ABB Totalflow X Series User guide

XFC Series
RC
X
/
X
Start-Up Guide
SERIES

2
Introduction:
This startup guide is to assist in the startup of any flow computer or
remote controller of the XFC (flow computer) or XRC (remote controller)
series. It is however, primarily intended for gas orifice applications. It is
hoped that this guide in conjunction with other drawings and
documentation that accompanies your order will result in a smooth
installation. If for some reason, you have questions that are not
answered in this guide or your other documentation, call your local
Totalflow representative or call the number listed on the back page of
this guide.
Installation & 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.
Physical mounting and piping:
1. Unpack
2. Inspect for damage and missing or incorrect components.
3. Determine where to mount the unit.
4. Install bracing for unit; (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 unit; Right port of unit is NORMALLY
high pressure (upstream side). Check the AMU model number to see
if it is designed for flow from left to right (4CYC) or right to left
(4AYC). You can also look on the transducer for (H or +) for high
side and (L or –) for low side. 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 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 3 (Typical Manifold Mount)
Figure 2 (Pipe Mount)

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Install RTD Probe:
7. Install RTD and connect wiring to connector block J7 on the XFC
board. The XRC board does not have RTD inputs. (See Figure 5)
Install Battery(s):
8. Verify that Memory Backup is Enabled. This is J13 on the XFC and
J1 on the XRC. (See Figures 5 & 6)
9. Mount and connect a fully charged battery to J1 on the XFC board or
J16 on the XRC board. The connectors are located in the same
position on both boards. (See Page 7 & Figures 5 & 6)
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
(upper right) annunciator since the charging source has not been
connected. This is the typical annunciator for the I/O Subsystem but
could possibly 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 LCcode 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,
system must have been ordered from factory as single tube
application and with FS/2 support. PCCU32 must have software
Version 4.3 or higher and FS/2 must be 2018583-007 or higher.
13. Set date/time, ID, location and 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.

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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 unit 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 using PCCU.
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. This procedure is for the XFC; the
XRC does not have RTD inputs.
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 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 J7.
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 XFC’s RTD connector as follows: Before
making connections to terminal block, remove spade lugs if attached
and trim wire ends back 1/4". Remove J7 terminal block from the
XFC main electronics board. (See Figure 5)
6. Loosen terminal block securing screws, insert wire and then
retighten. Reinstall terminal block with wires attached.

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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. Remove the unit’s battery cover plate and insert battery pack into
battery compartment. Insert battery pack with its long dimension
facing outward. When cover plate is reinstalled, it will fit snugly
against some battery packs. The screws can be loosened to
accommodate large batteries.
3. Connect battery pack connector to main electronics board Battery
connector J1 on XFCs or J16 on XRCs, located in upper right corner
of Board.
4. Observe LCD, the display should power up displaying Warm Start
information and begin scrolling through the default display items.
5. 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 of J13 on the XFC or J1 on the XRC.
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.
AMU
Bracket
Battery
Communications
Enclosure
AMU
Bracket
Battery

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 XFC or XRC 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 the cable to the
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 XFC terminal block J5 or
XRC terminal block J17 Charger Input terminals. Refer to Figure 5
or 6 for terminal locations. Remove one of the hole plugs 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 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 unit, allow cable to "dip"
below, and then rise to access hole. This will provide a path for
rainwater away from the access hole.

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

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Figure 5 (XFC Layout)
NOTE: Refer to Wiring Interconnect drawing 2015225-WI for more
information on communications wiring.

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Figure 6 (XRC Layout)
NOTE: Refer to Wiring Interconnect drawing 2015225-WI for more
information on communications wiring.

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Remote Communications
The following discussion deals primarily with the unit communicating with
the Host (typically WinCCU).
To communicate with the Host, the XFC or XRC has remote
communication’s ports that can function as RS232, RS485 or RS422.
Depending on the customer’s order, most units are shipped with the
appropriate wiring in place for the specified communication’s equipment.
After installation of the unit and with the communications path complete,
the user needs to enter the appropriate communication’s parameters.
The unit was most likely shipped with Comm 1 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
Comm 1 port is active.
The data bits, stop bits and all required communications parameters can
be modified with PCCU32. Units will typically be shipped with correct
default comm port settings but may need fine tuning for optimum
operation.
Warning: As opposed to the XRC, the XFC has only one Switched V-
Batt/Operate line; if it is needed, Enable it only on one Comm Port even
though both ports may require its use. The V-Batt/Operate line will switch
on/off at the Listen Cycle timing of the port that enabled it.
Figure 7 (PCCU32 Entry Mode)

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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. Use the following checklist 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) The communication’s module in Comm 1 or Comm 2 is missing
or bad or the module is the wrong type (RS232 or RS485).
Note: Comm 1 and Comm 2 are in opposite locations when
compared to the previous electronics board (2015333).
3) 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 Totalflow device with that ID.
•Verify Baud rate, Stop Bits, Security Code, and Link Establishment
time are same as CCU.
•Verify WinCCU is using Packet Protocol. X Series devices support
only DB2 Packet Protocol.
•Verify wiring to antenna, to UCI, UCI to Radio for RS485 installation
or to Radio/Modem for RS232 installation.
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 unit to another. If black and
white wires are to be tested, disconnect both wires at both ends,
set 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 units are apart.

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•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 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. Insure that the phone number is
correct in the unit and WinCCU.
NOTE: Telephone companies in the United States typically use a 48
volt power supply so the 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 need to consult with their local
telephone company.
Wiring
Specific wiring drawings are sent with each unit, 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 XFC and XRC are shown on pages 10
and 11 of this guide.

15
Standard Displays
Items that appear on the unit’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 the unit 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 unit completes recording of 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
device’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 8 (Annunciator Locations)
Note: Applications in X Series devices can be assigned to any
annunciator. To verify the current assignments, see Annunciators under
Display in PCCU32’s Entry Mode. (See Figure 9)
Figure 9 (Annunciator Assignments)

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Table 1 Alarm & Status - Codes and Description
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 the 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.

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M MODBUS ASCII: Modbus ASCII protocol is selected for this
port.
m MODBUS RTU: Modbus RTU protocol is selected for this
port.
L Local Protocol: Displayed when PCCU32 port is active and
running Totalflow Local Protocol.
¥ Packet Protocol: Totalflow Packet Protocol is active on this
port.
R LevelMaster Protocol: LevelMaster protocol is selected for
this port.
Valve Control
V Valve Control: Displayed when the Valve Control option is
installed and no other Valve Control symbols are valid.
= Valve Control: Valve Control option installed. Process Value
(PV) is within the user set dead band. No control action
required.
⎡Valve Control: Valve Control option installed. Valve is in full
open position.
⎦Valve Control: Valve Control option installed. Valve is in full
closed position.
↑Valve Control: Valve Control option installed. Valve is opening
(open signal is being sent to valve actuator).
↓Valve Control: Valve Control option installed. Valve is closing.
(Close signal is being sent to valve actuator).
ÖValve Control: Valve Control option installed. Valve controller
override conditions met (DP/SP override set point or Low
Battery).
LLValve Control: Valve Control option installed. Local Lock-out
is initiated.

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Measurement Applications
BFBack Flow Condition: Visible only when DP variable
displayed.
Z Zero Flow Condition: Visible only when Flow Rate 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.
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)
2100204 Boot/Loader PROM
2100809-002 (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 2100826-003
X Series Flow Computer
2100826-003 (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 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