ABB XSeries G4 6200 User manual

Totalflow product line
Proprietary information
© Copyright 2018 ABB, All rights reserved.
2104349 (AD)
User manual
XSeries G4 6200/6201EX Flow Computer
2104349 ver. AD

Intellectual property & copyright notice
©2018 by ABB Inc., Totalflow (“Owner”), Bartlesville, Oklahoma 74006, U.S.A. All rights reserved.
Any and all derivatives of, including translations thereof, shall remain the sole property of the Owner, regardless
of any circumstances.
The original US English version of this manual shall be deemed the only valid version. Translated versions, in
any other language, shall be maintained as accurately as possible. Should any discrepancies exist, the US
English version will be considered final.
Notice: This publication is for information only. The contents are subject to change without notice and should not
be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by
Owner.
Inquiries regarding this manual should be addressed to ABB Inc., Totalflow Products, Technical
Communications, 7051 Industrial Blvd., Bartlesville, Oklahoma 74006, U.S.A.
Trademark Ownership
Windows® is a registered trademark of Microsoft
Teflon® is a registered trademark of Dupont

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Table of contents
Introduction...........................................................................................................................................x
Organization & style..................................................................................................................................x
Getting help ..............................................................................................................................................x
Before you call............................................................................................................................x
Key symbols .............................................................................................................................................x
Safety practices and precautions.............................................................................................................xi
Safety guidelines...................................................................................................................... xii
Safety first ................................................................................................................................ xii
Equipment markings.................................................................................................................xiii
Grounding the product..............................................................................................................xiii
Operating voltage.....................................................................................................................xiii
Danger from loss of ground......................................................................................................xiii
Safe equipment....................................................................................................................... xiv
Fuse replacement.................................................................................................................... xiv
Compliance............................................................................................................................................ xiv
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE).................... xiv
1System description .............................................................................................................1–1
1.1 Overview ................................................................................................................................1–1
1.1.1 Capabilities...............................................................................................................1–2
1.1.2 Functionality.............................................................................................................1–2
1.1.3 Flow computer calculations......................................................................................1–3
1.1.4 Log period records...................................................................................................1–4
Display function........................................................................................................1–5
1.1.6 Display annunciators................................................................................................1–5
1.2 Computer hardware................................................................................................................1–7
1.2.1 Enclosure.................................................................................................................1–8
1.2.2 G4 EX main processor board.................................................................................1–10
1.2.3 G4 EX termination board........................................................................................1–12
1.2.4 Explosion proof multivariable transducer (EXIMV).................................................1–17
1.2.5 Display assembly...................................................................................................1–19
1.2.6 Resistive temperature detector (RTD)....................................................................1–19
1.2.7 6270 Optional Equipment Unit (OEU)....................................................................1–20
1.2.8 Solar panel.............................................................................................................1–21
1.2.9 Lithium battery........................................................................................................1–22
1.3 G4 EX application licensing..................................................................................................1–22
1.3.1 Credit Key (USB)....................................................................................................1–24
1.4 Laptop computer running PCCU32 ......................................................................................1–24
1.5 Local G4 EX connectors.......................................................................................................1–25
1.5.1 RS-232 serial PCCU cable (round military cable) ..................................................1–25
1.5.2 PCCU32 USB connection ......................................................................................1–25
1.5.3 Bluetooth connectivity ............................................................................................1–26
1.5.4 Network connectivity (dynamic IP with router)........................................................1–26
2Installation............................................................................................................................2–1
2.1 Unpacking and inspection ......................................................................................................2–1
2.1.1 Unpacking................................................................................................................2–1
2.1.2 Inspection.................................................................................................................2–1
2.1.3 Damaged components.............................................................................................2–1
2.2 2” Pole mount installation .......................................................................................................2–1
2.2.1 Type A......................................................................................................................2–2
2.2.2 Type B......................................................................................................................2–3
2.2.3 Type C .....................................................................................................................2–4
2.2.4 Manifold input lines ..................................................................................................2–6

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2.2.5 Standard RTD probe installation ..............................................................................2–7
2.2.6 Explosion proof RTD probe assembly......................................................................2–8
2.2.7 6270 Optional Equipment Unit (OEU) installation ..................................................2–10
2.2.8 Battery Pack Installation.........................................................................................2–12
2.2.9 Lithium battery installation......................................................................................2–13
2.2.10 Solar panel installation...........................................................................................2–14
2.2.11 AC charging unit installation...................................................................................2–16
2.2.12 Uninterrupted power supply (UPS) to the G4 EX ...................................................2–18
3G4 EX start-up ......................................................................................................................3–1
3.1 PCCU32 installation and setup...............................................................................................3–1
3.1.1 Step-by-step instructions..........................................................................................3–1
3.2 Establishing local communication...........................................................................................3–1
3.2.1 Connecting to a local port via a RS-232 cable .........................................................3–2
3.2.2 Connecting to local USB port ...................................................................................3–3
3.2.3 Setup of the G4 EX for Bluetooth connectivity .........................................................3–5
3.2.4 Setup of the G4 EX for Ethernet connectivity...........................................................3–7
3.3 Setting up the G4 EX............................................................................................................3–13
3.3.1 Date/time................................................................................................................3–13
3.3.2 Station ID ...............................................................................................................3–14
3.3.3 Location..................................................................................................................3–14
3.4 Security system....................................................................................................................3–14
3.4.1 Device legacy bi-level security...............................................................................3–14
3.4.2 WinCCU32 software security .................................................................................3–16
3.4.3 Role Based Access Control (RBAC) ......................................................................3–17
3.5 Application licensing Credit Key ...........................................................................................3–25
3.5.1 Credit Key driver installation...................................................................................3–25
3.5.2 Access/view the Credit Key with PCCU32 7.0 (or later).........................................3–25
3.5.3 Adding credits to the Credit Key by telephone .......................................................3–27
3.5.4 Transferring credits to the G4 EX from the Credit Key...........................................3–28
3.5.5 Transferring Credits to the Credit Key from the G4 EX ..........................................3–29
3.6 G4 EX configuration .............................................................................................................3–30
3.6.1 Contact hour...........................................................................................................3–30
3.6.2 Log period..............................................................................................................3–31
3.6.3 Volume calculation period......................................................................................3–31
3.6.4 Calculated method .................................................................................................3–31
3.6.5 Supercompressibility calculation (Fpv)...................................................................3–32
3.6.6 Constants...............................................................................................................3–33
3.6.7 Alarm Limits ...........................................................................................................3–34
3.6.8 Reset Volume.........................................................................................................3–34
3.7 Start Up the G4 EX...............................................................................................................3–35
3.7.1 Putting the G4 EX On Line.....................................................................................3–35
3.7.2 Setting G4 EX Temperature Calculation ................................................................3–35
3.8 G4 EX Standard Displays.....................................................................................................3–35
3.8.1 Program Display.....................................................................................................3–35
4G4 ex Maintenance...............................................................................................................4–1
4.1 Overview ................................................................................................................................4–1
4.1.1 Maintenance Support...............................................................................................4–1
4.1.2 How to Use This Chapter.........................................................................................4–1
4.1.3 Cleanliness...............................................................................................................4–1
4.1.4 Front Mounted LCD..................................................................................................4–1
4.1.5 Returning Parts for Repair........................................................................................4–1
4.2 Backing Up Configuration Files ..............................................................................................4–1
4.2.1 Step-by-step instructions..........................................................................................4–2

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4.3 Restoring Configuration Files.................................................................................................4–2
4.3.1 Step-by-Step Instruction...........................................................................................4–2
4.4 Performing a Warm Boot........................................................................................................4–2
4.4.1 Hardware Warm Boot...............................................................................................4–2
4.4.2 Software Warm Boot................................................................................................4–3
4.5 Performing a Cold Boot..........................................................................................................4–4
4.5.1 Hardware Cold Boot.................................................................................................4–4
4.5.2 Software Cold Boot..................................................................................................4–5
4.6 Changing the G4 EX Clock.....................................................................................................4–6
4.6.1 Clock Change Not Crossing an Hour Boundary.......................................................4–6
4.6.2 Forward Clock Change Crossing an Hourly Boundary.............................................4–6
4.6.3 Backward Clock Change Crossing an Hourly Boundary..........................................4–6
4.7 Replacing the G4 EX battery Pack........................................................................................4–6
4.7.1 Step-by-step instructions..........................................................................................4–7
4.8 Replacing the G4 EX board....................................................................................................4–8
4.8.1 Step-by-step instructions..........................................................................................4–9
4.9 Replacing the G4 EX termination board...............................................................................4–13
4.9.1 Step-by-step instructions........................................................................................4–13
4.10 Replacing the Liquid Crystal Display (LCD) board ...............................................................4–15
4.10.1 Step-by-step instructions........................................................................................4–15
4.11 Replacing the lithium battery ................................................................................................4–16
4.11.1 Step-by-step instructions........................................................................................4–16
4.12 Replacing the transducer (EXIMV).......................................................................................4–17
4.12.1 Step-by-step instructions........................................................................................4–17
4.13 Calibration............................................................................................................................4–19
4.13.1 Required test equipment........................................................................................4–19
4.13.2 Hold mode..............................................................................................................4–20
4.13.3 Static pressure (SP) calibration checks..................................................................4–20
4.13.4 Differential pressure (DP) calibration checks .........................................................4–22
4.13.5 Calibrating static pressure (SP)..............................................................................4–23
4.13.6 Calibrating differential pressure (DP) .....................................................................4–25
4.14 Onboard I/O calibration overview .........................................................................................4–26
4.14.1 Hold mode..............................................................................................................4–26
4.14.2 Calibrating onboard analog inputs..........................................................................4–26
4.14.3 Onboard pulse and digital inputs............................................................................4–27
4.15 Zero transducer....................................................................................................................4–28
4.15.1 Static pressure.......................................................................................................4–28
4.15.2 Differential pressure...............................................................................................4–28
4.16 RTD calibration and bias......................................................................................................4–28
4.16.1 Step-by-step instructions........................................................................................4–29
4.16.2 Calibrating RTD temperature bias..........................................................................4–30
4.17 Changing the orifice plate.....................................................................................................4–30
4.17.1 Taking meter run out of service (simplex fitting).....................................................4–30
4.17.2 Leaving meter run in-service procedure (senior fitting)..........................................4–31
5Troubleshooting ..................................................................................................................5–1
5.1 Overview ................................................................................................................................5–1
5.1.1 Troubleshooting support ..........................................................................................5–1
5.1.2 Visual alarm codes...................................................................................................5–1
5.1.3 Sleep mode..............................................................................................................5–1
5.1.4 Solar panel...............................................................................................................5–1
5.1.5 Communication........................................................................................................5–1
5.2 Troubleshooting visual alarm codes.......................................................................................5–2

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5.2.1 Troubleshooting a blank LCD screen.......................................................................5–4
5.2.2 Troubleshooting a Low Lithium alarm (LL)...............................................................5–4
5.2.3 Troubleshooting an Analog to Digital Failure alarm (AD) .........................................5–4
5.2.4 Resistive Temperature Detector (RTD) Continuity test ............................................5–6
5.2.5 RTD Current Source (Resistive) test........................................................................5–6
5.2.6 RTD Impedance test ................................................................................................5–7
5.3 Power troubleshooting............................................................................................................5–8
5.3.1 Overview..................................................................................................................5–8
5.3.2 Power supply test.....................................................................................................5–8
5.3.3 Charger Circuit test ..................................................................................................5–9
5.3.4 Solar panel charging system test ...........................................................................5–10
5.3.5 AC charging system unit test..................................................................................5–11
5.3.6 Auxiliary equipment isolation test...........................................................................5–12
5.3.7 Sleep mode............................................................................................................5–13
5.3.8 Reset procedures...................................................................................................5–13
5.4 Communications troubleshooting .........................................................................................5–14
5.4.1 Overview................................................................................................................5–14
5.4.2 Setting up communication......................................................................................5–15
5.4.3 Transceiver supply voltage test..............................................................................5–16
5.4.4 6270 OEU supply voltage test................................................................................5–16
5.4.5 Transceiver check..................................................................................................5–17
5.4.6 Termination board supply voltage test....................................................................5–17
5.4.7 RS-232 communication..........................................................................................5–18
5.4.8 RS-232 termination board test ...............................................................................5–18
5.4.9 RS-232 OEU termination strip test.........................................................................5–19
5.4.10 RS-485 communication test ...................................................................................5–20
5.4.11 RS-485 termination board test ...............................................................................5–20
5.4.12 RS-485 OEU termination strip test.........................................................................5–22
6Reference material.................................................................................................................23
6.1 Reference materials on ABB/Totalflow website........................................................................23
6.2 I/O daughter card......................................................................................................................24
6.2.1 Materials supplied in the upgrade kit..........................................................................24
6.2.2 I/O daughter card specifications.................................................................................24
6.2.3 Installation..................................................................................................................24
6.2.4 Upgrading the flash....................................................................................................25
6.2.5 Unit operating status shut down instructions..............................................................26
6.2.6 Internal PCCU connector disassembly (if installed)....................................................26
6.2.7 I/O daughter card installation .....................................................................................26
6.2.8 Internal PCCU connector reassembly (if previously installed)....................................28
6.2.9 Implementation...........................................................................................................28
6.3 4–20 milliamp transmitters........................................................................................................34
6.3.1 Powering 4–20 Milliamp Transmitters ........................................................................34
6.3.2 Example 1 ..................................................................................................................36
6.3.3 Example 2 ..................................................................................................................36
6.3.4 Conclusion .................................................................................................................36

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Table of figures
Figure 1–1 Typical G4 EX installation ................................................................................................1–2
Figure 1–2 Liquid Crystal Display (LCD) and indicators.....................................................................1–6
Figure 1–3 G4 EX enclosure ..............................................................................................................1–9
Figure 1–4 G4 EX enclosure left side.................................................................................................1–9
Figure 1–5 G4 EX enclosure right side.............................................................................................1–10
Figure 1–6 G4 EX main processor board.........................................................................................1–11
Figure 1–7 G4 EX termination board................................................................................................1–13
Figure 1–8 Typical DI point schematic .............................................................................................1–14
Figure 1–9 DI connection example...................................................................................................1–14
Figure 1–10 DI connection example.................................................................................................1–15
Figure 1–11 Typical DO point schematics........................................................................................1–16
Figure 1–12 DO connection example...............................................................................................1–16
Figure 1–13 Typical AI point schematic............................................................................................1–17
Figure 1–14 AI example connections...............................................................................................1–17
Figure 1–15 Explosion proof multivariable transducer (EXIMV) ......................................................1–18
Figure 1–16 Liquid Crystal Display (LCD) assembly........................................................................1–19
Figure 1–17 Explosion proof RTD....................................................................................................1–20
Figure 1–18 Optional communication enclosure..............................................................................1–21
Figure 1–19 Solar panel –typical installation...................................................................................1–22
Figure 1–20 RS-232 local communication cable..............................................................................1–25
Figure 1–21 USB local communication cable...................................................................................1–26
Figure 1–22 Ethernet communication cable.....................................................................................1–27
Figure 1–23 Ethernet connectivity diagram......................................................................................1–27
Figure 2–1 Type A Installation Configuration .....................................................................................2–3
Figure 2–2 Type B Installation Configuration .....................................................................................2–4
Figure 2–3 Type C installation configuration......................................................................................2–5
Figure 2–4 G4 EX EXIMV ports..........................................................................................................2–6
Figure 2–5 Thermowell installation into the meter run .......................................................................2–7
Figure 2–6 RTD probe wiring .............................................................................................................2–8
Figure 2–7 Explosion proof RTD overview.........................................................................................2–8
Figure 2–8 Explosion proof RTD disassembled.................................................................................2–9
Figure 2–9 RTD probe wiring ...........................................................................................................2–10
Figure 2–10 6270 OEU pipe mounting installation...........................................................................2–11
Figure 2–11 6270 OEU wall mount installation ................................................................................2–12
Figure 2–12 6270 OEU enclosure....................................................................................................2–13
Figure 2–13 Lithium battery..............................................................................................................2–14
Figure 2–14 Solar panel installation.................................................................................................2–15
Figure 2–15 AC charger installed.....................................................................................................2–17
Figure 2–16 AC charger outlet box installation ................................................................................2–17
Figure 2–17 AC charger inside the conduit enclosure .....................................................................2–18
Figure 2–18 G4 EX to UPS ..............................................................................................................2–19
Figure 3–1 System Setup Screen.......................................................................................................3–2
Figure 3–2 Windows found new hardware wizard..............................................................................3–3

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Figure 3–3 Specific location selection window....................................................................................3–4
Figure 3–4 Specify location for USB driver (Totalflow.inf)..................................................................3–4
Figure 3–5 System setup - Bluetooth..................................................................................................3–6
Figure 3–6 Select a Bluetooth device dialog box................................................................................3–6
Figure 3–7 System Setup dialog box - Bluetooth ...............................................................................3–7
Figure 3–8 Network tab.......................................................................................................................3–8
Figure 3–9 Communication setup.......................................................................................................3–9
Figure 3–10 System Setup window ..................................................................................................3–10
Figure 3–11 Windows desktop Shortcut dialog box..........................................................................3–11
Figure 3–12 Network tab...................................................................................................................3–12
Figure 3–13 System setup................................................................................................................3–13
Figure 3–14 Station Setup tab ..........................................................................................................3–15
Figure 3–15 Security Setup dialog box.............................................................................................3–16
Figure 3–16 WinCCU32 Edit a Device ID dialog box .......................................................................3–17
Figure 3–17 Role administration menu path.....................................................................................3–18
Figure 3–18 Security Editor dialog box.............................................................................................3–18
Figure 3–19 Roles dialog box ...........................................................................................................3–19
Figure 3–20 User Name and Password dialog box ..........................................................................3–20
Figure 3–21 System Setup dialog box..............................................................................................3–20
Figure 3–22 Send Role Based Access Control File dialog box........................................................3–21
Figure 3–23 Totalflow-TCP Setup tab...............................................................................................3–21
Figure 3–24 Login dialog box............................................................................................................3–22
Figure 3–25 System Setup dialog box..............................................................................................3–23
Figure 3–26 Security Log tab............................................................................................................3–24
Figure 3–27 Credit Key License Utility..............................................................................................3–26
Figure 3–28 Credit Key License Utility –Status ...............................................................................3–26
Figure 3–29 Application Credit Key entry screen .............................................................................3–27
Figure 3–30 Application Credit verification codes.............................................................................3–28
Figure 3–31 App Licensing tab .........................................................................................................3–29
Figure 3–32 Transfer to Credit Key...................................................................................................3–30
Figure 4–1 Reset Button Location ......................................................................................................4–3
Figure 4–2 Lithium battery Connector.................................................................................................4–5
Figure 4–3 6270 OEU Configuration...................................................................................................4–7
Figure 4–4 G4 EX Front End Exploded View......................................................................................4–9
Figure 4–5 Termination board...........................................................................................................4–10
Figure 4–6 G4 EX board ...................................................................................................................4–11
Figure 4–7 G4 EX board Secondary Component Side.....................................................................4–12
Figure 4–8 G4 EX Back End Exploded View....................................................................................4–13
Figure 4–9 Termination board secondary component side ..............................................................4–14
Figure 4–10 EXIMV installation overview .........................................................................................4–17
Figure 4–11 G4 EX with block manifold............................................................................................4–18
Figure 4–12 Calibration diagram.......................................................................................................4–22
Figure 4–13 RTD calibration screen .................................................................................................4–29
Figure 5–1 Troubleshooting flowchart.................................................................................................5–2

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Figure 5–2 LCD and indicators...........................................................................................................5–3
Figure 5–3 Power supply –G4 EX termination board........................................................................5–4
Figure 5–4 G4 EX termination board..................................................................................................5–9
Figure 5–5 6270 OEU charger regulator..........................................................................................5–11
Figure 5–6 Current measurement troubleshooting cable.................................................................5–12
Figure 5–7 Communication troubleshooting flow chart....................................................................5–15
Figure 5–8 OEU termination strip.....................................................................................................5–20
Figure 6–1 Termination panel with I/O daughter card installed............................................................25
Figure 6–2 32-Bit Loader screen..........................................................................................................25
Figure 6–3 I/O Interface screen............................................................................................................27
Figure 6–4 I/O daughter card ...............................................................................................................28
Figure 6–5 Generic Wiring Diagram.....................................................................................................29
List of tables
Table 1–1 XFC family genealogy .......................................................................................................1–1
Table 1–2 Typical G4 EX display options...........................................................................................1–5
Table 1–3 Default annunciator locations............................................................................................1–6
Table 1–4 G4 EX status and alarm description..................................................................................1–6
Table 1–5 G4 EX main processor board specifications ...................................................................1–11
Table 1–6 Explosion proof EXIMV specifications.............................................................................1–18
Table 1–7 Standard RTD probes......................................................................................................1–20
Table 1–8 Standard Thermowells.....................................................................................................1–20
Table 3–1 Configurable calculation factors ......................................................................................3–31
Table 3–2 Fpv analysis data.............................................................................................................3–32
Table 3–3 Gas Orifice Constants .....................................................................................................3–33
Table 3–4 Alarm Limits.....................................................................................................................3–34
Table 3–5 G4 EX Displayed Items ...................................................................................................3–35
Table 4–1 Calibration configurable parameters ...............................................................................4–19
Table 5–1 Visual alarm codes............................................................................................................5–3
Table 5–2 Specifications for solar panels.........................................................................................5–10
Table 5–3 RS-232 field wiring on the G4 EX termination board ......................................................5–18
Table 5–4 RS-485 field wiring on the G4 EX termination board ......................................................5–21

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Introduction
This manual is designed to provide an experienced flow meter technician with the
requirements necessary to install, set up and operate a Totalflow XFCG4
6200/6201EX.
Organization & style
Each of the chapters in this manual presents information in an organized and
concise manner. Readers are able to look at the headings and receive a broad
picture of the content without reading every word. Also, there are overviews at the
beginning of each chapter that provides the user with an idea of what is in the
chapter and how it fits into the overall manual.
Readers will also note that each heading level number is formatted to include the
chapter, section, and subsection numbers. E.g. 4.15.2 indicates that the reader is
reading subsection 2 of section 15 in chapter 4.
Getting help
At Totalflow, we take pride in the ongoing support we provide our customers.
When you purchase a product, you receive documentation which should answer
your questions; however, Totalflow Technical Support provides you an 800
number as an added source of information.
If you require assistance, call:
USA: [phone] International: 001-918-338-4888
Before you call
- Know your Totalflow’s model and serial number. Serial numbers can be
found on a plate located on each unit.
- Be prepared to give the customer service representative a detailed
description of the problem.
- Note any alarms or messages as they appear.
- Prepare a written description of problem.
- Know your software version, board and optional part numbers.
Key symbols
The following symbols may be used frequently in this manual. These are intended
to catch your eye and draw your attention to important information.
Intended to draw your attention to useful information or to
clarify a statement made earlier.
Intended to draw your attention to a fact that may be useful or
helpful in understanding a concept.