ABB XFC6200EX User guide

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MADE IN U. S.A.
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Introduction
This startup guide is to assist in the startup of the XFC6200EX flow
computer. 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 25 is a recommended start-up sequence and some of
the steps do not go into any great detail. Some steps because detail is
not required and some because more information is available later in the
Start-Up Guide. For example there are later topics such as installing the
RTD, batteries, solar panel etc. So, scan through the guide to see what
information is available before you begin the installation.
1. Unpack the XFC6200EX and 6270 OEU (Optional Equipment Unit) if
purchased. Inspect for damage and missing or incorrect
components.
2. Determine where to mount the 6200EX and OEU. Install the 6200EX
first and the OEU will be covered later. The 6200EX is rated for
Division 1, but the OEU must be installed in a Division 2 or General
Purpose area.
3. Install the support for the 6200EX (pipe saddle, direct mount,
standalone pipe, etc.). If mounting pipe to meter run, use a saddle
mount kit as shown in Fig. 1. Different size Saddle Mount kits are
available based on the meter run size. If mounting the 6200EX to a
pipe, use the 2-piece bracket Mtg. kit (Pt. # 210193) as shown in Fig.
2. Attach the side mount bracket to the 2” pipe with the two U-bolts
and then attach the 6200EX Mtg. bracket with available hardware.
The 6200EX can be on either side of the pipe depending on how the
side mount bracket is mounted (See Fig. 1). Use silicone spray or
Teflon tape to prevent galling of threads.
4. The method of mounting the 6200EX using the bracket mounting kit
depends on whether a discrete or block manifold is used. For
discrete manifolds, mount the 6200EX directly to the bracket as
shown in Figure 1 and then screw the tubing from the discrete
manifold into the bottom of the 6200EX’s transducer. If a block
manifold is used, sandwich the manifold between the 6200EX’s
transducer and the top of the bracket as shown in Figure 3. Block
manifolds as shown in Figure 3 can be mounted with four bolts
inserted up through the bottom of the bracket, through the manifold
and into the threaded holes of the 6200EX transducer. Larger block
manifolds with flanges on top and bottom will require separate
hardware to mount the manifold to the 6200EX’s transducer and then

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mount the manifold to the mounting bracket. Do not forget to install
the o-ring flange seals in the recessed grooves on the block manifold
flange(s).
To verify direction of flow, look at the (+) and (-) signs on the
transducer tag. Plus(+) indicates high side (upstream) and (-)
indicates the low side (downstream), therefore flow is from (+) to (-).
If this causes the device to face the wrong direction, loosen the Allen
Head set screw on the neck of the device and with the hands turn
the unit clockwise until the unit is facing the correct direction. If the
unit gets tight before achieving the correct position, turn counter-
clockwise (no more than 360 degrees) until the correct position is
obtained; then re-tighten the set screw.
Figure 1 (Typical Installation)
Saddle
Meter Run
2" Mounting Pipe
2 - Piece
Mounting Bracket
MADE IN U.S.A.
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Figure 2 (Side Mounting Kit P/N 2101913)
Figure 3 (Typical Block Manifold Setup)
MADEIN U.S.A.
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Meter Run
2" Mounting Pipe
Saddle
2 - Piece
Mounting Bracket
3 - Valve
Block Manifold

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5. Connect stainless steel tubing from manifold to orifice tap valves. For
best measurement, use large bore, short, equal length gage lines
with a downward slope to taps (at least 1" per 3 feet). With the
manifold equalized to avoid damaging the device’s transducer, apply
pressure to the manifold and check for leaks.
6. Assemble and install the RTD using the instructions included with the
RTD kit. Wire RTD to unit per local codes. See page 7 for additional
information. See also Figures 6 & 9 for wiring terminations.
Installing the 6270 Optional Equipment Unit
The 6270 OEU (Optional Equipment Unit) contains the power supply,
battery and any optional communication’s equipment. If the user is
providing their own power and/or communications and not using the
Optional Equipment Unit go to Step 10.
The OEU can only be installed in a Division 2 or General Purpose
area. All wiring between the 6200EX which can be in a Div 1 area
and the OEU must be done per local codes. See pages 12 & 13 for
wiring terminations.
7. Mount the OEU on a 2” pipe or flat surface using the supplied
installation kit. If a solar panel is used and is to be pipe mounted, use
a pipe long enough or be able to add a coupling and pipe joint on top
of the existing pipe.
Figure 4 (6270 OEU Pipe or Panel Mount)

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8. Assemble, mount, and run solar panel power cable down to 6270
OEU. If using an external AC power supply, run the DC output wiring
to the OEU. Remove one of the rubber plugs and using an approved
cord connector, run solar panel power cable or DC cable into OEU. If
using Totalflow’s external AC power Supply, it can be connected
directly to the side of the enclosure. Do not connect solar panel
wiring until all other wiring is complete. If using AC, the DC wiring
can be connected as long as the AC power remains off. See “Solar
Panel Installation” on page 9 for more information.
9. Run the appropriate conduit and wiring between the 6200EX and the
6270 OEU or customer supplied equipment. See pages 12 and 13
for terminations.
10. Verify all wiring is correct per drawings. If enclosed Wiring
Interconnect drawings (WIs) or User Drawings (UDs) conflict with
illustrations in this startup guide, the drawings should take
precedence. All wiring must meet local electrical codes.
11. If using the OEU, Mount and connect a fully charged battery to one
of the battery connectors or apply customer supplied power to the
6200EX.
12. The display on the 6200EX should go quickly through the startup
routine then start scrolling through the default display items. (If not,
see Tip on Page 22). This typically insures that the components and
power wiring are good. Refer to “Standard Displays" on page 18 for
typical default displays. Refer to “Visual Alarm & Status Codes" on
page 19 for location, symbols, and descriptions.
14. Connect FS/2 or laptop running PCCU32 to the unit. To use an FS/2,
the 6200EX must have been configured at the factory for FS/2
support. PCCU32 must have software Version 4.3 or higher and the
FS/2 must be 2018583-007 or higher.
15. Configure the 6200EX: Set date/time, ID, location, AGA setup, using
Entry Mode in PCCU32 or an FS/2.
16. If device supports multiple pressure ranges, select the correct Sp &
Dp range from the Range Select tab in Calibration Mode. (PCCU32)
17. In Calibration Mode, verify registers for Static pressure, Differential
pressure and Temperature. (PCCU32)
18. In Calibration Mode, assuming a temperature input device is used,
select TF Device Connected, un-check Use Fixed TF.
19. In Calibration Mode, perform (as found) calibration checks.
20. If calibration is needed or required by company policy, 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.

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21. Perform (as left) calibration checks.
22. 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.
23. Verify that the unit is calculating volume correctly. Watch the display
or look at the Current Values in the Entry Mode of PCCU32.
24. Collect data and review the event and characteristic files to insure all
parameters are set properly.
25. 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.
Note: This is the end of the startup sequence, individual topics follow.
Installing and Wiring RTD
If the 6200EX is installed in a Div 1 area, a Div 1 approved RTD
assembly must be used. RTD kits are available from ABB Totalflow. If
the customer orders the RTD kit but provides their own thermowell, the
U-length must be provided. Various sizes of thermowells are available
from Totalflow, but the U-length or insertion depth will be required.
The following procedure assumes a Totalflow kit was provided.
(Reference drawing 2101779-AI provided with the kit.)
1. Install thermowell into meter run and tighten.
2. Install the ½” stainless steel nipple into the thermowell and tighten.
Figure 5 (RTD Probe Assembly)
3. Separate the union and install the female end of the union along with
its nut onto the nipple and tighten. With the RTD Head still loose,
screw the male end of the union into the bottom of the Head and
tighten.

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4. Insert the RTD sensor probe down through the top of the RTD Head
and holding the sensor probe from underneath the Head, turn the
probe screwing the spring into the threaded hole in the terminal
block. Stop when the top of the spring is flush with the top of the
terminal block. If the probe came with a terminal block, remove it,
since there should be a terminal block already mounted inside the
RTD Head.
5. Guide the sensor probe down through the bottom half of the union.
As the two halves of the union come together, you should feel some
resistance as the sensor probe contacts the bottom of the
thermowell. You should see the top of the probe rise (3/4” max.)
above the terminal block as you push the two halves of the union
together. If the assembly is to long or to short, you may need to
change-out the nipple for a different length.
6. Slide the union nut up and screw on to the top half of the union but
do not tighten.
7. Align the RTD Head such that the connecting conduit or cable will be
pointing in the desired direction and then tighten the union.
8. Install the probe wire spade lugs under the small screw heads per
drawing. One color (typically white) is one side of the RTD and will
go to the RTD (Out & +) connections on the 6200EX and the other
color (typically red) is the other side of the RTD and will go to (In & -).
See Figure 9 on page 12 for a view of the 6200EX RTD terminals.
Figure 6 (RTD Terminal Block)

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Solar Panel Installation (6270 OEU Only)
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. (Reference Fig. 7 for the following procedure).
1. Attach 2-inch pipe collar to top end of the 6200EX mounting pipe.
Securely tighten.
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 Solar Panel
wiring to the OEU (Optional Equipment 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 the Array Input terminals
(See Fig. 10). Remove one of the hole plugs from the OEU 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 Array Input +/-
terminals.
9. Secure Solar Panel cable using grommet, sealing ring and nut.
Tip: To prevent moisture from entering the enclosure, 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
Cable
Solar Panel
U - Bolts
6270 OPTIONAL
EQUIPMENT ENCLOSURE
Figure 7 (Solar Panel Mounting)