled
OFF
Flash
LK15 1-2 Write Prohibited - Block 0 - 1M
2-3 Write Enabled
2-3 Write Enabled
2-3 Write Enabled
2-3 Write Enabled

Clock Multiply
LK19 ON DX2: Off
OFF DX4: On = Clk x3, Off = Clk x2
586: On = Clk x4, Off = Clk x3
BIOS ROM Size
LK20 1-2 1M EPROM
2-3 4M EPROM
SQFP 486 CPU
LK21 ON Link to upgrade SQFP 486 CPU
OFF
Ethernet
LK24 ON ENEEP
OFF
LK25 ON IOS 2
OFF
LK26 ON IOS 1
OFF
LK27 ON IOS 0
OFF
Cache Select
LK28 ON Non-Enhanced = Off
OFF Enhanced
On = Writethrough
Off = Writeback
LK29 ON Link when write-back processor fitted
OFF
Table 5-9. Clock Speed Selection
Clock Speed Link 22 Link 23

33 MHz OFF OFF
40 MHz ON OFF
50 MHz ON ON
66 MHz OFF ON

5.4 P144 I/O Board
The P144 I/O board measures process signals used by the CPU while running the flow computer
functions.
The backplate has three low density D-type connectors for field wiring. These connectors are labeled
SKT-A, SKT-B, and SKT-C. There is also a version available with standard plug-in screw terminal
blocks.
SKT-A
ANIN 1-10
ANOUT 1-4
SKT-B
ANIN 11 - 12
DIGIN 1-6
DIGOUT 1 - 2
Freq Inputs
Pulse Outputs
SKT-C
DIGIN 7-16
DIGOUT 3-12
Turbine Inputs
Figure 5-4. I/O Backplate
5.4.1 Analog Inputs

There are two fully floating A/D converters per I/O board, each measuring five single-ended analog
input (ANIN) channels. There are also two current-only inputs (ANIN 11 and 12). This provides a
total of 12 analog inputs.
The ANIN channels use the connectors labeled SKT-A and SKT-B, which are located on the backplate
of the P144 board.
Channels CH1 to CH10 are located on connector SKT-A and channels CH11 and CH12 are located on
connector SKT-B.
The primary measurement for ANIN 1-10 is voltage, which is compared to a stable reference source.

Each channel (ANIN 1-10) is configurable as a 0 to 5.25V or 0 to 22mA input range using a jumper
(link) on the board to place a high accuracy calibrated shunt resistor in parallel with the input.
Note: The channels for each A/D converter should be similarly configured to guarantee
accuracy.
The ANIN pin connections are shown in Table 5-10 and Table 5-11.
Table 5-10. ANIN Pin Connections for SKT-A
Pin Function
8 ANIN-CH1
21 ANIN-CH2
9 ANIN-CH3
22 ANIN-CH4
10 ANIN-CH5
20 RETURN CH1-5
11 ANIN-CH6
24 ANIN-CH7
12 ANIN-CH8
25 ANIN-CH9
13 ANIN-CH10
23 RETURN CH6-10
Table 5-11. ANIN Pin Connections for SKT-B
Pin Function
7 ANIN-CH12 (current)
8 ANIN-CH11 (current)
20 GND
5.4.2 Digital Inputs

There are 16 optically-isolated digital inputs (DIGIN) per plug-in board.
The digital inputs have been grouped into four banks of 4-off single ended inputs with a common
return to reduce the termination count.
The DIGIN channels use the connectors labeled SKT-B and SKT-C, which are located on the
backplate of the P144 board. Channels CH1 to CH6 are located on connector SKT-B, and channels
CH7 through CH16 are located on connector SKT-C.
The sample period is 500 milliseconds.

Note: The return lines (Ex. pin 17 on SKT-B) must be connected to a 24VDC source such as
provided by the external termination board, while the DIGIN lines (Ex. pin 13 on SKT-B)
expect typical “open collector” (referenced to GND) connections.
The DIGIN pin connections are in Table 5-12 and Table 5-13.
Table 5-12. DIGIN Pin Connections for SKT-B
Pin Function
13 DIGIN-CH1
14 DIGIN-CH2
15 DIGIN-CH3
16 DIGIN-CH4
17 RETURN CH1-4
18 DIGIN-CH5
19 DIGIN-CH6
Table 5-13. DIGIN Pin Connections for SKT-C
Pin Function
19 DIGIN-CH7
18 DIGIN-CH8
17 RETURN CH5-8
16 DIGIN-CH9
15 DIGIN-CH10
14 DIGIN-CH11
13 DIGIN-CH12
12 RETURN CH9-12
11 DIGIN-CH13
10 DIGIN-CH14
9 DIGIN-CH15
8 DIGIN-CH16
7 RETURN CH13-16
5.4.3 Turbine Pulse Inputs

The four pulse inputs may be used either independently or in pairs of two. Generally, they are used for
dual pulse measurement, such as turbine applications.
In dual pulse mode, level A or B pulse checking can be enabled.
Each input has an input range of 1 to 10,000 Hz. Each channel has live integrity checking. A circuit
fail alarm is activated if cabling faults develop or the pre-amp power fails.

The electrical connection of these inputs is dependent on which DPR mezzanine is fitted to the P144
I/O module. For example, a P148 Mezzanine is suitable for Spectra-Tek pre-amp signals.
The dual-pulse input channels use the connector labeled SKT-C, which is located on the backplate of
the P144 board.
The dual-pulse input pin connections are shown in Table 5-14.
Table 5-14. Dual-pulse Input Pin Connections for SKT-C
Pin Function
4 SINGLE/DUAL PULSE-CH1+
23 SINGLE/DUAL PULSE-CH1-
5.4.4 Frequency Inputs

The three frequency inputs are typically used for density transducer signals. Each input has a an input
range of 0 to 10,000 Hz. The frequency input channels use the connector labeled SKT-B, which is
located on the backplate of the P144 board.
The frequency input pin connections are shown in Table 5-15.
Table 5-15. Frequency Input Pin Connections for SKT-B
Pin Function
9 FREQUENCY-CH1+
27 FREQUENCY-CH1-
10 FREQUENCY-CH2+
28 FREQUENCY-CH2-
11 FREQUENCY-CH3+
29 FREQUENCY-CH3-
5.4.5 PRT/RTD Inputs

There are three Platinum Resistance Thermometer (PRT)/Resistance Temperature Detector (RTD)
inputs.
The PRT inputs are suitable for Class A, 4-wire PRT devices that conform to the BS EN 60751:1996
standard. In CONFIG 600 there are two options:

♦ DIN (coefficient of 0.00385 ohm/ohms degrees Celsius).

♦ AMERICAN (coefficient of 0.003926 ohm/ohms degrees Celsius).
The “DIN” 43760 selection is typical in Europe and common in the United States, while the
“AMERICAN” STANDARD coefficient (alpha) is still common for circumstances where a slightly
more pure Platinum is used to effect a higher absolute accuracy.
The temperature measurement range is -100 to +200° C (-148 to +392° F).
The PRT input channels use the connector labeled SKT-B, which is located on the backplate of the
P144 board.
The PRT input pin connections are shown in Table 5-16.
Table 5-16. PRT Input Pin Connections for SKT-B
Pin Function
4 PRT-CH1 I+
1 PRT-CH1 V+
21 PRT-CH1 V-
24 PRT-CH1 I-
5 PRT-CH2 I+
2 PRT-CH2 V+
22 PRT-CH2 V-
25 PRT-CH2 I-
6 PRT-CH3 I+
3 PRT-CH3 V+
23 PRT-CH3 V-
26 PRT-CH3 I-
5.4.6 Analog Outputs

There are four analog outputs (D/A Converter). Each D/A Converter channel is fully floating and
provides its own floating supply. Loads up to a 650-ohm loop impedance can be connected directly.
The D/A Converter output channels use the connector labeled SKT-A, which is located on the
backplate of the P144 board.
The D/A Converter output pin connections on the back of the I/O card are shown in Table 5-17. The
unit can be used in either source or sink configuration.

Table 5-17. D/A Converter Output Pin Connections for SKT-A
Pin Function
1 DAC-CH1 +15 V SOURCE
14 DAC-CH1 SINK
2 DAC-CH1 0 VDC
3 DAC-CH2 SINK
16 DAC-CH2 0 VDC
17 DAC-CH3 SINK
5 DAC-CH3 0 VDC
6 DAC-CH4 SINK
19 DAC-CH4 0 VDC
Figure 5-5 shows an example of how Channel 1 would be used in the source or sink configuration. See
drawing DE-20400 Field Wiring Model FloBoss S600 for external terminal board connection
assignments.
Figure 5-5. Analog Output Channel 1 as a Source or Sink

5.4.7 Digital Outputs

There are 12 digital output channels. The DC polarity must be carefully checked. Use an external DC
supply in series with the load. When using inductive loads, such as relay coils, place a diode across the
load.
The digital outputs (DIGOUT) are high current, open collector type. The maximum current rating is
100 mA at 24 VDC. Output frequencies up to 0.5 Hz are possible.
The DIGOUT channels use the connectors labeled SKT-B and SKT-C, which are located on the
backplate of the P144 board. Channels CH1 to CH2 are located on connector SKT-B and channels
CH3 and CH12 are located on connector SKT-C.
The DIGOUT pin connections are shown in Table 5-18 and Table 5-19.
Table 5-18. DIGOUT Pin Connections for SKT-B
Pin Function
36 DIGOUT-CH1
37 DIGOUT-CH2
Table 5-19. DIGOUT Pin Connections for SKT-C
Pin Function
37 DIGOUT-CH3
36 DIGOUT-CH4
35 RETURN CH1-4
34 DIGOUT-CH5
33 DIGOUT-CH6
32 DIGOUT-CH7
31 DIGOUT-CH8
30 RETURN CH5-8
29 DIGOUT-CH9
28 DIGOUT-CH10
27 DIGOUT-CH11
26 DIGOUT-CH12
25 RETURN CH9-12

5.4.8 Pulse Outputs

There are five programmable pulse outputs, typically used for electronic counters or sampler control.
The pulse output channels (PULSEOUT) use the connector labeled SKT-B, which is located on the
The PULSEOUT pin connections are shown in Table 5-20.
Table 5-20. PULSEOUT Pin Connections for SKT-B
Pin Function
30 PULSEOUT-CH1
31 PULSEOUT-CH2
32 PULSEOUT-CH3
33 PULSEOUT-CH4
35 RETURN CH1-4
34 PULSEOUT-CH5
12 RETURN CH5
5.4.9 P144 I/O Berg Jumpers (Links)

The entries shown in boldface are the default configuration settings; these may not apply to your
specific configuration. Refer to Table 5-21, Table 5-22, and Table 5-23.
Table 5-21. Flash Link Setting
Jumper (Link) Position Description

LK1 ON Write Enable
OFF Write Protected
LK2 ON Point to Point mode enabled
OFF Point to Point mode off

Table 5-22. P144 I/O Berg Links
MUX Address: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LK3 ● ●
LK4 ● ●
LK5 ● ●
LK6 ● ●
LK7 ● ●
LK8 ● ●
LK9 ● ●
LK10 1-2 ● ● ● ● ● ● ●
2-3 ● ● ● ● ● ● ●
LK12
LK13-15
Note: A/D Converter Shunts are configured in groups of five and must be used together as
current OR voltage.
Table 5-23. A/D Converter Shunt Mode
A/D Shunts
LK16 ON Current Mode ADC-CH1
OFF Voltage Mode
OFF Voltage Mode
OFF Voltage Mode
OFF Voltage Mode
OFF Voltage Mode
**LK16-19 should be fitted as a set
OFF Voltage Mode
OFF Voltage Mode
OFF Voltage Mode
OFF Voltage Mode
OFF Voltage Mode
**LK21-25 should be fitted as a set

5.5 P154 Prover Board

The P154 is a dedicated prover interface card that has been designed to work with compact or
microprover, unidirectional and bi-directional provers, with 2 or 4 detector switches. In addition, it
contains high resolution timing circuits so that dual chronometry methods can be utilized to increase
the apparent resolution for instances when insufficient turbine pulses are present with the prover
volume available. The prover can also be used in master meter proving and supplies 32 digital inputs,
12 digital outputs, 2 frequency (density) inputs, and 4 hardware-assisted pulse outputs. There are no
analog functions on the prover board.
The backplate has three low density D-type connectors for field wiring. These connectors are labeled
SKT-D, SKT-E, and SKT-F. There is also a version available with standard plug-in screw terminal
blocks.
SKT-D
RAW IN 1-3
DENSITY 1-2
SPHERE SWITCH 1-4
PLLIN
RAW OUT
SKT-E
DIGIN 1-6 AND 17-32
DIGOUT 1-2
Pulse Outputs 1-4
SKT-F
DIGIN 7-16
DIGOUT 3-12
DUAL PULSE 1-4
PLLOUT
Figure 5-6. Prover I/O Backplate
5.5.1 Digital Inputs

There are 32 optically-isolated digital inputs (DIGIN) per plug-in board. The digital inputs have been
grouped into four banks of 4-off single ended inputs with a common return to reduce the termination
count.

The DIGIN channels use the connectors labeled SKT-E and SKT-F, which are located on the backplate
of the P154 board. Channels CH1 to CH6 are located on connector SKT-E, and channels CH7 through
CH16 are located on connector SKT-F.
The sample period is 500 milliseconds.
Note: The return lines (Ex. pin 17 on SKT-E) must be connected to a 24VDC source such as
provided by the external termination board, while the DIGIN lines (Ex. pin 13 on SKT-E)
expect typical “open collector” (referenced to GND) connections.
The DIGIN pin connections are shown in Table 5-24 and Table 5-25.
Table 5-24. DIGIN Pin Connections for SKT-E
Pin Function
13 DIGIN-CH1
14 DIGIN-CH2
15 DIGIN-CH3
16 DIGIN-CH4
17 RETURN CH1-4
18 DIGIN-CH5
19 DIGIN-CH6
1 DIGIN CH-17
2 DIGIN CH-18
3 DIGIN CH-19
4 DIGIN CH-20
5 RETURN CH-17-20
6 DIGIN CH-21
7 DIGIN CH-22
8 DIGIN CH-23
9 DIGIN CH-24
10 RETURN CH 21-24
20 DIGIN CH-25
21 DIGIN CH-26
22 DIGIN CH-27
23 DIGIN CH-28
24 RETURN CH 25-28
25 DIGIN CH-29
26 DIGIN CH-30
27 DIGIN CH-31
28 DIGIN CH-32
29 RETURN CH 29-32

Table 5-25. DIGIN Pin Connections for SKT-F
Pin Function
19 DIGIN-CH7
18 DIGIN-CH8
17 RETURN CH5-8
16 DIGIN-CH9
15 DIGIN-CH10
14 DIGIN-CH11
13 DIGIN-CH12
12 RETURN CH9-12
11 DIGIN-CH13
10 DIGIN-CH14
9 DIGIN-CH15
8 DIGIN-CH16
7 RETURN CH13-16
5.5.2 Turbine Pulse Inputs

The four pulse inputs may be used either independently or in pairs of two. Generally, they are used for
dual pulse measurement, such as turbine applications.
In dual pulse mode, level A or B pulse checking can be enabled. The dual-pulse input channels use the
connector labeled SKT-F, which is located on the backplate of the P154 board.
Each input has an input range of 1 to 10,000 Hz. Each channel has live integrity checking. A circuit
fail alarm is activated if cabling faults develop or the pre-amp power fails.
The electrical connection of these inputs is dependent on which DPR mezzanine is fitted to the P144
I/O module. For example, a P148 Mezzanine is suitable for Spectra-Tek pre-amp signals.
The dual-pulse input pin connections are shown in Table 5-26.
Table 5-26. Dual-pulse Input Pin Connections for SKT-F
Pin Function
4 DUAL PULSE-CH1+
23 DUAL PULSE-CH1-
3 DUAL PULSE-CH2+
22 DUAL PULSE-CH2-
2 DUAL PULSE-CH3+
21 DUAL PULSE-CH3-
1 DUAL PULSE-CH4+
20 DUAL PULSE-CH4-

5.5.3 Frequency Inputs

There are two frequency inputs, typically used for density transducer signals. Each input has an input
range of 0 to 10,000 Hz.
The frequency input channels use the connector labeled SKT-D, which is located on the backplate of
the P154 board.
The frequency input pin connections are shown in Table 5-27.
Table 5-27. Frequency Input Pin Connections for SKT-D
Pin Function
9 FREQUENCY-CH1+
21 FREQUENCY-CH1-
10 FREQUENCY-CH2+
22 FREQUENCY-CH2-
5.5.4 Digital Outputs

There are 12 digital output channels. The DC polarity must be carefully checked. Use an external DC
supply in series with the load. When using inductive loads, such as relay coils, place a diode across the
load.
The digital outputs (DIGOUT) are high current, open collector type. The maximum current rating is
100 mA at 24 VDC. Output frequencies up to 0.5 Hz are possible.
The DIGOUT channels use the connectors labeled SKT-E and SKT-F, which are located on the
backplate of the P154 board. Channels CH1 to CH2 are located on connector SKT-E and channels
CH3 and CH12 are located on connector SKT-F.
The DIGOUT pin connections are shown Table 5-28 and Table 5-29.
Table 5-28. DIGOUT Pin Connections for SKT-E
Pin Function
36 DIGOUT-CH1
37 DIGOUT-CH2

Table 5-29. DIGOUT Pin Connections for SKT-F
Pin Function
37 DIGOUT-CH3
36 DIGOUT-CH4
35 RETURN CH1-4
34 DIGOUT-CH5
33 DIGOUT-CH6
32 DIGOUT-CH7
31 DIGOUT-CH8
30 RETURN CH5-8
29 DIGOUT-CH9
28 DIGOUT-CH10
27 DIGOUT-CH11
26 DIGOUT-CH12
25 RETURN CH9-12
5.5.5 Pulse Outputs

There are five programmable pulse outputs, typically used for electronic counters or sampler control.
The pulse output channels (PULSEOUT) use the connector labeled SKT-E, which is located on the
The PULSEOUT pin connections are shown Table 5-30.
Table 5-30. PULSEOUT Pin Connections for SKT-E
Pin Function
31 PULSEOUT-CH1
32 PULSEOUT-CH2
33 PULSEOUT-CH3
34 PULSEOUT-CH4
35 RETURN CH1-4

5.5.6 P154 Prover Berg Jumpers (Links)

The entries shown in boldface in Table 5-31 are the default configuration settings; these may not apply
to your specific configuration.
Table 5-31. P154 Prover Berg Jumpers (Links)
Link Position Descriptions

Flash
LK1 ON Write Enable
OFF Write Protected
Node Address (see Table 5-32)
LK2 ON
OFF Multiplexed mode (MUX)
LK11 ON
OFF Multiplexed mode (MUX)
MUX Address: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LK3 ● ●
LK4 ● ●
LK5 ● ●
LK6 ● ●
LK7 ● ●
LK8 ● ●
LK9 ● ●
LK10 1-2 ● ● ● ● ● ● ●
2-3 ● ● ● ● ● ● ●
Altera Voltage
LK12 1-2 3.465V
2-3 5V - Vcc
Raw Pulse Output Mode
LK13/14 1-2 RS422 differential driver
2-3 Open collector
Raw Pulse Input #3 – Line Determination
LK15/16 ON Line determination resistors connected: +ve pulled up to Vcc and –ve down
to 0V
OFF Lines undetermined

Table 5-32. Node Addressing: Communications Mode Selection
Node Addressing: Communications Mode Selection

Mode Link 2 Link 11 Link 3-10
Point-to-point ON OFF IGNORED
Multi-dropped ON ON IGNORED
Multiplexed (MUX) OFF OFF ADDRESS


SECTION 6 – SOFTWARE INTERFACE
6.1 Scope
This section introduces the FloBoss S600 user interface and lists the system requirements, software
installation instructions, and file locations on the host PC.
Information on using the FloBoss S600 software is only provided via the online help files.
The following sections apply to IPL 600, Config 600 Lite and Config 600 Professional, except where
noted.


Scope 6.1 6-1
System Requirements 6.3 6-2
System Requirements 6.3 6-2
Software Installation Procedure 6.4 6-2
File Locations 6.5 6-3
StartUp 6.6 6-4
Connecting to the FloBoss S600 6.7 6-4
8/01 Software Interface 6-1

6.3 System Requirements

The FloBoss S600 optional software is supplied on CD-ROM. The software is a Windows-based
program package. To install and operate the FloBoss S600 software, you require either a portable or
desktop PC that meets the following minimum requirements:
Table 6-1. System Requirements
Component Required Minimum Suggested

CPU Pentium 133 MHz Pentium 233 MHz
Memory Windows 95: 16MB > 32 MB of RAM
Windows NT: 32 MB
Free Disk Space 50MB 100MB
Operating System Windows 95 Windows 95 with Internet Explorer 4
CD-ROM 2x speed 16x speed
Serial Port 1 No. (38400 Baud) 1 No. (38400 Baud)
Display Resolution Super VGA: 800x600 with 256 Super VGA: 1024 x 768 with 256 colors or
colors greater
Selection Device Pointing device compatible with Mouse recommended
Windows operating systems
6.4 Software Installation Procedure

If you are installing the software from a remote CD-ROM drive, ensure you map a network drive letter
to the path of the CD-ROM drive before you begin installation.
To install on a Windows 95/98 or NT 4.0 operating system:

1. Insert the FloBoss S600 software disc into your CD-ROM drive. The CD should “autorun”.
However, if this does not occur, continue with the following steps.
2. Click the Start button on the Task bar.
3. Click the Run button and the Run Window displays. Refer Figure 6-1.
Figure 6-1. Run Dialog
6-2 Software Interface 8/01

4. Type x:\Setup (where x is your designated CD-ROM drive) in the Open field and then
click OK.
5. Windows opens the setup file and the Installation Wizard begins. Follow the instructions
provided on each screen.
6.5 File Locations

All files associated with the FloBoss S600 software are located in the respective default directory paths
noted:
Config Pro=C:\Program Files\Daniel Ltd\Config Pro
Config Lite=C:\Program Files\Daniel Ltd\Config Lite
IPL600=C:\Program Files\Daniel Ltd\IPL600, unless you specified a different
drive or directory during installation.
The configuration files containing the settings that appear in the database manager window are located
in the Configs directory. A separate sub-directory is then used for each configuration.
When you receive new configuration files, they are typically in the form of a self-executing .exe file.
Place this file in the Configs directory. Run (execute) the file. Running the executable files creates a
unique new subdirectory within the Configs directory that contains all of the required directories,
.txt, .pcs, .1c and .cfg files for the new configuration.
The files that define the report format are located in the Reports directory, and the files specifying the
Modbus settings are located in the Modbus directory.
The following files are downloaded to the FloBoss S600 during the configuration process:
vxworks.bin.x.x.x.x. – the operating system and task firmware binary file (where x.x.x.x.
is the version number of the vxworks file).
s600conf.cfg – the main configuration file for the metering database and all the initialization
values.
display.txt – the configuration file for the display menus and data pages.
Mbxx.txt – the Modbus configuration files including Slave register maps and Master polling
sequences (where xx indicates the file name is application-specific).
Mbpseq.txt – the prover sequence configuration file.
Repxx.txt – the report format configuration files (where xx indicates the file name is
application-specific).
8/01 Software Interface 6-3

6.6 StartUp
After the FloBoss S600 software as been successfully installed, use Start > Programs to start the
program.
Note: Refer to the online help for detailed instructions on using CONFIG 600.
To start the program directly from the executable file, use the directory path you specified when
installing the software. The default setting is:
C:\Program Files\Daniel Ltd\Config Pro\ Config 600 Pro.exe
C:\Program Files\Daniel Ltd\Config Lite\Config 600 Lite.exe
C:\Program Files\Daniel Ltd\IPL600\IPL600.exe
6.7 Connecting to the FloBoss S600

A special serial cable is required to connect the host PC to the FloBoss S600 unit. A ready-made link
cable is available for a PC with a 9-pin serial port.
Alternatively, you may fabricate your own link cable using the wiring details in Figure 6-2.
Note: Due to the high baud rate used for the communications between the host PC and the
FloBoss S600, it is recommended that the maximum cable length be restricted to 5 meters (15
feet).
Figure 6-2. Link Cable
6-4 Software Interface 8/01

APPENDIX A – TECHNICAL DATA
A.1 Scope
This appendix contains a complete list of physical, performance, and environmental specifications of
the FloBoss S600 and its plug-in boards.
The FloBoss S600 unit consists of an 80486 microprocessor-controlled CPU board, an I/O board, and a
power supply back-plane, all fitted inside a zinc-coated pressed mild steel case with a display and
keypad in the front panel of the unit.
A.2 Section Contents


Scope A.1 A-1
Section Contents A.2 A-1
Mechanical and Environmental A.3 A-2
Power Supply A.4 A-3
P152 CPU A.5 A-4
Battery Backup A.5.1 A-4
Communications A.5.2 A-5
Other Peripherals A.5.3 A-6
Watchdog Relay A.5.4 A-7
P144 I/O A.6 A-7
Analog Inputs (voltage or current type) A.6.1 A-8
PRT Inputs A.6.2 A-9
Frequency/Density Inputs A.6.3 A-9
Turbine Pulse Inputs A.6.4 A-10
Digital Status Inputs A.6.5 A-10
Analog Outputs A.6.6 A-11
Digital Outputs A.6.7 A-11
Pulse Outputs A.6.8 A-12
Raw Pulse Outputs A.6.9 A-12
P154 Prover A.7 A-13
Frequency/Density Inputs A.7.1 A-13
Turbine Pulse Inputs A.7.2 A-14
Digital Status Inputs A.7.3 A-14
Digital Outputs A.7.4 A-15
8/01 Technical Data A-1

Pulse Outputs A.7.5 A-15

Raw Pulse Outputs A.7.6 A-16
Display-Keypad A.8 A-16
Mezzanine Boards A.9 A-16
Spectra-Tek DPR Mezzanine A.9.1 A-16
Daniel Mezzanine A.9.2 A-16
A.3 Mechanical and Environmental

Table A-1 and Table A-2 display the computer case and mounting specifications.
Table A-1. Computer Case and Mounting
Display Keypad Moulding 85 mm (3.35") width x 269 mm (10.59") height x 28 mm (1.10") deep
Case 84.5 mm (3.327") width x 270 mm (10.63") height x 303.8 mm (11.94") deep
Panel Cutout 66 mm (2.6") width x 150 mm (5.9") height (both with ±1 mm tolerance)
Pitch Between Cases 110 mm (4.33") giving 25 mm (0.98") air gap
Max Panel Thickness 10 mm (0.39")
Weight 4.3 kg (9.48 lb) approx. with a single I/O board space configuration
Structure Painted, welded steel outer case with plastic front panel
Circuit Boards Eurocard-compatible which slide in and out from the rear
Access Allow 300 mm (11.81") clearance directly behind case for maintenance
Table A-2. Environmental Conditions
Operating Temperature 0° C to +60° C (32° F to 140° F)

Storage Temperature -40° F to 158° F (-40° C to +70° C)
Relative Humidity 90% non-condensing
Safety Classification For use in a classified safe electrical area
EMC Complies with European Union EMC regulations
A-2 Technical Data 8/01

A.4 Power Supply

Table A-3 details power inputs.
Table A-3. Power Inputs
Supply Voltage 20-32VDC, 24W nominal, 48W maximum; typically 18W with single I/O board
Inrush Current Thermistor protection providing 6A at 25° C
Supply Isolation Three-way, galvanically isolated from input to computer, supply and earth
Hold-up Period 4 ms after power fail flag
Input Fuse 2.5A anti-surge 20 mm
Maximum Input Ripple 2V pk-pk
DC Input Power Fail Flag 17-19V
Table A-4. Power Outputs - 24 Volts
Regulation Fully regulated 24V

Output Current 500mA
Output Protection Resettable fuse and electronic current limit
Isolation Level 50VDC
Isolation Type Isolated from both the input 24VDC and the computer 0V, but shared with 15V output
Table A-5. Power Outputs - 15 Volts
Regulation Full linear regulation

Output Current 100mA
Output Protection Resettable fuse and electronic current limit
Isolation Level 50VDC
Isolation Type Isolated from both the input 24VDC and the computer 0V, but shared with 24V output

A.5 P152 CPU

The CPU module is based on a PC-compatible architecture. The P152 CPU contains a complete set of
PC peripherals, such as interrupt controllers (PICs), timer (PIT) DMA controllers, RTC, and PC104
(ISA compatible) expansion bus.
Table A-6. CPU Module Components
Processor Intel 50 MHz 80486 DX2/50 (208 Pin SQFP) with built-in floating point maths
co-processor
DRAM Memory 16MByte standard, with 32-bit data path using 2 off 64Mbit 3V EDO expandable
up to 32MByte max
SRAM Memory 1MByte standard, optional 2 MByte on 16-bit wide ISA bus. Battery backed
Flash Memory 4MByte standard on 16-bit ISA bus, write protected in 1MByte blocks
Monitor/BIOS 128KByte on 8-bit ISA bus
Real Time Clock Battery supported calendar clock chip, maintains system time during power loss
Expansion Bus PC/104 format; power restrictions - contact factory for details
A.5.1 Battery Backup

The battery backup is used to retain the contents of the SRAM on the CPU, the PC compatible BIOS
CMOS memory area and the calendar clock. The standard battery is a Ni-MH rechargeable 3.6V,
140mAh unit. To ensure that the battery is fully functional, a regular load test is performed on the unit.
Table A-7. Standard Ni-MH Rechargeable
Charging Time (20%-80%) 48 hours

Hold-up Time (without recharge) 3 months at 20° C (68° F), 1 month at 40° C (104° F)
Battery Life (Typical) 5-7 years
Battery Backup Holdup Time (after battery has failed 2 weeks at 20° C (68° F)
its load test)

A.5.2 Communications
The following tables detail communications ports.
Note: Ports 3 through 7 are configurable for remote communications by the customer.
Table A-8. In Total
Port Type Location

Total Number of Serial Ports 8
RS232 Ports 2 uncommitted + front panel + configuration port
RS422 Ports 3 uncommitted
Dedicated Port Link to I/O / RIO boards
Port Number Location
Port 1 Keypad
Port 2 PC download
Port 3 RS 232
Port 4 RS 232
Port 5 RS 422/485
Port 6 RS 422/485
Port 7 RS 422/485
Port 8 I/O Remote Connection
Table A-9. Front Panel Port
Connector Type 20-pin IDC header

Communication Standard RS232D
Signals Supplied Tx, Rx, CTS, Enter Interlock Control, GND
Baud Rate 9600 Baud
Format 8 bit data, 1 stop bit, odd parity
Note: Located on the back side of the front panel, and connects to a dedicated 20-pin connector
on the P155 power supply, and routes the configuration port to a bottom mounted RJ12.
Table A-10. Configuration Port (bottom side of front panel)
Connector Type 6 pin RJ12

Signals Supplied Tx, Rx, RTS, CTS, GND
Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400
Format Config 600 protocol

Table A-11. RS232 Ports
Connector Type FCC-68 RJ45

Signals Supplied Tx, Rx, RTS, CTS, DTR, DSR, GND, DCD
Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400
Format Software configurable
Data Protocol ASCII, MODBUS (ASCII, RTU)
Table A-12. RS422/RS485 Ports
Connector Type standard screw terminals, 3.5 mm pitch, 13-pin

Communications RS422 - point-to-point - 4 wire
RS422 – Multidrop (RS485 4 wire) - 4 wire
RS485 - Multimaster - 2 wire
Signals Supplied Tx+, Tx-, Rx+, Rx-, Common Shield
Baud Rate 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600
Format Software controlled on each channel
Data Protocol ASCII, MODBUS (ASCII, RTU)
A.5.3 Other Peripherals

The following tables detail other peripherals.
Table A-13. Ethernet
Speed 10 Mbit/second
Media Connectivity 10baseT, twisted pair utilizing standard RJ45
Table A-14. Clock Facilities
Time Battery-supported calendar clock

Clock Accuracy 10 seconds per day
(battery supported)
Clock Accuracy (powered on) 0.5 seconds per day
Watchdog Period 2.5 seconds maximum

A.5.4 Watchdog Relay

Table A-15 details the watchdog relay.
Table A-15. Watchdog Relay
Contact Form Change-over contacts

Max Current 1A
Max Voltage 50VDC
Maximum Power 30VA
Control Released on de-power, or watchdog restart, or software controlled
A.6 P144 I/O

The P144 Intelligent I/O board is the data gathering component in a hierarchical flow computer. Up to
seven P144 I/O boards, or other expansion boards, can be addressed by a single P152 486 processor
board. The P144 can be case or rack mounted.
Table A-16. P144 I/O
I/O Connection Qty Description

Analog Inputs 12 Single-ended, 1-5V or 4- 20mA DC type. Two of these are current only
ANINS 2 Current only
Analog Outputs 4 4-20mA DC type
Digital Inputs 16 Voltage sensing
Digital Outputs 12 Open collector type
Dual Pulse Inputs 2 Turbine inputs, 0 to 10,000Hz
Frequency Inputs 3 Density period / frequency 0 to 10,000Hz
PRT Inputs 3 4-wire RTD (IEC 751)
Pulse Outputs 5 Programmable DC to 100Hz
Raw Pulse Output 1 Raw pulse output for proving: DC to 5 kHz

A.6.1 Analog Inputs (voltage or current type)

The following tables detail the AI voltage and AI current types.
Table A-17. Analog Inputs
Type of Inputs Two groups of 5 single-ended voltage or current inputs, each group
sharing a common return; channels 11 and 12 are current input only
Scan Rate All channels can be acquired in under 1 second
Conversion Method Integrating charge - balance
Effective Resolution More than 16 bits, auto zero, auto calibrate
Conversion Time Less than 100ms per channel
Series Mode Rejection >100dB at 50Hz and 60Hz
Voltage Common Mode Range ±50V as a group relative to computer ground
Common Mode Rejection >100dB at 50Hz and 60Hz
Signal Level 0 to 5.125V or 0 to 22mA
Input Impedance >10M-Ohms (voltage mode), approx 250 Ohms (current mode)
Temperature Drift <100 ms per channel, all channels 500 ms
Calibration Period 2 years to 0.005% of voltage
5 years to 0.01% of voltage
Table A-18. A/D Converter Inputs Voltage Mode
Type of Inputs Single-ended voltage inputs

Input Range 0 to 5.2V
Accuracy ±0.005% of FSD at 23° C (73° F)
Ambient Temperature Effect ± 7 ppm/°C (± 4 ppm/° F) from 23°C (73° F) in the range 0 to 45° C
(32 to 113° F)
Table A-19. A/D Converter Inputs Current Mode
Type of Inputs Single-ended current inputs

Input Range 0 to 22mA
Accuracy ± 0.02% of FSD at 23°C (73°F)
Ambient Temperature Effect ± 10 ppm/° C (± 5.5 ppm/° F) from 23° C in the range 0 to 45° C
(32 to 113° F)
Common Mode Range Not Applicable

A.6.2 PRT Inputs

Table A-20 details PRT inputs.
Table A-20. PRT Inputs
Type of Input 4 wire connection using Pt 100 transducers

PRT Resistance 100 Ohms (Pt 100 to IEC 751)
Excitation Current 1mA nominal
Measuring Range 60 to 216 Ohms (-100° C to +300° C) (-148° F to +572° F)
Resolution 0.01° C (0.018° F)
Accuracy -100° C to 200° C (-148° F to 392° F) ± 0.01%
-200° C to 300° C (392° F to 572° F) ± 0.02%
PRT Cables Core resistance up to 600 Ohms
Barriers 9V, 100 Ohms are satisfactory
Security Continuous cable/PRT integrity tests for earths/open circuits
A.6.3 Frequency/Density Inputs

Table A-21 details frequency and density inputs.
Table A-21. Frequency/Density Inputs
Configuration DC coupled, galvanically isolated

Number of Inputs 3
Signal Level 3V min pk-pk
Maximum Input Voltage 12V pk-pk
Current Limit Internally limited to 3mA
Frequency Range DC to 10kHz
Accuracy of Frequency Measurement 10 ppm
Resolution 5 nanoseconds

A.6.4 Turbine Pulse Inputs

Table A-22 details turbine pulse inputs.
Table A-22. Turbine Pulse Inputs
Number of Inputs 2 dual pulse stream or 4 single pulse streams

Input Type Spectra-Tek differential or Daniel preamp mode depending on mezzanine type fitted
Signal Level Dependent on mezzanine fitted
Security Monitoring IP 252/76 (ISO 6551), level A or B
Note: Refer to Section A.9, Mezzanine Boards, on page A-16 for mezzanine details.
A.6.5 Digital Status Inputs

Table A-23 describes the digital status inputs.
Table A-23. Digital Status Inputs
Configuration 16 opto-isolated inputs, arranged in 4 groups of 4 with common positive

connection to allow simple interface to Open Collector outputs
Max Input Voltage 30V
Min Input On Voltage 12V
Max Input Off Voltage 3.0V
Input Impedance 2-2.5k Ohms typical
Protection Reverse voltage protection

A.6.6 Analog Outputs

Table A-24 describes analog outputs.
Table A-24. Analog Output
Type of Input Four galvanically-isolated 4 to 21 mA outputs

Resolution 12 bit minimum
Accuracy ± 0.1% at 23° C (73° F)
Temperature Coefficient 20ppm/° C (11ppm/° F)
Load Loop Resistance 650 Ohms maximum when powered by local isolated source, 470W -
1000W when powered from +24V external supply
Maximum External Supply 32V
Output Form Controlled active current sink to ground return of local floating supply
Number of Field Connections 3 terminals per channel
Update Time 100ms to within 1%
A.6.7 Digital Outputs

Table A-25 describes digital outputs.
Table A-25. Digital Outputs
Configuration Galvanically isolated in 3 groups of 4 with common negative

Number of Outputs 12
Frequency Range DC to 0.5 Hz
Max Output Saturation
Voltage 1.5V @ 100mA
Low current Saturation
Voltage 600mV @ 1mA to suit TTL style input, with 4.7kΩ pull up to 5 V
Max Output Standoff
Voltage 42V limited by Transorb
Max Output Current 100mA
Reset/Power on State All digital outputs - OFF

A.6.8 Pulse Outputs

Table A-26 details pulse outputs.
Table A-26. Pulse Outputs
Number of Outputs 5 driven from TPU channels

Configuration Opto-isolated open collectors in a group of 4 and one single
Frequency Range DC to 100Hz
Max Output Saturation Voltage 1.5V @ 100mA
Low Current Saturation Voltage 600mV @ 1mA to suit TTL style input
Max Output Standoff Voltage 42V limited by Transorb
A.6.9 Raw Pulse Outputs

Table A-27 details raw pulse outputs.
Table A-27. Raw Pulse Outputs
Configuration Digital ground referenced open collector

Gating Software controlled
Max Output Saturation 1.5V
Max Output Standoff Voltage 26V (limited by Transorb)
Minimum On Period 100µs (microsecond)
Use To bus together several streams to a common prover computer

A.7 P154 Prover

The P154 is a dedicated prover interface board that has been designed to work with compact or
microprover, unidirectional and bi-directional provers with 2 or 4 sphere switches.
Table A-28. P154 Prover
I/O Connection Qty Description

Digital Inputs 32 Voltage sensing
Digital Outputs 12 Open collector type
Dual Pulse Inputs 2 Turbine inputs, 0 to 10,000Hz
Frequency Inputs 2 Density period / frequency 0 to 10,000Hz
Pulse Outputs 4 Programmable DC to 100Hz
Raw Pulse Output 1 Raw pulse output for proving: DC to 5 kHz
Raw Pulse Input 3
Phase Loop Lock 2
Input
Switch Detect 4
A.7.1 Frequency/Density Inputs

Table A-29 details Frequency/Density Inputs.
Table A-29. Frequency/Density Inputs
Configuration DC coupled, galvanically isolated

Number of Inputs 3
Signal Level 3V min pk-pk
Maximum Input Voltage 12V pk-pk
Current Limit Internally limited to 3mA
Accuracy of Frequency Measurement 10 ppm
Resolution 5 nanoseconds

A.7.2 Turbine Pulse Inputs

Table A-30 describes Turbine Pulse Inputs.
Table A-30. Turbine Pulse Inputs
Number of Inputs 2 dual pulse stream or 4 single pulse streams

Input Type Spectra-Tek differential or Daniel preamp mode depending on mezzanine type fitted
Signal Level Dependent on mezzanine fitted
Security Monitoring IP 252/76 (ISO 6551), level A or B
Note: Refer to Section A.9, Mezzanine Boards, on page A-16 for mezzanine details.
A.7.3 Digital Status Inputs

Table A-31 describes Digital Status Inputs.
Table A-31. Digital Status Inputs
Configuration 16 opto-isolated inputs, arranged in 4 groups of 4 with common

positive connection to allow simple interface to Open Collector outputs
Max Input Voltage 30V
Min Input On Voltage 12V
Max Input Off Voltage 3.0V
Input Impedance 2-2.5k Ohms typical
Protection Reverse voltage protection

A.7.4 Digital Outputs

Table A-32 details Digital Outputs.
Table A-32. Digital Outputs
Configuration Galvanically isolated in 3 groups of 4 with common negative

Number of Outputs 12
Frequency Range DC to 0.5 Hz
Max Output Saturation
Voltage 1.5V @ 100mA
Low current Saturation
Voltage 600mV @ 1mA to suit TTL style input, with 4.7kΩ pull up to 5 V
Max Output Standoff
Voltage 42V limited by Transorb
Reset/Power on State All digital outputs - OFF
A.7.5 Pulse Outputs

Table A-33 details pulse outputs.
Table A-33. Pulse Outputs
Number of Outputs 5 driven from TPU channels

Configuration Opto-isolated open collectors in a group of 4 and one single
Frequency Range DC to 100Hz
Max Output Saturation Voltage 1.5V @ 100mA
Low Current Saturation Voltage 600mV @ 1mA to suit TTL style input
Max Output Standoff Voltage 42V limited by Transorb

A.7.6 Raw Pulse Outputs

Table A-34 details the Raw Pulse Output.
Table A-34. Raw Pulse Outputs
Configuration Digital ground referenced open collector

Gating Software controlled
Max Output Saturation 1.5V
Max Output Standoff Voltage 26V (limited by Transorb)
Minimum On Period 100µs (microsecond)
Use To bus together several streams to a common prover computer
A.8 Display-Keypad
Table A-35 details the Display and Keypad.
Table A-35. Display-Keypad
Graphics Display LCD 128 x 64 pixel (8 lines of 20 alpha-characters) with

LED backlight, using a Toshiba T6963 LCD controller
Alarm/Status 3 color LED: green, amber, red
Keyboard 29 self-colored silicon rubber keys with tactile feel
Configuration Port RJ12 connector for the CONFIG 600 package on the
bottom face of the front panel moulding
Connectivity Watchdog Front panel signals the user if no update or poll occurs
after the time-out period
Watchdog Time-out Period 10 seconds
Connection to FloBoss S600 20-pin ribbon cable
Communications to FloBoss S600 9600 baud, 8 bit, odd parity
Display Test User initiated

A.9 Mezzanine Boards

The following sections detail the mezzanine boards.
A.9.1 Spectra-Tek DPR Mezzanine

Table A-36 details the Spectra-Tek DPR Mezzanine board.
Table A-36. P148 Spectra - Tek Pre-amp Mezzanine
Configuration Opto-coupled inputs

Input Signal Levels +/- 3.5V to +/- 12V
Input Current Minimum 5mA
Line Integrity Dual back-to-back optos, allowing full quiescent line and electronic
integrity testing, when used with S-Tek pre-amps and pulsers
Dual Pulse Compliance IP 252/76 level A or B
A.9.2 Daniel Mezzanine

This section details the Daniel Mezzanine board.
Table A-37. P148 US Version Mezzanine
Configuration Opto-coupled inputs

Input Signal Levels +/- 10V to +/- 24V
Input Current Minimum 5mA
Line Integrity Dual back-to-back optos, allowing full quiescent line and electronic
integrity testing, when used with S-Tek pre-amps and pulsers
Dual Pulse Compliance IP 252/76 level A or B


APPENDIX B – ENGINEERING DRAWINGS
B.1 List of Engineering Drawings
♦ DE-20400 Field Wiring Diagram Model DS600 (Sheets 1-3)

♦ DE-20438 Outline and Dimensional and Mounting Instructions S600 (Sheets 1-2)
♦ DE-20472 CPU Remote Terminal Board Layout (Optional)
♦ DE-20473 Intelligent I/O Remote Terminal Board Layout (Optional)
♦ DE-20474 P152 CPU Board S600 Connection Diagram
♦ DE-20475 P144 I/O Board S600 Connection Diagram
♦ DE-20476 P154 Prover Board S600 Connection Diagram
♦ BE-20477 Template Panel Cutout S600
8/01 Engineering Drawings B-1

GLOSSARY
Glossary for the FloBoss S600

A
ADC – Analog to Digital Converter, also known as A/D Converter.
ADDRESS – A character, or group of characters, used in order to identify a particular item, e.g.
particular area of memory or particular computer on a communication link with many computers.
AGA – American Gas Association.
ALPHANUMERIC – Consisting of only the letters A to Z and the numerals 0 to 9.
ANALOG – A signal that has no defined steps, its value being determined by its size.
ANIN – Analog input, also known as AI.
ANOUT – Analog output, also known as AO.
API – American Petroleum Institute.
ASCII – American Standard Code (for) Information Interchange. The representation of alphanumeric
characters and control codes as a single byte within the range 0 to 127.
ASTM – American Society for Testing and Materials.
B
BAUD – Refers to the rate of serial data transfer, e.g. baud rate of 10 = 10 bits per second.
BINARY – Numbers in base 2, i.e. only numbers 0 and 1 are used.
BIT – A binary digit.
BITSWITCH – Switches that represent data bits by on or off state.
BTU – British Thermal Unit.
BUFFER – A device inserted between devices to match impedance, equipment speeds or to supply
additional drive capability.
BUS – One or more conductors used as a path over which information is transmitted.
BYTE – Block of 8 bits, can define 256 states (0 thru 255).
8/01 Glossary G-1

C
COMPRESS – Compressibility calculated using AGA8.
CONFIG 600 LITE – Tool for configuring the FloBoss S600.
CONFIG 600 PROFESSIONAL – Tool for creating new applications.
CONSTANTS – Numbers which are only infrequently changed.
CONTROL BUS – Bus Connections for Control Signals, e.g. Read/Write.
CPU – P152 Central Processing Unit module.
CTS – Clear to Send.
CURRENT LOOP – Serial Communication Technique (0mA/20mA).
CV – Calorific Value calculated using AGA5 or ISO6976.
D
DAC – Digital to Analog Converter, also known as D/A Converter.
DATABUS – A group of bi-directional lines capable of transferring data to and from the CPU storage
and peripheral devices.
DCU – Data Concentrator Unit.
DI – Digital input.
DIGITAL – A signal that has only two states e.g. On/Off 1/0 5V/0V.
DO – Digital output.
DP – Differential Pressure.
DPR – Dual Pulse Receiver or turbine input.
DRAM – Dynamic Random Access Memory. Volatile storage memory used by the FloBoss S600.
When power is removed from the FloBoss S600, the contents of the DRAM memory are assumed
to be lost.
DSR – Data Set Request.
DTR –Data Terminal Ready.
E
EEPROM – Electrically Erasable Programmable Read Only Memory.
G-2 Glossary 8/01

EEROM – Electrically Erasable Read Only Memory.
E-FORMAT – Mathematical notation where the mantissa is between 1 and 9 and the exponent is the
multiplier.
ETHERNET – Network hardware connection.
EXPONENT – Base 10 Multiplier.
F
FCU – Flow computer unit.
FLASH MEMORY – Non-volatile storage memory. Although slower to access than SRAM and
DRAM, once its contents have been programmed, it requires no further attention to support that
data. The configuration files and operating system are kept here. Write protect jumpers are used to
prevent accidental programming of this memory.
FRQ – Frequency or period input.
FTP – File transfer protocol. Used to copy a file or multiple files from one computer to another.
H
HEX – Numbers in base 16, i.e. numbers 0 to 9 and letters A to F are used.
I, J, K
INTEGER – A whole number.
INTELLIGENT I/O – P144 Intelligent Input Output module, also known as IIO.
I/O – Input and Output.
IP – Institute of Petroleum.
IP – Ingress protection standard, refer to British standard 5420 or International Electro-Technical

commission standard 144.
IPL 600 – Interactive program loader tool for transferring application programs from the PC to the
FloBoss S600.
IS – Intrinsically safe to CENELEC standard EN50020.
L
LED – Light Emitting Diode (an indicator).
8/01 Glossary G-3

M
MANTISSA – Numerically significant part of a floating point number.
MICRO – Microcomputer is the complete microprocessor based instrument.
MNEMONIC – Grouping of characters used to aid memory.
MODBUS – Modbus is the communication protocol utilized on the station supervisory computer data
link.
MODEM – Modulator Demodulator.
MODULATE – The superimposing of one signal upon another.
MULTIPLEXOR – Multiple Input Selector.
N
NOISE – Random Electrical Interference.
NON-VOLATILE – Memory type that retains data when the power supply is disconnected.
O
OCTAL – Numbers in base 8, i.e. numbers 0 to 7 are used.
OPEN COLLECTOR – Digital output that is driven by a transistor and requires external power.
OPTO-ISOLATOR – Optical Device for connecting signals while maintaining electrical isolation.
OVERRANGE – Over the present current limit for ADC.
P, Q
PCB – Printed Circuit Board.
PERIPHERAL – Equipment connected outside the main processor.
PID – Three term control action. Using Proportional, Integral and Derivative components to modify a
control output, with the goal of achieving a measured process variable at a set point.
PORT – A group of inputs or outputs to the computer.
PROGRAM – Series of instructions.
PROM – Programmable ROM.
PROTOCOL – Precise description of data interchange over a telemetry link.
G-4 Glossary 8/01

PRT – Platinum Resistance Thermometer.
PSU – Power Supply Unit.
R
ROM – Read Only Memory (fixed storage).
RS232 – Voltage standard for serial data transmission.
RTD – Resistance Thermometer Device.
RTS – Request to Send.
RTU – Remote Terminal Unit.
RX – Received information.
S
SECURITY CODE – Security Codes are used to limit access by operators to parameters retained in
the micro memory.
SRAM – Static Random Access Memory (battery backed).
S600 –FloBoss S600 Flow Computer.
T
TAGNAME – Alphanumeric string of up to twelve characters used to associate data with I/O points.
TCP/IP – Transfer Control Program/Internet Protocol.
TOTALIZER – Area of RAM for integrating totals.
TRANSDUCER – Device which converts energy from one form to another.
TRI-REG – Triple Register - area of RAM where data is stored in triplicate.
TX – Transmitted information.
U
UNDERRANGE – Under preset current limit for A/D Converter.
V
VARIABLES – Changeable values.
8/01 Glossary G-5

VOLATILE – Memory - unstable in the absence of power.
VDU – Visual Display Unit.
W, X, Y, Z
WATCHDOG – A hardware circuit that monitors correct program operation and causes program
restart in the event of malfunction.
G-6 Glossary 8/01

INDEX
Config Report ............................................................ 3-20

A Configuration Port ...................................................... A-5
Constants Log............................................................ 3-20
A/D Converter Inputs Current Mode.......................... A-8 Contrast ..................................................................... 3-21
A/D Converter Inputs Voltage Mode ......................... A-8 CPU
Accept P152 ....................................................................... A-4
Alarm.................................................................... 3-18 CPU Board .................................................................. 5-2
Alarm......................................................................... 3-22 CPU On-board Connectors
Accept................................................................... 3-18 P152 ........................................................................ 5-9
Alarm Light............................................................... 3-17 Current Alarms .......................................................... 3-20
Alarm Light and Keys ................................................. 3-4 Current Report ........................................................... 3-20
Alarms ....................................................................... 3-17
View ..................................................................... 3-17
D
All Alarms................................................................. 3-20
AMERICAN ............................................................. 5-16 Daniel Mezzanine ..................................................... A-17
Analog Inputs ............................................................ 3-11 Data
(voltage or current type) ........................................ A-8 Entering ................................................................ 3-12
ANIN .................................................................... 5-12 Data Pages ................................................................... 3-7
Analog Outputs ............................................... 5-16, A-11 Date & Time .............................................................. 3-21
Archived Reports....................................................... 3-20 Decimal Point .............................................................. 3-6
Asterisk ....................................................................... 3-6 Default Display.......................................................... 3-22
Density Inputs................................................... A-9, A-13
B Digital Inputs
DIGIN................................................................... 5-21
Backup DIGIN................................................................... 5-13
Battery ................................................................... A-4 Digital Outputs ............................................... A-11, A-15
On-Board Battery ................................................... 5-7 DIGOUT ......................................................5-18, 5-24
Battery Backup........................................................... A-4 Digital Status Inputs ....................................... A-10, A-14
On-Board ................................................................ 5-7 DIN............................................................................ 5-16
Boards Disp ....................................................................3-5, 3-12
Removing and Replacing Plug-in........................... 4-7 Display......................................................................... 3-5
LCD ........................................................................ 3-6
C Navigating ............................................................ 3-11
Display Dump............................................................ 3-20
Cable ........................................................................... 5-5
Display Matrix....................................................3-7, 3-21
Calculations................................................................. 3-7
Display Setup............................................................. 3-21
Change ........................................................................ 3-6
Display T/O ............................................................... 3-21
Change Mode ............................................................ 3-22
Display Test............................................................... 3-21
Change Value ............................................................ 3-22
display.txt .................................................................... 6-3
Changing a Value ...................................................... 3-12
Display-Keypad........................................................ A-16
Changing Mode ......................................................... 3-14
Download and Reflash Config File ............................. 4-4
Changing the Fuse....................................................... 4-7
Chng ............................................................................ 3-6
Clear ................................................................... 3-5, 3-22 E
Clear SRAM................................................................ 4-5 Enter ............................................................................ 3-6
Clock Facilities........................................................... A-6 Entering Data............................................................. 3-12
Cold Start .............................................. 3-9, 4-1, 4-2, 4-4 Environmental
COM1.......................................................................... 5-8 Specifications......................................................... A-2
COM2................................................................... 5-7, 5-8 Environmental Considerations..................................... 2-2
Communications................................................ 3-21, A-5 Ethernet ...................................................................... A-6
Config 600 Lite ........................................................... 1-6 Ethernet LAN Port....................................................... 5-6
Config 600 Professional .............................................. 1-6
8/01 Index I-1

Example Format..................................................................... 4-6

Mode Change ........................................................3-15 Reflash.................................................................... 4-4
Value Change ........................................................3-13 Flash Failed ................................................................. 4-3
Exponent ..................................................................... 3-5 FloBoss S600 Flow Computer.............................. 1-1, 1-3
Exponential Format....................................................3-16 Format Flash................................................................ 4-6
Expt .................................................................... 3-5, 3-16 Frequency Inputs .............................................. 5-15, 5-24
Frequency/Density Inputs................................. A-9, A-13
F Front Panel .................................................................. 2-3
Reinstalling............................................................. 2-9
F Keys ......................................................................... 3-3 Front Panel Port................................................... 5-7, A-5
Factory Setup ....................................................... 4-3, 4-5 Function Keys
Figure 1-1. The FloBoss S600 System....................... 1-2 Program ................................................................ 3-22
Figure 1-2. CPU Board .............................................. 1-3 Fuse
Figure 1-3. Intelligent I/O Board................................ 1-5 Changing................................................................. 4-7
Figure 2-1. All Parts of the Basic FloBoss S600 System
................................................................................... 2-2
I
Figure 2-2. Removing the Front Panel ....................... 2-4
Figure 2-3. Lift up Panel ............................................ 2-4 I/O ............................................................................... 3-7
Figure 2-4. Remove Connector .................................. 2-5 Ident T/O ................................................................... 3-21
Figure 2-5. Panel Mount ............................................ 2-6 Initial Checks............................................................... 4-7
Figure 2-6. Unscrewing the Retention Screws ........... 2-7 Initialization ................................................................ 3-9
Figure 2-7. Preparing to use the pull tabs for board Installation................................................................... 2-3
release........................................................................ 2-8 Boards..................................................................... 2-7
Figure 2-8. Using the Pull Tabs ................................. 2-8 Panel-Mounted Unit ............................................... 2-5
Figure 2-9. Board Ready for Removal or Final Insertion Plug-In Boards........................................................ 2-9
................................................................................... 2-9 Preparing................................................................. 2-1
Figure 3-1. Front Panel .............................................. 3-3 Reinstalling the Front Panel.................................... 2-9
Figure 3-10. Standard DENS ....................................3-15 Removing the Front Panel ...................................... 2-3
Figure 3-11. Calculated.............................................3-15 Software.................................................................. 6-2
Figure 3-12. Confirm ................................................3-16 Tools ....................................................................... 2-3
Figure 3-13. Alarm Display ......................................3-17 Unpacking............................................................... 2-2
Figure 3-14. Print Options.........................................3-18 IPL 600........................................................................ 1-6
Figure 3-15. Print Options 2......................................3-19
Figure 3-16. Print Options 3......................................3-19 K
Figure 3-17. Print Options 4......................................3-20
Figure 3-18. Display Setup Menu .............................3-21 Keypad .......................................................3-2, 3-3, A-16
Figure 3-2. LCD Display............................................ 3-6
Figure 3-3. Status ID Line.......................................... 3-7 L
Figure 3-4. Database Matrix....................................... 3-8
LAN Port
Figure 3-5. Startup Screen.......................................... 3-9
Ethernet................................................................... 5-6
Figure 3-6. Main Menu .............................................3-10
LCD Display ........................................................ 3-2, 3-6
Figure 3-7. Submenu.................................................3-11
Navigating ............................................................ 3-11
Figure 3-8. Analog Inputs .........................................3-11
Logout T/O................................................................ 3-21
Figure 3-9. Alarm Limits ..........................................3-13
Figure 4-1. Startup Menu ........................................... 4-2
Figure 4-2.................................................................... 4-8 M
Figure 5-1. CPU Backplate ........................................ 5-3 Main Menu
Figure 5-2. Pin Connections....................................... 5-5 Return ................................................................... 3-22
Figure 5-3. COM2 Alternative Connections .............. 5-7 Maintenance ................................................................ 4-1
Figure 5-4. I/O Backplate..........................................5-12 Matrix
Figure 5-5. Analog Output Channel 1 as a Source or Display.................................................................... 3-7
Sink ..........................................................................5-17 Mbpseq.txt................................................................... 6-3
Figure 5-6. Prover I/O Backplate ..............................5-21 Mbxx.txt ...................................................................... 6-3
Figure 6-1. Run Dialog .............................................. 6-2 Mechanical and Environmental .................................. A-2
Figure 6-2. Link Cable ............................................... 6-4 Menu Keys .................................................................. 3-4
File Locations.............................................................. 6-3 Menus .......................................................................... 3-6
Flash..................................................................... 3-9, 4-3
I-2 Index 8/01

Mezzanine Boards .................................................... A-17 R

Modbus Maps............................................................ 3-20
Mode RAM............................................................................ 3-9
Change Example................................................... 3-15 RAM Disc Start ........................................................... 4-6
Changing .............................................................. 3-14 Raw Pulse Outputs ......................................... A-12, A-16
Modem Port................................................................. 5-5 Reflash Config............................................................. 4-3
Multidrop Port Reflash Config File...................................................... 4-4
RS422/485 .............................................................. 5-6 Reflash Firmware ........................................................ 4-3
Reinstalling the Front Panel ........................................ 2-9
Remote Display or PC ................................................. 5-8
N Removal of the Boards ................................................ 2-7
Network Setup...................................................... 4-2, 4-5 Removing and Replacing Plug-in Boards.................... 4-7
Numeric Keys.............................................................. 3-5 Repxx.txt ..................................................................... 6-3
Requirements
O System .................................................................... 6-2
Return to Main Menu ................................................ 3-22
On-Board Battery Backup ........................................... 5-7 RS232 Modem Port ..................................................... 5-5
Operation..................................................................... 3-1 RS232 Ports ................................................................ A-6
Overview ..................................................................... 1-1 RS422/485 Multidrop Port .......................................... 5-6
RS422/RS485 Ports .................................................... A-6
P RTD Inputs ................................................................ 5-16
Run Mode .................................................................... 4-2
P144 I/O Berg Jumpers (Links)................................. 5-19
P144 I/O Board ................................................. 5-12, A-7
P152 CPU................................................................... A-4 S
P152 CPU Berg Jumpers (Links) .............................. 5-10 s600conf.cfg ................................................................ 6-3
P152 CPU Board ......................................................... 5-2 Scientific Notation..................................................... 3-22
P152 CPU On-board Connectors ................................ 5-9 Security...................................................................... 3-21
P154 Prover.............................................................. A-13 Security Code ............................................................ 3-16
P154 Prover Berg Jumpers (Links) ........................... 5-26 Security Dump........................................................... 3-20
P154 Prover Board .................................................... 5-21 Setup
Panel-Mounted Unit Factory .................................................................... 4-5
Installation .............................................................. 2-5 Setup and Wiring......................................................... 5-1
Peripherals.................................................................. A-6 Software....................................................................... 1-5
Plant I/O .................................................................... 3-11 Config 600 Lite....................................................... 1-6
Plug-in Boards Config 600 Professional.......................................... 1-6
Removing and Replacing........................................ 4-7 Installation .............................................................. 6-2
Plug-In Boards IPL 600 ................................................................... 1-6
Installation .............................................................. 2-9 Special Pages ............................................................. 3-20
Power Inputs............................................................... A-3 Spectra-Tek DPR Mezzanine ................................... A-17
Power Outputs - 15 Volts ........................................... A-3 SRAM.......................................................................... 3-9
Power Outputs - 24 Volts ........................................... A-3 Clear........................................................................ 4-5
Power Supply ...................................................... 5-3, A-3 StartUp......................................................................... 6-4
Print....................................................3-5, 3-8, 3-18, 3-22 Startup List .................................................................. 4-8
Program Function Keys............................................. 3-22 Status/ID Line.......................................................3-4, 3-7
Prover Summary of Operation .............................................. 3-21
P154..................................................................... A-13 System Requirements .................................................. 6-2
Prover Board
P154...................................................................... 5-21 T
PRT Input .................................................................... 3-8
PRT Inputs ................................................................. A-9 Table 1-1. I/O Functions............................................. 1-4
PRT/RTD Inputs ....................................................... 5-16 Table 4-1. Startup List ................................................ 4-9
Pulse Inputs Table 5-1. TB-1 Pin Connections ............................... 5-4
Turbine ....................................5-14, 5-23, A-10, A-14 Table 5-10. ANIN Pin Connections for SKT-A ....... 5-13
Pulse Outputs ................................................. A-12, A-15 Table 5-11. ANIN Pin Connections for SKT-B........ 5-13
PULSEOUT................................................. 5-19, 5-25 Table 5-12. DIGIN Pin Connections for SKT-B ...... 5-14
Table 5-13. DIGIN Pin Connections for SKT-C ...... 5-14
8/01 Index I-3

Table 5-14. Dual-pulse Input Pin Connections for SKT- Table A-21. Frequency/Density Inputs ..................... A-9
C ...............................................................................5-15 Table A-22. Turbine Pulse Inputs............................ A-10
Table 5-15. Frequency Input Pin Connections for SKT- Table A-23. Digital Status Inputs ............................ A-10
B ...............................................................................5-15 Table A-24. Analog Output..................................... A-11
Table 5-16. PRT Input Pin Connections for SKT-B .5-16 Table A-25. Digital Outputs .................................... A-11
Table 5-17. D/A Converter Output Pin Connections for Table A-26. Pulse Outputs ...................................... A-12
SKT-A ......................................................................5-17 Table A-27. Raw Pulse Outputs .............................. A-12
Table 5-18. DIGOUT Pin Connections for SKT-B...5-18 Table A-28. P154 Prover......................................... A-13
Table 5-19. DIGOUT Pin Connections for SKT-C...5-18 Table A-29. Frequency/Density Inputs ................... A-13
Table 5-2. TB-1 Pin Connections............................... 5-4 Table A-3. Power Inputs............................................ A-3
Table 5-20. PULSEOUT Pin Connections for SKT-B..... Table A-30. Turbine Pulse Inputs............................ A-14
..................................................................................5-19 Table A-31. Digital Status Inputs ............................ A-14
Table 5-21. Flash Link Setting..................................5-19 Table A-32. Digital Outputs .................................... A-15
Table 5-22. P144 I/O Berg Links ..............................5-20 Table A-33. Pulse Outputs ...................................... A-15
Table 5-23. A/D Converter Shunt Mode ...................5-20 Table A-34. Raw Pulse Outputs .............................. A-16
Table 5-24. DIGIN Pin Connections for SKT-E .......5-22 Table A-35. Display-Keypad................................... A-16
Table 5-25. DIGIN Pin Connections for SKT-F .......5-23 Table A-36. P148 Spectra - Tek Pre-amp MezzanineA-
Table 5-26. Dual-pulse Input Pin Connections for SKT- 17
F ...............................................................................5-23 Table A-37. P148 US Version Mezzanine .............. A-17
Table 5-27. Frequency Input Pin Connections for SKT- Table A-4. Power Outputs - 24 Volts ........................ A-3
D...............................................................................5-24 Table A-5. Power Outputs - 15 Volts ........................ A-3
Table 5-28. DIGOUT Pin Connections for SKT-E. ..5-24 Table A-6. CPU Module Components ...................... A-4
Table 5-29. DIGOUT Pin Connections for SKT-F ...5-25 Table A-7. Standard Ni-MH Rechargeable ............... A-4
Table 5-3. COM3 and COM4 Pin Connections ......... 5-5 Table A-8. In Total.................................................... A-5
Table 5-30. PULSEOUT Pin Connections for SKT-E5- Table A-9. Front Panel Port....................................... A-5
25 Technical Data............................................................ A-1
Table 5-31. P154 Prover Berg Jumpers (Links)........5-26 Tools............................................................................ 2-3
Table 5-32. Node Addressing Totals........................................................................... 3-7
Communications Mode Selection..........................5-27 Troubleshooting........................................................... 4-6
Table 5-4. COM5, COM6, and COM7 Pin Connections Flash Failed ............................................................ 4-3
................................................................................... 5-6 Startup List ............................................................. 4-8
Table 5-5. COM2 Alternative Connections ............... 5-7 Turbine Pulse Inputs.....................5-14, 5-23, A-10, A-14
Table 5-6. COM1-2 Pin Connections......................... 5-8
Table 5-7. Miscellaneous Device Connectors for the U
P152 CPU Module .................................................... 5-9
Table 5-8. Default Configuration Settings for the P152 Unpack ........................................................................ 2-2
CPU Berg Jumpers (Links) ......................................5-10
Table 5-9. Clock Speed Selection .............................5-11 V
Table 6-1. System Requirements ................................ 6-2
Value
Table A-1. Computer Case and Mounting .................A-2
Changing............................................................... 3-12
Table A-10. Configuration Port (bottom side of front
Changing Example ............................................... 3-13
panel).........................................................................A-5
Vector and Menu Keys................................................ 3-4
Table A-11. RS232 Ports ...........................................A-6
View Alarm ............................................................... 3-17
Table A-12. RS422/RS485 Ports ...............................A-6
View Parameter ......................................................... 3-22
Table A-13. Ethernet..................................................A-6
vxworks.bin.x.x.x.x ..................................................... 6-3
Table A-14. Clock Facilities ......................................A-6
Table A-15. Watchdog Relay.....................................A-7
Table A-16. P144 I/O.................................................A-7 W
Table A-17. Analog Inputs.........................................A-8 Warm Start ........................................................... 3-9, 4-2
Table A-18. A/D Converter Inputs Voltage Mode.....A-8 Watchdog Relay .................................................. 5-4, A-7
Table A-19. A/D Converter Inputs Current Mode .....A-8 Wiring.......................................................................... 5-1
Table A-2. Environmental Conditions .......................A-2
Table A-20. PRT Inputs .............................................A-9
I-4 Index 8/01

8/01 Index I-5

For information, contact your local sales representative or:

Emerson Process Management
Flow Computer Division
Marshalltown, Iowa 50158 U.S.A.
Website: www.EmersonProcess.com/flow
I-6 Index 8/01

Floboss S600 Flow Manager: Instruction Manual

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FLOBOSS S600™ FLOW MANAGER

Flow Computer Division

Revision Tracking Sheet

 Fisher Controls International, Inc. 2001. All rights reserved.

Printed in the U.S.A.

8/01 Table of Contents iii

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

5.2 Section Contents........................................................................................................................ 5-1

iv Table of Contents 8/01

1.1 Section Contents

Information Section Page Number

1.2 Scope of Manual

1.2.1 Organization of Manual

8/01 Overview 1-1

♦ Appendix A – Technical Data contains a complete list of physical, performance, and

Figure 1-1. The FloBoss S600 System

1-2 Overview 8/01

1.3 FloBoss S600 Flow Computer

The FloBoss S600 provides the following hardware features:

Figure 1-2. CPU Board

8/01 Overview 1-3

♦ Functions such as:

Table 1-1. I/O Functions

1-4 Overview 8/01

Figure 1-3. Intelligent I/O Board

The FloBoss S600 incorporates the following software features:

1.4 IPL 600

8/01 Overview 1-5

1.5 Config 600 Lite

1.6 Config 600 Professional

Config 600 Professional allows you to perform the following functions:

1-6 Overview 8/01

The online help is content-sensitive and accessible via the F1 key.

8/01 Overview 1-7

1-8 Overview 8/01

2.2 Section Contents

Information Section Page Number

2.3 Preparing for Installation

8/01 Installation 2-1

Figure 2-1. All Parts of the Basic FloBoss S600 System

2.4 Unpacking the FloBoss S600

2.5 Environmental Considerations

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2.6 Required Tools for Installation

2.7 Installing the FloBoss S600

2.7.1 Removing the Front Panel

8/01 Installation 2-3

Figure 2-2. Removing the Front Panel

Figure 2-3. Lift up Panel

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Figure 2-4. Remove Connector

2.7.2 Installing the Panel-Mounted Unit

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Figure 2-5. Panel Mount

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2.7.3 Installation and Removal of the Boards

Removal of the plug-in boards:

Figure 2-6. Unscrewing the Retention Screws

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Figure 2-8. Using the Pull Tabs

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Figure 2-9. Board Ready for Removal or Final Insertion

2.7.4 Installing Plug-In Boards