ABB XSeriesG4 User manual

An engineering milestone in
the development of remote,
low power, powerful control
and measurement devices
User's manual 2103334MNAB
XSeriesG4
Remote Controller
G4
XRC

i
Contents
Contents ....................................................................................................................................................................... i
List of figures..............................................................................................................................................................v
List of tables..............................................................................................................................................................vii
Health and safety.....................................................................................................................................................viii
General information and notes .............................................................................................................................................viii
Safety, warning, and note symbols.......................................................................................................................................viii
Storage...................................................................................................................................................................................ix
Compliance ............................................................................................................................................................................ix
Additional publications.............................................................................................................................................. x
Typographical conventions......................................................................................................................................xi
1System overview.................................................................................................................................................1
Overview........................................................................................................................................................................1
XSeries remote controller hardware ..............................................................................................................................2
Standard enclosure........................................................................................................................................................4
Rack mount enclosure...................................................................................................................................................6
XRCG4 board specifications ...........................................................................................................................................6
XSeries on-board input/output.......................................................................................................................................9
Display function ...........................................................................................................................................................13
Functions of the XRCG4................................................................................................................................................14
XRCG4 application licensing.........................................................................................................................................15
Display annunciators....................................................................................................................................................16
Laptop computer running PCCU32..............................................................................................................................18
Local PCCU connections.............................................................................................................................................18
Network connectivity (dynamic IP with router).............................................................................................................19
Optional keypad...........................................................................................................................................................19
Optional Totalflow input/output modules......................................................................................................................22
2Installation......................................................................................................................................................... 26
Overview......................................................................................................................................................................26
Unpacking and inspection............................................................................................................................................26

ii
Pipe saddle mount installation......................................................................................................................................26
Wall mount installation .................................................................................................................................................29
Battery pack installation ...............................................................................................................................................31
Solar panel installation.................................................................................................................................................32
AC charging unit installation.........................................................................................................................................34
XRCG4 6990 rack mount installation .............................................................................................................................36
XRCG4 communication field-wiring ...............................................................................................................................38
3XRCG4 startup.....................................................................................................................................................44
Overview......................................................................................................................................................................44
PCCU32 installation and setup ....................................................................................................................................44
Establishing initial local communication .......................................................................................................................44
Set up the XRCG4 for Ethernet communication ............................................................................................................46
Setting up the XRCG4 ...................................................................................................................................................55
Application licensing credit key ....................................................................................................................................59

iii
On-board I/O calibration...............................................................................................................................................65
Keypad.........................................................................................................................................................................67
4Maintenance ......................................................................................................................................................69
Overview......................................................................................................................................................................69
Backing up configuration files ......................................................................................................................................69
Changing the XRCG4 clock...........................................................................................................................................70
Components and spare parts.......................................................................................................................................71
Replacing the lithium battery........................................................................................................................................74
Replacing the XRCG4 battery pack...............................................................................................................................74
Replacing the main electronic board (XRCG4)..............................................................................................................76
Replacing the CPU engine card...................................................................................................................................78
Replacing the Liquid Crystal Display (LCD) board.......................................................................................................79
5Troubleshooting................................................................................................................................................81
Overview......................................................................................................................................................................81
Troubleshooting visual alarm codes ............................................................................................................................83
Power troubleshooting.................................................................................................................................................87

iv
Troubleshooting communications.................................................................................................................................94
Getting technical support help......................................................................................................................................99
Returning devices.......................................................................................................................................................100

v
List of figures
Figure 1: XRCG4 6490................................................................................................................................................... 4
Figure 2: XRCG4 6790................................................................................................................................................... 4
Figure 3: XRCG4 6890................................................................................................................................................... 5
Figure 4: XRCG4 6990 rack mount................................................................................................................................ 6
Figure 5: XRC board..................................................................................................................................................... 8
Figure 6: Typical DI point schematic ..........................................................................................................................10
Figure 7: DI connection examples..............................................................................................................................10
Figure 8: Typical DO point schematic.........................................................................................................................11
Figure 9: DO connection example..............................................................................................................................12
Figure 10: Typical AI point schematic.........................................................................................................................12
Figure 11: AI connection examples ............................................................................................................................13
Figure 12: Liquid crystal display and indicators..........................................................................................................16
Figure 13: RS-232 local communication cable...........................................................................................................18
Figure 14: USB local communication cable................................................................................................................19
Figure 15: Ethernet communication cable..................................................................................................................19
Figure 16: Optional keypad.........................................................................................................................................20
Figure 17: XRCG4 6990 with dual keypads.................................................................................................................20
Figure 18: XRCG4 6490 with optional keypad .............................................................................................................21
Figure 19: XRCG4 6790 with optional keypad .............................................................................................................21
Figure 20: XRCG4 6890 with optional keypad .............................................................................................................22
Figure 21: TFIO module housing................................................................................................................................23
Figure 22: XRCG4 6490 inside view ............................................................................................................................24
Figure 23: XRCG4 6790 inside view ............................................................................................................................24
Figure 24: XRCG4 6890 inside view ............................................................................................................................25
Figure 25: XRCG4 6990 inside view............................................................................................................................25
Figure 26: Typical pipe saddle installation..................................................................................................................27
Figure 27: XRCG4 pipe-mounting................................................................................................................................27
Figure 28: Model XRCG4 6490, pipe-mounted............................................................................................................28
Figure 29: Model XRCG4 6790, pipe-mounted............................................................................................................28
Figure 30: Model XRCG4 6890, pipe-mounted............................................................................................................29
Figure 31: Model XRCG4 6490, wall-mounted ............................................................................................................30
Figure 32: Model XRCG4 6790 wall-mounted .............................................................................................................30
Figure 33: Model XRCG4 6890 wall-mounted .............................................................................................................31
Figure 34: Battery and charger input connections......................................................................................................32
Figure 35: Typical solar panel installation ..................................................................................................................33
Figure 36: Mounting AC charger ................................................................................................................................34
Figure 37: DC wiring instructions................................................................................................................................35
Figure 38: AC wiring instructions................................................................................................................................35
Figure 39: XRCG4 6990 rack mount ............................................................................................................................36
Figure 40: Single and dual unit termination panels ....................................................................................................37
Figure 41: XRCG4 standard communication wiring.....................................................................................................39
Figure 42: XRCG4 panel-mount field-wiring diagram ..................................................................................................40
Figure 43: XRCG4 main electronic board jumper configuration ..................................................................................41
Figure 44: Other field-wiring I/O connections.............................................................................................................43
Figure 45: Setup for local communication..................................................................................................................45
Figure 46: Network ID setup.......................................................................................................................................47

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Figure 47: Communication setup for Totalflow /TCP protocol (default TCP port) ......................................................48
Figure 48: Set up TP/IP communication over Ethernet ..............................................................................................49
Figure 50: Network tab: Configure static IP addresses ..............................................................................................51
Figure 53: Meter setup and security screen................................................................................................................57
Figure 54: PCCU32 Security Code setup ...................................................................................................................58
Figure 55: WinCCU32 Security Code entry in meter ID .............................................................................................59
Figure 56: Loading credit key status...........................................................................................................................60
Figure 57: Loaded credit key status............................................................................................................................61
Figure 58: Credit key telephone update......................................................................................................................61
Figure 59: Application credit entry screen...................................................................................................................62
Figure 60: Application Credit Verification Codes ........................................................................................................62
Figure 61: Transfer to Device: type and amount.........................................................................................................63
Figure 62: Transferred to Device application credits ..................................................................................................64
Figure 63: Transfer to credit key application credit selections....................................................................................65
Figure 64: Transferred to credit key application credits..............................................................................................65
Figure 65: XRCG4 board- analog input calibration points............................................................................................66
Figure 66: XRCG4 board- pulse/digital input calibration points....................................................................................67
Figure 67: Optional Keypad (P/N 2100652-xxx).........................................................................................................68
Figure 68: XRCG4 6490 component/cable locations ...................................................................................................71
Figure 69: XRCG4 6890 component/cable locations ...................................................................................................72
Figure 70: memory backup enable jumper .................................................................................................................75
Figure 71: XRCG4 battery and charger connections....................................................................................................75
Figure 72: XRCG4 board connections..........................................................................................................................77
Figure 73: Engine Card Removal................................................................................................................................78
Figure 74: Engine card replacement...........................................................................................................................79
Figure 75: Troubleshooting flowchart..........................................................................................................................82
Figure 76: Liquid Crystal Display and indicators.........................................................................................................83
Figure 77: Battery charger and battery pack connections ..........................................................................................84
Figure 78: RTD wiring diagram...................................................................................................................................86
Figure 80: Power troubleshooting flowchart................................................................................................................88
Figure 81: AC-DC charger wiring instructions.............................................................................................................91
Figure 82: Current measurement troubleshooting cable ............................................................................................91
Figure 83: Lithium Battery Backup Enable/Disable.....................................................................................................93
Figure 84: Communication troubleshooting flow chart................................................................................................95
Figure 85: XRCG4 Communication Wiring...................................................................................................................97

vii
List of tables
Table-1: Typographical conventions.............................................................................................................................xi
Table 2: General specifications ....................................................................................................................................1
Table 5: 2103329-xxx board specifications ..................................................................................................................6
Table 6:XRC board identification..................................................................................................................................9
Table 7: Typical XRCG4 display options......................................................................................................................13
Table 8: Status and alarm description........................................................................................................................17
Table 9: TFIO module loading....................................................................................................................................23
Table 10: XRCG4 Main Electronic Board to Termination Panel Correlation Chart......................................................36
Table 11: XRCG4 on-board jumper settings................................................................................................................41
Table 12: XRCG4 displayed items...............................................................................................................................57
Table 13: Optional Keypad Commands......................................................................................................................68
Table 14: XRCG4 6490 and 6890 component identifications ......................................................................................72
Table 15: Additional spare parts.................................................................................................................................73
Table 16: Visual alarm codes .....................................................................................................................................83
Table 17: Specifications for solar panels....................................................................................................................89
Table 18: RS-232 field wiring on XRCG4 electronic board..........................................................................................98
Table 19: RS-485 field wiring on XRCG4 board ..........................................................................................................99
Table 20: RS-485 terminations...................................................................................................................................99

viii
Health and safety
General information and notes
Read these instructions carefully prior to installation and commissioning. For reasons of clarity, these instructions do not contain
all details about every type or version of the product and, therefore, do not take into account every conceivable assembly,
operating, or maintenance scenario. For further information, or if specific problems arise which are not addressed in the
instructions, please ask the manufacturer. The content of these instructions is neither part of nor provided for changing a
previous or existing agreement, promise, or legal relationship. All obligations to ABB result from the respective sales contract,
which also contains the full and solely valid warranty clauses. These are neither limited to, nor extended by, the content of these
instructions.
Observe warning labels on the packaging, on the device, and in this manual.
Safety, warning, and note symbols
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.
DANGER –Serious damage to health / risk to life. This symbol, in conjunction with the signal word "DANGER", indicates
an imminent electrical hazard. 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 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 potential electrical
hazard. 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.
CAUTION –Minor injuries. 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.
NOTICE –Property damage. This symbol indicates a potentially damaging situation. Failure to observe this safety
information may result in damage to or destruction of the product and / or other system components.
NOTE: This symbol indicates operator tips, particularly useful information, or important information about the product or its
further uses. The signal word "NOTE" does not indicate a dangerous or harmful situation.
Only qualified and authorized specialists are to be employed for the assembly, electrical connection, commissioning, and
maintenance of the transmitter. Specific training and skills required include:
–The relevant sections of these instructions must be read carefully before starting work.
–Training, instruction, and authorization to operate and maintain devices or systems according to safety engineering
standards for electrical circuits, high pressures, and corrosive media. Noncompliance with these instructions will transfer full
liability to the user.
–Training or instruction in accordance with safety engineering standards regarding maintenance and use of adequate safety
systems.

ix
WARNING –Bodily injury. For electrical connections, the user must use sufficiently insulated tools according to
the EN 60 900 standard.
Follow the applicable standards, regulations, and recommendations for installation, including:
–The construction and operation of electrical installations. For example, follow the regulation for technical working materials
(safety guidelines for tools).
–Explosion protection, if transmitters with explosion protection are installed.
The device can be operated at high levels of pressure and with corrosive media. Serious injury and/or considerable material
damage can result if the transmitter is handled incorrectly. Ensure compliance with the regulations applicable in the country of
use when working with transmitters.
Additional safety advice concerning the operation of the equipment described in this manual or relevant safety data sheets
(where applicable), along with information about spare parts and customer service, can be obtained by contacting the
manufacturer at the address indicated on the back cover of this manual.
Storage
The device does not require any special treatment if stored as dispatched and within the specified ambient conditions. Although
there is no limit to the storage period, the warranty conditions as agreed with the Company and as specified in the order
acknowledgment remain unaffected.
Compliance
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE)
ABB Industrial Automation, Measurement and Analytics, is committed to actively protecting the environment. Do not dispose of
WEEE as unsorted municipal waste. Collect WEEE separately. Participation in the management of WEEE is critical to the
success of WEEE collection.
Electrical and electronic equipment marked using the crossed-out wheeled bin symbol shall not be mixed with
general household waste. Correct disposal at a recycling facility will help save valuable resources and prevent
potential negative effects on health and the environment. These steps ensure compliance with the Waste Electrical
and Electronic Equipment (WEEE) Directive.
Waste electrical and electronic equipment (WEEE) shall be treated separately using the national collection framework available
to customers for the return, recycling, and treatment of WEEE.