ABB Totalflow G5 Series User guide

Easy parts replacement in the
most accurate and reliable single
run gas flow computer
Introduction
This guide is designed for typical installations only. Maintenance must be performed
by personnel knowledgeable of the ABB Totalflow
®
µFLO
G5
flow computer, the
integral multivariable transducer (IMV), and the theory of natural gas electronic flow
measurement. Maintenance personnel must also be knowledgeable of local and
national codes as they apply to hazardous areas, communication wiring, and
electrical wiring.
Read and consider the contents of this guide prior to beginning installation of the
equipment. If for some reason there are questions that are not answered in this
guide, or other documentation listed in the following section, call the local ABB
representative, or call the main office number listed on the back page of this guide.
CAUTION – Equipment damage. The µFLO
G5
flow computer operating
temperature range differs from the µFLO
G4
. The µFLO
G5
is rated for
ambient temperatures between -40 °F and +158 °F (-40 °C and +70 °C).
Purpose
This guide provides easy-to-follow instructions for replacement of all available spare
part components.
Application guide
G5 flow computers
µFLOG5 (microFLOG5)
Component replacement instructions

Additional information
Additional free publications for the µFLOG5 are available for download at
www.abb.com/totalflow or by scanning this code:
µFLOG5 flow computer user manual 2105614
µFLOG5 flow computer startup guide 2105513
µFLOG5 upgrade kit 2105515
µFLOG5 flow computer data sheet 2102800
µFLOG5 (2104939 BD) wiring guide 2105507
µFLOG5 enclosure measurements 2105508
µFLOG5 I/O expansion board (2104395 BD) installation and wiring guide 2105506
µFLOG5 (2104939 BD) solar panel connection 2105509
NRTL/C (Class 1, Div 2) 60 °C 2015246
NRTL/C (Class 1, Div 2) 70 °C 2104615
ATEX Cert, EX II 3G, Ex nA IIB (Zone 2) 2104152
IECEx Cert, Ex nA IIB (Zone 2) 2100750
Assumptions
For any questions that are not answered in this guide or the other documentation
listed in the previous section, call the local ABB representative, or call the main office
number listed on the back page of this guide.
The following apply to the instructions in this guide:
— A µFLOG5 flow computer is already installed and the replacement parts are
suitable.
— The host computer is running PCCU32 version 7.58 or newer.
— Specific instructions about collecting data, shutting in the measurement sensor,
disconnecting the high and low input lines, and manifold connections are outside
the scope of this document. At the appropriate times, guidelines prompt when
these procedures are to be performed.

2105514-001 rev. AB | 3
1 Safety warning and note symbols
Read and follow the instructions contained in this guide before and during equipment
installation. Failure to do so could result in bodily injury or equipment damage.
IMPORTANT NOTE: Installation and maintenance must only be
conducted by personnel authorized to work on electrical installations,
and in accordance with relevant national and local codes.
1.1 Safety conventions
DANGER – Serious damage to health / risk to life. This symbol, in
conjunction with the signal word "DANGER", indicates an imminent
danger. Failure to observe this safety information will result in death or
severe injury. The text may state the hazard, how to avoid the hazard,
and what the result would be if not followed.
WARNING – Bodily injury. This symbol, in conjunction with the signal
word "WARNING", indicates a potentially dangerous situation. Failure
to observe this safety information may result in death or severe injury.
The text may state the hazard, how to avoid the hazard, and what the
result would be if not followed.
WARNING – Bodily injury. This symbol, in conjunction with the signal
word "WARNING", indicates a potentially dangerous electrical situation.
Failure to observe this safety information may result in severe injury.
The text may state the hazard, how to avoid the hazard, and what the
result would be if not followed.
CAUTION – Equipment damage. This symbol, in conjunction with the
signal word "CAUTION", indicates a potentially dangerous situation.
Failure to observe this safety information may result in minor or
moderate injury. The symbol may also be used for property damage
warnings. The text may state the hazard, how to avoid the hazard, and
what the result would be if not followed.
IMPORTANT NOTE: This symbol indicates useful information, important
information, or information to clarify a concept. The signal words
"IMPORTANT NOTE" do not indicate a dangerous or harmful situation.
1.2 Potential safety hazards
Pressurized natural gas is present in the measurement pipeline. Because of this, a
possibility exists for natural gas to escape from the pipeline or tubing during
installation or calibration, or following damage to the pipeline or tubing. Only properly
trained and authorized personnel should work in hazardous locations.
The flow computer operates on 9 - 30 Vdc. However, optional equipment may
convert power from alternating current to direct current. There are no hazardous
voltages present.

4 | 2105514-001 rev. AB
2 Overview
The µFLOG5 flow computer field-replaceable components are:
— I/O expansion board
— µFLOG5 electronic board
— µFLOG5 Transducer (differential or linear, without the µFLOG5 electronic board)
— µFLOG5 IMV assembly (complete)
2.1 Procedure overview
Disassembly and reassembly of the flow computer does not follow a linear pattern.
However, to present the procedures in a linear manner, the following table will assist
in determining which procedures will be required for component replacement, but not
necessarily the order in which they should be followed. (Table 1). Each procedure
will call out the specific section to be used in the order in which they should be used.
Table 1: Procedure and component instruction matrix
Section for procedures related to component
replacement Page
I/O expansion board µFLOG5 electronic board µFLOG5 transducer µFLOG5 IMV assembly
3.1 Preserving data and configuration files 5 
3.2 Disconnect power 5 
3.3 Restore power 6 
3.4.1 Remove the I/O expansion board 6 
3.4.2 Reinstall the I/O expansion board 8 
3.5.1 Remove the electronic board 10 
3.5.2 Reinstall the electronic board 12 
3.6.1 Remove the IMV assembly 12 
3.6.2 Reinstall the IMV Assembly 15 
3.7 Replacing the µFLOG5 transducer assembly (only) 17 
4 Considerations outside the scope of this document 18 
2.2 Requisite tools
The following list of items are necessary to perform these procedures:
— Phillips screwdriver
— Small slotted screwdriver
— ¼ inch hex driver
— ½ inch socket with ratchet

2105514-001 rev. AB | 5
3 Procedures
Prior to all component replacement procedures, the following sections must be
completed:
— 3.1 Preserving data and configuration files
— 3.2 Disconnect power
Completion of these two sections indicates that all files have been protected from a
loss of power and that the flow computer has been powered down and is deemed
safe.
3.1 Preserving data and configuration files
If local communication is still possible, collect data from the flow computer and back
up the station configuration files.
To back up the station files:
1. Collect all data. Use the Data collection procedure detailed in the user manual
listed earlier in the Additional information section of this guide.
2. If not previously done, update the TFCold (Cold) configuration with the running
(warm) configuration. Use the Delete and Re-create TFCold function of the
Update TFCold Start Configuration procedure which is detailed in the user
manual listed earlier in the Additional information section of this guide.
3. Back up all device software to the host computer operating PCCU32 software.
Use the Save the TFCold (Cold) configuration to the PC procedure detailed in
the user manual listed earlier in the Additional information section of this guide.
3.2 Disconnect power
CAUTION – Equipment damage. The external power/charger and
battery connections must be removed before removing all other cables,
boards, and field connections. Connecting or disconnecting cables and
wires on the electronic board while power is applied can damage the
electronic components.
To disconnect power from the µFLOG5 electronic board:
1. Disconnect the external power / charger connector from J17 (Figure 1).
2. Disconnect the battery cable plug from J15.
Figure 1: µFLOG5 electronic board power connections
(+)
(-)
1
2
J15 S1
SECURITY
ON
OFF
D8
D9 9-30 Vdc
BA TT
J17
BATTERY
EXT PWR / CHARGER
+–

6 | 2105514-001 rev. AB
3.3 Restore power
To restore power to the µFLOG5 electronic board, all cables and onboard and field
wiring connections should be complete. Do not restore power until ready to restart
the flow computer.
1. Reconnect the battery cable plug from J15.
2. Reconnect the external power / charger connector from J17 (Figure 1, on page
5).
3.4 Replacing the I/O expansion board
3.4.1 Remove the I/O expansion board
To remove the I/O expansion board:
1. Follow the procedure in section 3.1, Preserving data and configuration files, on
page 5. Return here when completed.
2. Follow the procedure in section 3.2, Disconnect power, on page 5. Return here
when completed.
3. If removing the I/O expansion board as part of another service procedure, it may
not be necessary to disconnect the field wiring. Otherwise, disconnect the
following field wiring connections on the I/O expansion board (Figure 2):
a. Communication wiring from J2
b. DI wiring from J9
c. DO wiring from J5
d. AI #1 wiring from J4
e. AI #2 wiring from J8.
IMPORTANT NOTE: Do not unplug the lithium battery connector from
the electronic board unless or until instructed to do so.
To maintain the continuity of the flow computer date and time stored in
RAM memory and for the purposes of record keeping, the lithium
battery must remain connected.

2105514-001 rev. AB | 7
J12
DO
+
-
DI
1
2
COMMUNICATIONS
+
-
1
2
J13
J10
S1
J8
J5
J2
J9
DI
DO
3
1
J7
3
1
J10
3
1
J6
J6/J10 CFG
1-2
2-3
0-20 mA
0-10 V
AI2
J4
AI1
WHEN OPERATING IN
RS-232 MODE
S1: 1 & 2 MUST
BE SET TO O FF
RS485/TBUS
RBUS
Bus
Ter m in at io n
ON
Communications
Expansion board
mounting screws
Expa nsi on b oard
mounting screws
Figure 2: µFLOG5 I/O expansion board
4. Use a small slotted screwdriver to loosen the four (4) mounting screws that
attach the I/O board to the µFLOG5 board. Alternate between the four screws,
one to two turns each. As the screws are loosened, the J2 connector is
gradually disconnected from the electronic board socket. The mounting screws
are held in place with a screw keeper.
5. Grasp the expansion board on either side and gently lift up from the µFLOG5
electronic board.
If only replacing the I/O expansion board, continue to section 3.4.2, Reinstall the I/O
expansion board, on page 8. Otherwise, set the board aside to reinstall at a later
time.

8 | 2105514-001 rev. AB
3.4.2 Reinstall the I/O expansion board
WARNING – Bodily injury and property damage. Wiring peripheral
devices to the flow computer electronic board should be performed
prior to applying power. Do not apply power until instructed to do so.
1. Fit the I/O expansion board connector (J1) onto the expansion port (J2) on the
electronic board, but do not push down to seat the expansion board.
Figure 3: µFLOG5 Board – J2 Connector
2. Using a small slotted screwdriver, begin turning each captive screw a few turns
each, moving sequentially to each of the 4 (four) corners of the board, to slowly
seat the board into the onboard connector. Continue until the board is fully
seated.
1
18 A
V
1
2
3
7
8
9
AB
CD
EFGHJ K
V
VI
I
V
VI
I
V
V
II
J7
987654321
S1
J6
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J11
6
5
4
3
2
1
S2
S5
S4
J16
J4
J9
J12
J8
J1
BA R COD E
TAG
DO
+
-
DI
1
2
RESET
WA RM WA KE
RESET
COLD
SH L D
(OUT)
(IN)
(-)
(+)
uSD
ACTI VITY LINK
ETH E RNE T
DISPLAY
MMI
USB
RESET
OFF
ON
SECURITY
R12
COMMUNICATIONS
S3
O
N
+
-
1
2
J13
J10
J3
RTD
1
2
1
2
3
S1
J8
J5
J2
J9
DI
DO
3
1
J7
3
1
J10
3
1
J6
J6/J10 CFG
1-2
2-3
0-20 mA
0-10 V
AI2
J4
AI1
WHEN OPERATING IN
RS-232 MODE
S1: 1 & 2 MUST
BE SET TO OFF
RS485/TBUS
RBUS Termination
ON
Fit the I/O card connector J1
into J2 on the board. Do not
push down to seat.
Gradua lly tighte n th e screw s, 2-3 hal f-
turns at a ti me. T ake turns,
sequentially, around the board until the
boar d is secure and the connector i s
properly seated.
The (4) captive screws at the corners
must be used tog ether to work the board
into its corr ect position.
J17
CHRG/
EXT
POWER
J15
12 V SLA BAT

2105514-001 rev. AB | 9
3. Reconnect field terminations, if removed:
a. Communication wiring from J2
b. DI wiring from J9
c. DO wiring from J5
d. AI #1 wiring from J4
e. AI #2 wiring from J8.
4. If performing additional procedures, return to those instructions. Otherwise,
follow the procedure in section 3.3, Restore power, on page 6.

10 | 2105514-001 rev. AB
3.5 Replacing the µFLOG5 electronic board
3.5.1 Remove the electronic board
This procedure is applicable only for the direct replacement of the µFLOG5 electronic
board. If removal of the electronic board is required during another procedure, those
instructions will be addressed in that procedure.
To remove the µFLOG5 electronic board:
1. Follow the procedure in section 3.1, Preserving data and configuration files, on
page 5. Return here when completed.
2. Follow the procedure in section 3.2, Disconnect power, on page 5. Return here
when completed.
3. Follow the procedure in section 3.4.1, Remove the I/O expansion board, on
page6. Return here when completed.
4. Disconnect the following, if connected, from the µFLOG5 electronic board:
a. LCD display cable from J8 connector.
b. Communication connections:
- MMI communication cable plug from J9
- USB cable plug from J4
- Ethernet cable plug from J1
c. Field wiring connections:
- Communication wiring from J10
- DI wiring from J12
- DO wiring from J13
- RTD sensor from J3
5. On the transducer housing assembly, use a phillips screwdriver to remove the
four (4) screws that attach the cover plate that contains the transducer
information. Remove and set the plate aside (Figure 4). The cover plate should
always stay with the IMV.
Static pressure sensor is on the
upstream (+ side) of DP sensor.
MADE IN U.S.A.
TOTALFLOW Products
Set f low computer SP tap
location to upstream.
2105263- __
IMV COMPLETE:
2104 60 0-00 9
PROCESS WETTED MATERIALS OF TRANSDUCERS CONFORM TO NACE MR-01-75
SENSOR ONLY (LOL NOTCRE): 2104797-0XX
SENSOR W/CONTROLLER BOARD INSTALLED: 21052634-5XX
CONTROLLER BOARD : 2104939-001
IN H2O
PSIA
Figure 4: Cover plate with transducer information
6. Using a ¼ inch hex driver, remove the six (6) hex standoffs that attach the
µFLOG5 electronic board to the transducer housing.