Emerson Fisher FLOBOSS 407 User manual

Field Automation Systems
Loose-leaf version: Part Number D301080X012
Bound version: Contact FAS
FLOBOSS™ 407 FLOW MANAGER
Instruction Manual
Form A6013
May 2000

FloBoss 407 Instruction Manual
ii Rev 5/00
Revision Tracking Sheet
May 2000
This manual may be revised periodically to incorporate new or updated information. The date revision
level of each page is indicated at the bottom of the page opposite the page number. A major change in
the content of the manual also changes the date of the manual which appears on the front cover. Listed
below is the date revision level of each page.
Page Revision
All 5/00
Previous Editions:
November 1998 - Added changes for 1.05/1.06 firmware and added references to ROCLINK.
Fisher Controls International, Inc. 1995-2000. All rights reserved.
FloBoss is a trademark of Fisher Controls International, Inc.
HART is a registered trademark of the HART Communication Foundation.
Printed in the U.S.A.
While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from
reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the
performance, merchantability, fitness or any other matter with respect to the products, nor as a recommendation to use any product or
process in conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the
products described herein.

FloBoss 407 Instruction Manual
Rev 5/00 iii
Table of Contents
(For a more detailed listing, see the Section Contents at the front of each section.)
SECTION 1 — GENERAL INFORMATION............................................................1-1
1.1 Scope of Manual...............................................................................................................................1-1
1.2 Section Contents...............................................................................................................................1-2
1.3 Product Overview.............................................................................................................................1-2
1.4 Installation Guidelines......................................................................................................................1-5
1.5 Power Consumption Calculation......................................................................................................1-9
1.6 Startup and Operation.....................................................................................................................1-13
1.7 Keypad Operation...........................................................................................................................1-14
1.8 Service Bulletins.............................................................................................................................1-15
SECTION 2 — THE FLOBOSS 407 BASE UNIT .....................................................2-1
2.1 Scope..................................................................................................................................................2-1
2.2 Product Description............................................................................................................................2-2
2.3 Installation........................................................................................................................................2-11
2.4 Connecting the FloBoss 407 to Wiring............................................................................................2-14
2.5 Troubleshooting and Repair.............................................................................................................2-19
2.6 Specifications...................................................................................................................................2-32
SECTION 3 — INPUT/OUTPUT MODULES ...........................................................3-1
3.1 Scope.................................................................................................................................................3-1
3.2 Product Descriptions.........................................................................................................................3-2
3.3 Initial Installation and Setup.............................................................................................................3-7
3.4 Connecting the I/O Modules to Wiring............................................................................................3-8
3.5 Troubleshooting and Repair ...........................................................................................................3-29
3.6 Removal, Addition, and Replacement Procedures .........................................................................3-37
3.7 I/O Module Specifications..............................................................................................................3-40

FloBoss 407 Instruction Manual
Table of Contents (Continued)
iv Rev 5/00
SECTION 4 — COMMUNICATIONS CARDS.........................................................4-1
4.1 Scope.................................................................................................................................................4-1
4.2 Product Descriptions.........................................................................................................................4-1
4.3 Initial Installation and Setup.............................................................................................................4-8
4.4 Connecting Communication Cards to Wiring ................................................................................4-11
4.5 Troubleshooting and Repair ...........................................................................................................4-18
4.6 Communications Card Specifications.............................................................................................4-20
SECTION 5 — DISPLAY AND KEYPAD..................................................................5-1
5.1 Scope.................................................................................................................................................5-1
5.2 Product Description..........................................................................................................................5-1
5.3 Keypad Functions.............................................................................................................................5-4
5.4 Display of Parameters.......................................................................................................................5-9
5.5 Security...........................................................................................................................................5-17
5.6 Troubleshooting and Repair ...........................................................................................................5-18
APPENDIX A — LIGHTNING PROTECTION MODULE....................................A-1
A.1 Scope................................................................................................................................................A-1
A.2 Product Description .........................................................................................................................A-1
A.3 Initial Installation.............................................................................................................................A-2
A.4 Connecting the LPM to Wiring .......................................................................................................A-3
A.5 Troubleshooting and Repair ............................................................................................................A-4
A.6 Specifications...................................................................................................................................A-4
APPENDIX B — MULTI-VARIABLE SENSORS....................................................B-1
B.1 Scope................................................................................................................................................B-1
B.2 Description....................................................................................................................................... B-1
B.3 MVS Mounting................................................................................................................................B-3

FloBoss 407 Instruction Manual
Table of Contents (Continued)
Rev 5/00 v
B.4 Field Wiring..................................................................................................................................... B-7
B.5 Configuration.................................................................................................................................B-13
B.6 Calibration ..................................................................................................................................... B-14
B.7 MVS Troubleshooting and Repair................................................................................................. B-18
B.8 Specifications................................................................................................................................. B-19
APPENDIX C — I/O SIMULATION .........................................................................C-1
C.1 Scope................................................................................................................................................C-1
C.2 Analog Outputs to Analog Inputs....................................................................................................C-1
C.3 Analog Outputs to a meter...............................................................................................................C-2
C.4 Discrete Outputs to Discrete Inputs................................................................................................. C-3
C.5 Discrete Outputs to Pulse Inputs......................................................................................................C-4
C.6 Potentiometer to Analog Inputs.......................................................................................................C-5
C.7 Switch to Discrete Inputs.................................................................................................................C-6
C.8 Switch to Pulse Inputs .....................................................................................................................C-7
GLOSSARY OF TERMS.............................................................................................G-1
INDEX ..............................................................................................................................I-1

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FloBoss 407 Instruction Manual
Rev 5/00 1-1
SECTION 1 — GENERAL INFORMATION
1.1 SCOPE OF MANUAL
This manual describes the FloBoss™407 Flow Manager (also called the ROC407), part of the family of
FloBoss Flow Managers manufactured by Fisher Controls. Both the Standard version and the
Measurement Canada version of the FloBoss 407 are covered in this manual. Included are the
following sections:
♦Section 1 General Information
♦Section 2 FloBoss 407 Base Unit
♦Section 3 Input/Output Modules
♦Section 4 Communications Cards
♦Section 5 Display and Keypad
♦Appendix A Lightning Protection Module
♦Appendix B Multi-Variable Sensors
♦Appendix C I/O Simulation
♦Glossary Glossary of Terms
♦Index Topical Index
Section 1 describes this and related manuals. Section 1 also provides a summary of the FloBoss 407
hardware, installation guidelines, and information on power consumption, startup, and keypad
operation.
Section 2 provides information and specifications concerning the two main components of the FloBoss
407, the processor board and the termination board.
Section 3 provides information and specifications for the optional I/O modules available for the FloBoss
407.
Section 4 provides information and specifications for the communications card options available for the
FloBoss 407.
Section 5 describes the operation of the keypad and the display.
Appendix A describes the optional lightning protection module.
Appendix B describes the Multi-Variable Sensors available for the FloBoss 407.
Appendix C shows various ways to set up I/O simulation for troubleshooting I/O components and
configurations.

FloBoss 407 Instruction Manual
1-2 Rev 5/00
1.2 SECTION CONTENTS
This section contains the following information:
Information Section Page Number
Product Overview 1.3 1-2
Related Documents and Compatibility 1.3.1 1-4
Installation Guidelines 1.4 1-5
Environmental Requirements 1.4.1 1-5
Site Requirements 1.4.2 1-5
Compliance with Hazardous Area Standards 1.4.3 1-6
Power Installation Requirements 1.4.4 1-7
Grounding Installation Requirements 1.4.5 1-7
I/O Wiring 1.4.6 1-8
Power Consumption Calculation 1.5 1-9
Determining I/O Channel Power Consumption 1.5.1 1-9
Determining Radio Power Consumption 1.5.2 1-12
Totaling Power Requirements 1.5.3 1-12
Startup and Operation 1.6 1-13
Startup 1.6.1 1-13
Operation 1.6.2 1-13
Keypad Operation 1.7 1-14
Service Bulletins 1.8 1-15
1.3 PRODUCT OVERVIEW
The FloBoss 407 is a microprocessor-based flow computer (see Figure 1-1) that provides functions
required for gas flow measurement and custody transfer in accordance with standards such as AGA
1985 or 1992 orifice metering. More generally, the unit provides on-site functionality for applications
where there is a need for remote monitoring, measurement, data archival, communications, and control.
The design allows the user to configure the FloBoss 407 for specific applications including those
requiring calculations, logic, and sequencing control using function sequence tables, as well as PID
loop control.
The FloBoss 407 is available in two versions based on the type of approval: the standard hazardous
area version, and the Measurement (Industry) Canada custody transfer version, which includes
hazardous area approval. These versions have a number of differences both in firmware and hardware.
Both of these versions are further subdivided by the type of orifice metering calculations (either AGA
1992 or AGA 1985) included in the firmware.

FloBoss 407 Instruction Manual
Rev 5/00 1-3
Figure 1-1. FloBoss 407 Flow Manager
Physically, the FloBoss 407 consists of two printed circuit cards, a keypad, and a display housed in a
compact weather-tight case. The printed circuit cards are the processor board and the termination
board.
Built into the termination board are two analog input (AI) channels. Moving a jumper on the
termination board changes one of the built-in analog inputs to a pulse input (PI). The pulse input can be
wired either as a FloBoss-powered or a device-powered, medium-speed pulse counter. The pulse
circuitry is optically coupled to isolate the termination board from the input signal.
In addition, the termination board has slots for four plug-in input/output (I/O) modules (also called
modular I/O). The plug-in I/O modules allow any combination of discrete inputs, discrete outputs,
analog inputs, analog outputs, or pulse inputs an application requires.
NOTE
I/O modules must not be used as flow inputs for Industry Canada approved
FloBoss 407 units.
The built-in Liquid Crystal Display (LCD) and membrane keypad provide the ability to look at data and
configuration parameters while on site. The keypad also permits limited editing of parameter values.
The FloBoss 407 can have up to four Multi-Variable Sensor (MVS) devices connected to it. The MVS
provides the differential pressure, static pressure, and temperature inputs needed for performing orifice
flow calculations. As many as four MVS devices (one of which can be an integral MVS) can be used
with a FloBoss 407. The integral MVS is factory-mounted to the bottom of the enclosure with a
coupler and further secured with a stiffening plate. For detailed information on the MVS, refer to
Appendix B.

FloBoss 407 Instruction Manual
1-4 Rev 5/00
The FloBoss has two communication ports built in: a local operator interface port and an EIA-232
serial port. A variety of optional plug-in communication cards are available that allow you to add
another communications channel: EIA-232 serial, EIA-422/485 serial, dial-up modem, radio modem,
or leased-line modem communications.
The FloBoss 407 is packaged in a NEMA 4X windowed enclosure that can mount on a wall or a
pipestand. The enclosure, which protects the electronics from physical damage and harsh environ-
ments, is fabricated of die-cast, low-copper aluminum alloy. It consists of four pieces: the body, the
electronics cover, the keypad cover, and the lower cover. Silicone-rubber gaskets seal the unit when the
covers are closed. All covers are secured by captive screws.
Note that for the Measurement Canada version of the FloBoss 407, the electronics cover, and the lower
cover are secured by special captive screws. These screws have holes through the heads for adding
security wire seals according to Measurement (Industry) Canada requirements.
For the standard version of the FloBoss 407, an optional padlock adapter can be added in the field. This
adapter is installed on the captive screw that secures the electronics cover. With the shank (up to 0.25
inch diameter) of the padlock running through the adapter, the screw is inaccessible and the cover
cannot be opened. Refer to Section 2.3 for adapter installation instructions.
The FloBoss 407 unit can be mounted either on a wall or on a 2-inch pipestand (U-bolt mounting kit is
supplied). For installation information, refer to Section 1.4 and Section 2.3.
Configuration of the FloBoss 407, including installing user programs (special versions may be needed
for the Measurement Canada FloBoss), requires a personal computer and ROCLINK Configuration
Software. See Section 1.3.1 for compatible configuration software and its documentation.
For a more details about the FloBoss 407, refer to Section 2.
1.3.1 Related Documents and Compatibility
For software aspects such as configuration, refer to the following manual:
♦Type RL101 ROCLINK Configuration Software User Manual (Form A6051) – ROCLINK
Version 2.1 or greater is required for all Measurement Canada FloBoss 407 units as well as
standard FloBoss units with Version 1.05 firmware or greater. ROCLINK Version 2.1 also
works with standard FloBoss units that have an earlier version of firmware. ROCLINK
Version 2.0 can be used for standard FloBoss units with Version 1.04 or earlier firmware.
For FST information, refer to the following manual:
♦Function Sequence Table User Manual (Form A4625) – Provides information on setting up
an FST to run in the FloBoss, including how to use the FST Editor supplied with the
configuration software.