ABB Totalflow mflo Series User guide

FLO SERIES
FLO
Start-Up Guide

2
Introduction:
This startup guide is to assist in the startup of the µ FLO series flow
computer. Through this guide will be references to status codes that are
displayed in different annunciator positions on the unit’s display. Since
assignments can now be made to any of the eight annunciators, there is
no specific annunciator for a specific code. However, for those of you
familiar with previous assignments, units are typically shipped with the
assignments defaulted as you are accustomed to seeing. This pertains
more to communication’s ports since users may have custom
applications assigned to the other annunciators.
Recommended Start-Up Sequence
HINT: Step 1 thru 22 is a recommended start-up sequence and some of
the steps do not go into any great detail. Some steps because detail is
not needed and some because more information is available later in the
Start-Up Guide. For example there are later topics for installing and
wiring the RTD, installing the main battery, solar panel installation plus
other information. So, scan through the guide to see what information is
available before you begin the installation. Also keep in mind that units
on a RS485 bus may not have a battery or solar panel since they can be
powered from a remote power source such as another
µ FLO, which
does contain a battery and solar panel.
Physical mounting and piping:
1. Unpack
2. Inspect for damage and missing or incorrect components.
3. Determine where to mount the
µ FLO.
4. Install bracing for µFLO (pipe saddle, direct mount, pipe driven in
ground). Attach U-bolts to 2” pipe using silicone spray or Teflon tape
to prevent galling. (See Figures 1 & 2)
5. Mount manifold to bottom of the µFLO. Since the µFLO can be
ordered with the flow going left to right or right to left, verify direction
of flow by looking at the transducer tag that shows a (+) and (-).
Plus(+) indicates the high side (upstream side), therefore flow is from
(+) to (-). For direct mount manifolds, the direction is very important.
(See Figure 3 for a typical manifold configuration)
6. Connect stainless steel tubing from manifold to orifice tap valves.
With the manifold equalized to avoid damaging the µFLO’s
transducer, apply pressure to the manifold and check for leaks. For
best measurement, use large bore, short, equal length gage lines
with a downward slope to taps (at least 1" per 3 feet).

3
2" x 40"
Mounting Pipe
Meter Run
"U" Mounting
Bolt
Saddle
Figure 1 (Saddle Mount)
Flat and lock washers
2 " Mounting Pipe
U - Bolt
with 9/16" bolt
Figure 2 (Pipe Mount)
Figure 3 (Typical Manifold Mount)

4
Install RTD Probe:
7. Install RTD and connect wiring to connector block J9. (See Page 6
and Figure 5)
Install Battery(s):
8. Verify that the Memory Backup is Enabled. This is J1, terminals 1 &
2. (See Page 7 and Figure 5)
9. Mount and connect a fully charged battery to the battery connector
J6. (See Page 7 and Figure 5)
10. The display should go quickly through the startup routine then start
scrolling through the default display items. (If not, see Tip on Page
19) This typically insures that the components and wiring are good.
Refer to “Standard Displays" on page 15 for typical default displays.
Refer to “Visual Alarm & Status Codes" on page 16 for location,
symbols, and descriptions. You should see a LC code in the A7
annunciator (See Figure 10) since the charging source has not been
connected. This is the typical annunciator for the I/O Subsystem
application but could vary on different systems.
Install Solar Panel:
11. Assemble, mount, and connect solar panel or AC charger. NEVER
CONNECT CHARGER WITH THE MAIN BATTERY PACK
DISCONNECTED. (See pages 8 & 9) The LC code should go away
after the charging source is connected. Solar powered units will
naturally depend on available sunlight.
Setup:
12. Connect FS/2 or laptop running PCCU32 to the unit. To use an FS/2,
the µFLO must have been ordered from factory with FS/2 support.
PCCU32 must have software Version 4.3 or higher and the FS/2
must be 2018583-007 or higher.
13. Configure µFLO: Set date/time, ID, location, AGA setup, using Entry
Mode in PCCU32 or an FS/2.
14. In Calibration Mode, verify registers for Static pressure, Differential
pressure and Temperature. (PCCU32 Only)
15. In Calibration Mode, select RTD Installed, un-check Use Fixed TF,
and adjust RTD Bias if a temperature standard is used.
16. In Calibration Mode, perform as found calibration checks.

5
17. If calibration is needed, calibrate static pressure first, then differential
pressure, using a deadweight tester or acceptable standard. Insure
that both orifice taps are closed and bypass valves are open during
AP calibration to avoid a false DP. Make sure there are no leaks in
the manifold or test equipment.
18. Perform as left calibration checks as needed.
19. Place Flow Computer on line: To avoid inducing toggle and/or a
calibration shift, close vent valve, open both bypass valves, then
open orifice tap valves SLOWLY (high pressure side first). Once both
orifice tap valves are fully opened, the bypass valves can be closed.
20. Verify that the unit is calculating volume correctly. Watch the display
or look at the Current Values in the Entry Mode of PCCU32.
21. Collect data and review the event and characteristic files to insure all
parameters are set properly.
22. Optional: When you are reasonably sure that all setup and
calibration is complete and the unit is on line calculating volume, it is
recommended that a Reset Volume command be sent from the
PCCU32 Entry Mode. This allows the unit to have what might be
considered as an official starting point for good live data. The Reset
Volume will be recorded in the Events file to mark the date and time.

6
Installing and Wiring RTD and Probe
The RTD measures flowing gas temperature. Procedures presented in
this section enable the user to install the RTD into the meter run and wire
leads to the main electronics board.
Totalflow Materials Supplied
•RTD Probe with 10’ of cable. Optional lengths 15’, 25’, 30’, 40’,
and 50’.
•One (1) thermowell with ¾" NPT threads. Optional threads are
½" and 1".
•Nylon tie wraps
Customer Materials Supplied
•Customer must specify or provide Thermowell "U" length.
•Teflon tape
1. Install thermowell into meter run.
2. Using snap ring pliers, adjust probe length
so that it is spring loaded against bottom
of thermowell.
3. Remove one of the hole plugs from the
µ FLO enclosure and install cord connector.
Remove nut, sealing ring and rubber
grommet from cord connector. Slide nut,
sealing ring and grommet over RTD cable and insert cable through
body of cord connector. Allow enough cable to extend into unit for
connecting wires to RTD termination block J9. (See Figure 5)
4. Secure the cable with the grommet sealing ring and nut.
Note: Charging source and Power should be removed from unit
before performing any field wiring.
5. Connect RTD probe to the
µ FLO’s RTD connector as follows:
Before making connections to terminal block, remove spade lugs if
attached and trim wire ends back 1/4". Remove J9 terminal block
from the
µ FLO’s main electronics board. (See Figure 5)
6. Loosen terminal block securing screws, insert wire, and then
retighten. Reinstall terminal block with wires attached.

7
Battery Installation
1. To extend the life of the battery pack, fully charge the battery prior to
installation. A system using solar panels may not fully charge the
battery. Also a fast charge, which the solar panel can’t provide,
improves the life of the battery. (See tip below)
2. Insert the battery pack into the battery compartment with its long
dimension facing outward.
3. Connect battery pack connector to main electronics board Battery
connector J6. (See Figure 5)
4. Observe LCD, the display should power up displaying Warm Start
information and begin scrolling through the default display items.
Caution: Do not connect solar panel power cable to the unit
unless the main battery pack is connected.
TIP: To recharge a battery, a quick charge will remove the buildup in
the battery much more effectively than a "trickle charge". A
battery slowly drained by low light conditions on a solar charged
system or setting in storage for instance, will be less likely to
recover than a battery pack that was quickly discharged from a
short for instance. Store batteries in a cool environment for less
drainage.
Lithium Battery
1. Verify that the Memory Backup is Enabled with a jumper on the
upper two pins (1 & 2) of J1. J1 is located just beneath and a little left
of the RTD connector. (See Figure 5)
2. Verify that the LL (low lithium alarm) is not being displayed on the A7
annunciator (default). This alarm indicates the Lithium battery is
below 2.5 volts and should be replaced.

8
Solar Panel Installation
Totalflow
Materials
Supplied
•One Solar Panel and Cable
•Two U-Bolts and fastening hardware
•One Solar Panel Bracket
Customer
Materials
Supplied
•Cable Ties
•One 9-inch or greater extension of 2-inch pipe
•One 2-inch collar
Procedure:
Note: Step 1 and 2 are not required if pipe is tall enough without the
extension.
1. Attach 2-inch pipe collar to top end of
µ FLO mounting pipe.
Securely tighten. (See Figure 4)
2. Install a 2-inch pipe extension into collar and securely tighten.
3. Install Solar Panel on mounting bracket with provided hardware.
4. Attach Solar Panel mounting plate to top end of 2-inch pipe with U-
bolts and associated mounting hardware. Do not tighten U-bolts until
Solar Panel has been correctly oriented.
5. If needed, connect Solar Panel power cable to Solar Panel connector
on back of unit. DO NOT connect the other end of cable to
µ FLO
unit until all steps are complete AND main battery pack has been
connected.
6. Position Solar Panel to face south in the northern hemisphere and
north in the southern hemisphere. Tighten U-bolts securely to avoid
movement by wind or vibration.
7. Check solar panel polarity using digital voltmeter to insure (+) and (-)
wires are properly identified.
8. The Solar Panel power cable connects to terminal block J7 Charger
Input terminals (See Figure 5). Remove one of the hole plugs from
the
µ FLO enclosure and install cord connector. Remove nut,
sealing ring and rubber grommet from cord connector. Slide nut,
sealing ring and grommet over cable and insert cable through body
of cord connector. Allow enough power cable to extend into the unit
for connection to Charger Input +/- terminals.
9. Secure Solar Panel cable using grommet, sealing ring and nut.
TIP: To prevent moisture from entering the
µ FLO, allow cable to
"dip" below, and then rise to access hole. This will provide a path
for rainwater away from the access hole.

9
Solar Panel
Mounting Bracket
2 " Collar
2 " Extension Pipe
Flow Computer
Cable
Solar Panel
U - Bolts
Figure 4 (Solar Panel Mounting)

10
(+)
(-)
Figure 5 (
µ FLO Board Layout)
NOTE: For orientation purposes, only connectors and major
components are shown.

11
Figure 6 (RS-485 Termination Board
Figure 7 (RS-232 Termination Board)
Figure 8 (RS-422 Termination Board)
Figures 6, 7 and 8 are termination boards that plug into J3 of the
µ FLO board providing different communications options.
NO J2 SELECTIONS FOR
RS-422 COMMUNICATIONS
TERMINATION BOARD

12
Remote Communications
The following discussion deals primarily with communications between
the
µ FLO and Host (typically WinCCU).
To communicate with the Host, the
µ FLO has a remote communications
port that can function as RS232, RS485 or RS422. Depending on the
customer’s order, most units are shipped with an appropriate cable
between the 15-pin connector (J3) and the communication’s device such
as a radio. The other option is a termination board that plugs directly on
the 15-pin connector with appropriate terminals labeled. (See pages 10 &
11)
After installation of the
µ FLO and with the communications path
complete, the user needs to enter the appropriate communications
parameters. The
µ FLO was most likely shipped with Com1 set up for
Totalflow Remote Protocol. If not, select the protocol using the Entry
mode of PCCU32 as shown below. The protocol must be selected first
for the appropriate communications parameters to be displayed. A
blinking telephone pole symbol " " in annunciator position A8 (default)
indicates Com1 port is active. See Visual Alarm Codes on page 17 for a
full description of alarm characters, locations, and descriptions.
Other Communication Options
After selecting the protocol, verify the other communication parameters.
All communication parameters with the exception of modems are found
on the Setup and Advanced tabs. Modem parameters have there own
tab. Systems are shipped with default settings for communications but
may need fine tuning. The Schedule tab parameters are only required if
the user wants to power-up the communication’s port and
communication’s devices at designated times to conserve power.
Figure 9 (PCCU32 Entry Mode)

13
Communications Troubleshooting
A new radio or modem system that doesn’t communicate is difficult to
troubleshoot because proper operation has never been proven, and all
the initial hardware and software settings are suspect. More than one
problem can be present, causing component replacement to be an
inadequate trouble shooting technique. A checklist follows as an aid.
•Does the " " flash (Totalflow Remote Protocol only) with the Listen
Cycle time in the A8 display (default position)? If no,
1. The protocol needs to be selected in the Entry Mode using
PCCU32.
2. Inadequate 12 VDC battery voltage.
•Insure base radio is working for other locations.
•Verify Station ID and Device ID matches with WinCCU and is the
only flow computer with that ID.
•Verify Baud rate, Stop Bits, Security Code, and Listen Cycle time are
the same as WinCCU.
•Verify WinCCU is using Packet Protocol.
µ FLO Series devices only
support DB2 Packet Protocol.
•Verify a cable is in place from J3 on the
µ FLO electronics board to
the radio and a cable from the radio to the antenna.
•When using communications termination board, verify wiring to radio
or other communication’s device. Also verify setting for J2 on the
termination board. For RS232 set to DCD for Alarm Cryout feature.
(See page 11)
TIP: To check for wiring shorts or opens with two or more wire
connections, use a multimeter set on continuity (resistance).
Check two wires at a time from one device to another. If black
and white wires are to be tested, disconnect both wires at both
ends, put one probe on black, the other on white. The meter
should read OL or OFL (over range) if no shorts. Jumper the two
wires at the other end. The meter should read a low resistance if
no opens. This method requires only one end of wiring to be
tested, no matter how far the devices are apart.

14
•If a radio is used, verify directional antenna with correct frequency
range is pointed toward base (±6°). The antenna should be mounted
vertically, with the vanes perpendicular to the ground. Verify that the
radio is good, with the same frequencies used.
•If a modem is used, verify dial tone on line at the telephone
company’s termination box by checking Tip and Ring. Check wiring
from phone company’s box to dial-up modem. If cellular, also check
for proper Tip & Ring voltage available. Insure phone number is
correct in the
µ FLO and WinCCU.
NOTE: In the United States, telephone companies use a 48 volt power
supply so the typical on-hook voltage between the Tip and Ring
wires should be something less than 48 volts. Measuring another
way, Tip to ground is approx. zero volts and Ring to ground is
approx. –48 volts.
In the off-hook condition, Tip to ground will be approx. –20 volts
while Ring to ground will be approx. –28 volts or approx. 8 volts
between Tip and Ring.
Users in other countries will have to consult their local telephone
companies for voltage specifications.
Wiring
Specific wiring drawings are sent with each µ FLO, based on the options
ordered. Most wiring diagrams, including communications are available
on the web at http://www.abb.com/totalflow. Select “Continuing Customer
Service and Support”, and then select “Wiring Instructions”.
Communications pin-outs of the
µ FLO are shown on pages 10 and 11
of this guide.

15
Standard Displays
Items that appear on the device’s display are programmable by the user,
however based on the measurement application; units will be shipped
with some default display items. The following table is a typical set of
default displays for an AGA-3 application. Engineering units may vary
from those shown if device supports the “Selectable Units” feature.
Description Standard Display
Current Date and Time
24 hour clock
DATE/TIME
MM/DD/YY HH:MM:SS
Yesterday’s Percent DP Low Limit
Percent time below DP Low Set Point
Yest DP Low
NN PERCENT
Yesterday’s Percent DP High Limit
Percent time above DP High Set Point
Yest DP High
NN PERCENT
Current Flow Rate
Programmable SCF, MCF or MMCF
Flow Rate
NNNNNN.N SCF/HR
Total Accumulated Volume
Programmable SCF, MCF or MMCF
Total Accum. Volume
NNNNNN.NN MCF
Battery Voltage
Displayed in Volts
Battery Voltage
NN.N VOLTS
Station ID
ID of the box.
Station ID
Differential Pressure
Inches H2O
Diff. Pressure
NNN.N IN. H2O
Static Pressure Absolute
PSIA
Static Pressure
NNN.N PSIA
Flowing Temperature
°F
Temperature
NN.N DEG. F
Yesterday’s Volume
Programmable SCF, MCF or MMCF
Yesterday’s Volume
NNNN.N MCF
Previous Calculation Period Volume Last Calc. Volume
NNNN.N SCF
Device ID
Individual application ID
Device ID
Charger Voltage Charger
NN.N VOLTS
The duration that each parameter is displayed can vary from 1 to 255
seconds (default is 4 seconds); a setting of 0 seconds will turn that
display item off.

16
Visual Alarm & Status Codes
After the µ FLO completes recording Log Period flow and operational
records, the LCD will show any alarm conditions that have occurred.
Also, the date, hour and type of alarm conditions are stored in the
µ FLO’s memory. Status codes are also displayed when the conditions
exist. An alarm or status code can be a character, letter or symbol. The
alarm and status codes shown in Table 1 will appear on the right side of
the LCD screen; see illustration below. Descriptions of each code are
described in Table 1.
Figure 10 (Annunciator Locations)
Note: Applications in µ FLO Series devices can be assigned to any
annunciator. To verify the current assignments, see
Annunciators under Display in PCCU32’s Entry Mode. (See
Figure 11)
Figure 11 (Annunciator Assignments)
Table 1 Alarm & Status - Codes and Description

17
Alarm/
Status
Codes
Description
I/O Subsystem
LLLow Lithium Battery Alarm: When LL(low lithium) is displayed,
lithium battery voltage is below 2.5 VDC. A new lithium battery
measures approximately 3.6 VDC.
LCLow Charger: Displayed if battery charging voltage is less than
0.4 VDC greater than the battery voltage.
Communications
→Transmitting Data:
←Receiving Data:
! Nak. Negative Acknowledgement w/packet list.
+ Ack. Positive Acknowledge of receipt of request.
Waiting for Ack. Waiting for response after transmission.
? Exception Alarm Processing.
ID Recognized.
Listen Cycle. Flashes if this remote port is active and running
Totalflow Remote Protocol. Flashes in sync with listening
cycle that occurs at 1, 2 or 4 second intervals.
M MODBUS ASCII: Modbus ASCII protocol is selected for the
port assigned to this annunciator.
m MODBUS RTU: Modbus RTU protocol is selected for the port
assigned to this annunciator.

18
LLocal Protocol. Displayed when PCCU32 port is active and
running TOTALFLOW Local Protocol.
¥ Packet Protocol. The Totalflow Packet protocol is
selected for the port assigned to this annunciator.
R LevelMaster Protocol: The LevelMaster protocol is
selected for the port assigned to this annunciator.
Measurement Applications
BFBack Flow Condition: Visible only when the DP variable is
being displayed.
Z Zero Flow Condition: Visible only when the Flow Rate variable
is being displayed.
H Hold: Displayed when PCCU32 is in Calibration Mode
and has a measurement application in Hold mode.
A Alarm Condition. Need to view alarm. You may need to
compare application limits to current values to determine
where the alarm condition is present.
ADA to D Failure. Displayed if A to D Converter’s Differential
Pressure, Absolute Static Pressure or temperature readings
exceed maximum counts or are less than minimum counts.
Display Application
1A number represents the Display Group number currently
being displayed.
↑The displayed item’s value is above the Data High Limit value
specified on the display Item Setup screen.
↓The displayed item’s value is below the Data Low Limit value
specified on the display Item Setup screen.

19
TIP: If the Display Does Not Scroll As Expected
When power is first applied, the unit should quickly go through startup
and begin cycling through the pre-programmed display items. If the
display does not scroll after startup and/or looks similar to the following:
(Part numbers are for example only)
6200 µ FLO Boot Prom
2100917-001 (COPYRIGHT)
Disconnect the main power and then re-connect it. You should see
something similar to:
Verifying Flash
XXXXX
Checksum = XXXX
Verify Passed
or COLD BOOT
Flash 2100917-001
6213
µ FLO Flash
2100917-001 (COPYRIGHT)
If the display still doesn’t scroll, try disconnecting the power and re-
connecting it again. If still no success, do the following:
With PCCU32, connect to the unit and establish communications such as
Connect To Totalflow, Entry Mode, etc. Go into Terminal Mode and type
“0.0.0=COLD” (Do not enter quotes). The unit should go through a Cold
Start procedure and then begin scrolling. If this does not succeed, call
the number on the back of this guide and talk to a customer service
representative.

ABB Inc.
Totalflow Products
7051 Industrial Blvd.
Bartlesville, Oklahoma 74006
Tel: USA [phone]
International 001-918-338-4880