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

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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
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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
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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.

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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
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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.

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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.

FloBoss 407 Instruction Manual
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For accessories, refer to the following manual:
♦ROC/FloBoss Accessories Instruction Manual (Form A4637) – Provides information
concerning accessories such as RTD sensors for the MVS.
1.4 INSTALLATION GUIDELINES
This manual provides generalized guidelines for successful installation and operation of the FloBoss
407. Planning helps to ensure a smooth installation. Be sure to consider location, ground conditions,
climate, and site accessibility as well as the suitability of the FloBoss 407 application while planning an
installation.
The variety of application firmware (software) in the FloBoss 407 allows it to be used in many types of
installations. For additional information concerning a specific installation, contact your Fisher
Representative.
1.4.1 Environmental Requirements
The FloBoss 407 case is classified as a NEMA 4X enclosure. This provides the level of protection
required to keep the units operating under conditions such as harsh weather and corrosive atmospheres.
NOTE
In salt spray environments, it is especially important to ensure that the enclosure is
sealed properly, including all entry and exit points. If salt is allowed to enter, it can
shorten the life of the lithium battery in the FloBoss 407 and cause the battery to
leak corrosive chemicals.
The FloBoss 407 is designed to operate over a wide range of temperatures, as detailed in the
Environmental specifications (see Section 2.6). Outside of this range, it may be necessary to moderate
the temperature in which the unit operates.
1.4.2 Site Requirements
Careful consideration in locating the FloBoss 407 on the site can help prevent future operational
problems. The following items should be considered when choosing a location:
♦Local, state, and federal codes often place restrictions on monitoring locations and dictate
site requirements. Examples of these restrictions are fall distance from a meter run, distance
from pipe flanges, and hazardous area classifications.

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♦Locate the FloBoss 407 to minimize the length of signal and power wiring. By Code, line
power wiring must not cross meter runs.
♦Orient solar panels used with solar-powered FloBoss 407s to face True South (not magnetic)
in Northern hemispheres. Orient solar panels used with solar-powered FloBoss 407s to face
True North (not magnetic) in Southern hemispheres. Make sure nothing blocks the sunlight
from 9:00 AM to 4:00 PM.
♦Antennas for FloBoss 407s equipped for radio communications must be located with an
unobstructed signal path. If possible, locate antennas at the highest point on the site and
avoid aiming antennas into storage tanks, buildings, or other tall structures. Allow sufficient
overhead clearance to raise the antenna.
♦To minimize interference with radio communications, locate the FloBoss 407 away from
electrical noise sources such as engines, large electric motors, and utility line transformers.
♦Locate FloBoss 407s away from heavy traffic areas to reduce the risk of being damaged by
vehicles. However, provide adequate vehicle access to aid in monitoring and maintenance.
1.4.3 Compliance with Hazardous Area Standards
The FloBoss 407 has hazardous location approval for Class I, Division 2, Groups A, B, C, and D
exposures. The class, division, and group terms are defined as follows:
Class defines the general nature of the hazardous material in the surrounding atmosphere. Class
I is for locations where flammable gases or vapors may be present in the air in quantities
sufficient to produce explosive or ignitable mixtures.
Division defines the probability of hazardous material being present in an ignitable
concentration in the surrounding atmosphere. Division 2 locations are presumed to be
hazardous only in an abnormal situation.
Group defines the hazardous material in the surrounding atmosphere. Groups A to D are
defined as follows:
♦Group A - Atmosphere containing acetylene.
♦Group B - Atmosphere containing hydrogen, gases or vapors of equivalent hazards.
♦Group C - Atmosphere containing ethylene, gases or vapors of equivalent hazards.
♦Group D - Atmosphere containing propane, gases or vapors of equivalent hazards.
For the FloBoss 407 to be approved for hazardous locations, it must be installed according to the
National Electrical Code (NEC) Article 501.
CAUTION

FloBoss 407 Instruction Manual
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When installing units in a hazardous area, make sure components selected are
labeled for use in such areas. Installation and maintenance must be performed
only when the area is known to be non-hazardous.
NOTE
Measurement Canada approved units normally require a sealed installation. Refer
to your local codes for specifics.
1.4.4 Power Installation Requirements
Typical sources of primary power for FloBoss 407 installations are line power and solar power. Care
must be taken to route line power away from hazardous areas, sensitive monitoring devices, and radio
equipment. Local and company codes generally provide guidelines for line power installations.
Adhere rigorously to all local and National Electrical Code (NEC) requirements for line power
installations.
Solar power allows installation of the FloBoss 407 in locations where line power is not available. The
two important elements in a solar installation are solar panels and batteries. Each must be properly
sized for the application and geographic location to ensure continuous, reliable operation. Information
contained in the accessories manual can help you determine the solar panel and battery requirements to
fit your installation.
As a site may have additional power requirements for radios, repeaters, and other monitoring devices,
Fisher Controls Field Automation Systems offers power supply and converter accessories to minimize
the number of separate power sources required for an installation.
1.4.5 Grounding Installation Requirements
Grounding wiring requirements for line-powered equipment are governed by the National Electrical
Code (NEC). When the equipment uses line power, the grounding system must terminate at the service
disconnect. All equipment grounding conductors must provide an uninterrupted electrical path to the
service disconnect.
The National Electrical Code Article 250-83 (1993), paragraph c, defines the material and
installation requirements for grounding electrodes.
The National Electrical Code Article 250-91 (1993), paragraph a, defines the material
requirements for grounding electrode conductors.
The National Electrical Code Article 250-92 (1993), paragraph a, provides installation
requirements for grounding electrode conductors.

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The National Electrical Code Article 250-95 (1993) defines the size requirements for equipment
grounding conductors.
Proper grounding of the FloBoss 407 helps to reduce the effects of electrical noise on the units
operation and protects against lightning. Lightning Protection Modules (LPM) are available to provide
additional lightning protection for field wiring inputs and outputs. A surge protection device installed at
the service disconnect on line-powered systems offers lightning and power surge protection for the
installed equipment.
All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured with
a ground system tester. The grounding conductor should have a resistance of 1 ohm or less between the
FloBoss 407 case ground lug and the earth ground rod or grid.
The grounding installation method for the FloBoss 407 depends on whether the pipeline has cathodic
protection. On pipelines with cathodic protection, the FloBoss 407 must be electrically isolated from the
pipeline.
Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the
meter run. In this case, the FloBoss 407 could be flange mounted or saddle-clamp mounted directly on the
meter run and grounded with a ground rod or grid system.
Another way of providing electrical isolation would be to mount the FloBoss 407 on a pipestand and use a
remote Multi-Variable Sensor installed with non-conductive conduit. Ground the case of the FloBoss 407
to a ground rod or grid system.
On pipelines without cathodic protection, the pipeline itself may provide an adequate earth ground and the
FloBoss 407 could mount directly on the meter run. Test with a ground system tester to make sure the
pipeline to earth impedance is less than 25 ohms. If an adequate ground is provided by the pipeline, do not
install a separate ground rod or grid system. All grounding should terminate at a single point.
If the pipeline to earth impedance is greater than 25 ohms, the FloBoss 407 installation should be
electrically isolated and a ground rod or grid grounding system installed.
1.4.6 I/O Wiring
I/O wiring requirements are site and application dependent. Local, state, or NEC requirements
determine the I/O wiring installation methods. Direct burial cable, conduit and cable, or overhead
cables are options for I/O wiring installations. Sections 2 and 3 contain detailed information on
connecting I/O wiring to the FloBoss 407.

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1.5 POWER CONSUMPTION CALCULATION
A ROC/FloBoss system’s power consumption determines power supply and battery sizing for both line
and solar power supplies. Table 1-1 and Table 1-2 provide information to assist in determining power
requirements. For non-analog I/O, size the I/O module scaling resistors (see Section 3) for optimal
current to minimize current drain on the power supply.
1.5.1 Determining I/O Channel Power Consumption
In estimating total I/O power requirements, the “duty cycle” of each I/O channel (built-in I/O or
modular I/O) must be estimated. For a non-analog I/O channel, the duty cycle is essentially the
percentage of time that the I/O channel is active (maximum power consumption). For example, if a
discrete output is active for 15 seconds out of every 60 seconds, the duty cycle is:
Duty Cycle = Active time/(Active time + Inactive time) = 15 sec/60 sec = 0.25
For an analog I/O channel, the duty cycle is approximated by estimating the percentage of time the
channel spends in the upper half of its range (span) of operation. For example, if an analog input wired
as a current loop (4 to 20 mA) device operates in the upper half of its range 75% of the time, then 0.75
would be used as the duty cycle. If the analog channel generally operates around the midpoint of its
span, use 0.5 as the duty cycle.
To calculate the total power consumed by an I/O channel, first select either the 12 or 24 volt column in
Table 1-1 or Table 1-2. Then, read the minimum (Pmin) and maximum (Pmax) power consumption value
from the table for the desired I/O channel. Use the following equation to calculate the power
consumption for a channel with the duty cycle taken into account:
Power = (Pmax xDuty Cycle) + [Pmin (1 - Duty Cycle)]
Multiply this value by the quantity (Qty) of I/O channels with the same duty cycle and enter the
calculated value in the Subtotal column. Repeat the procedure for all other I/O channels used. For a
FloBoss 407, total the values in the Subtotal column in Table 1-2, and enter the value in the I/O
Modules row of Table 1-1.

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Table 1-1. Power Consumption of the FloBoss 407 and Powered Devices
POWER CONSUMPTION (mW) DUTY SUB-
DEVICE 12V System 24V System QTY CYCLE TOTAL
Pmin Pmax Pmin Pmax (mW)
Processor and I/O Termination Board
(includes minimum built-in I/O power
consumption)
N/A 800 N/A 1200 1 N/A
Built-in Analog Input — ROC/FloBoss-
Powered Current Loop 130 440 130 440
Built-in Analog Input — Externally-
Powered Voltage Signal 0 65 0 275
Built-in Pulse Input — ROC/FloBoss-
Powered 012024
Built-in Pulse Input — Externally-Powered 0 0 0 0
Serial Communications Card 135 135 N/A
Dial-up Modem Communications Card 395 395 N/A
Leased-Line Communications Card 110 110 N/A
Radio Modem Communications Card 110 110 N/A
MVS (Integral or Remote) N/A 240 N/A 480 N/A
I/O Modules Total from Table 1-2 N/A N/A N/A
Radio (from Section 1.4.2) N/A N/A N/A
TOTAL
NOTE: 1. For the Analog Input, the Duty Cycle is the percent of time spent in the upper half of the operating range.

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Table 1-2. Power Consumption of the I/O Modules
POWER CONSUMPTION (mW) DUTY SUB-
I/O MODULE 12V System 24V System QTY CYCLE TOTAL
Pmin Pmax Pmin Pmax (mW)
AI Loop 170 495 170 495
AI Differential 75 75 75 75
AI Source 110 305 130 470
AO Source 145 585 145 585
RTD Input (Pmin is at -50°C;
Pmax is at 100°C)
240 475 475 930
DI Isolated 1 10 1 10
DI Source 1 55 1 205
PI Isolated 1 30 1 30
PI Source 1 70 1 230
SPI Isolated 1 10 1 10
SPI Source 1 55 1 205
Low-Level PI 1 45 1 45
DO Isolated 1 25 1 25
DO Source (Pmax is at 57 mA) 30 815 30 1585
DO Relay 12V 15 375 N/A N/A
DO Relay 24V N/A N/A 20 470
HART Interface Module 85 685 85 1285
TOTAL
NOTES: 1. For analog I/O channels, the Duty Cycle is the percent of time spent in the upper half of the operating range.
2. The Pmax amount includes any power drawn by a ROC/FloBoss-powered field device, such as a transmitter.

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1.5.2 Determining Radio Power Consumption
In determining power requirements for radios, the duty cycle for the radio must be estimated. The duty
cycle is the percentage of time the radio is transmitting (TX). For example, if a radio is transmitting 1
second out of every 60 seconds, and for the remaining 59 seconds the radio is drawing receive (RX)
power, the duty cycle is:
Duty Cycle = TX time/(TX time + RX time) = 1 sec/60 sec = 0.0167
To calculate the total power consumed by a radio, obtain the power (P) consumption values for transmit
and receive from the radio manufacturer’s literature, then use the following equation to calculate the
power consumption for a particular duty cycle:
Power = (PTX xDuty Cycle) + [PRX (1 - Duty Cycle)]
Determine the power consumption for all radios that use power from the ROC/FloBoss, and enter the
total calculated value in Table 1-1.
1.5.3 Totaling Power Requirements
To adequately meet the needs of the ROC/FloBoss system, it is important to determine the total power
consumption, size solar panel, and battery backup requirements accordingly. For total power
consumption, add the device values in Table 1-1. Although Table 1-1 and Table 1-2 take into account
the power supplied by the ROC/FloBoss to its connected devices, be sure to add the power consumption
(in mW) of any other devices used with the ROC/FloBoss in the same power system, but not accounted
for in the tables.
Convert the total value (in mW) to Watts by dividing it by 1000.
mW / 1000 = Watts
For selecting an adequate power supply, use a safety factor (SF) of 1.25 to account for losses and other
variables not factored into the power consumption calculations. To incorporate the safety factor,
multiply the total power consumption (P) by 1.25.
PSF = P x1.25 = _____ Watts
To convert PSF to current consumption in amps (ISF), divide PSF by the system voltage (V), either 12 or
24 volts.
ISF = PSF / V = _____ Amps

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1.6 STARTUP AND OPERATION
Before starting the FloBoss 407, perform the following checks to ensure the unit is properly installed.
♦Make sure the enclosure has a good earth ground connected to the earth ground bus inside the
enclosure.
♦Seat and secure all I/O modules in their sockets.
♦Check the field wiring for proper installation.
♦Make sure the input power is fused at the power source.
♦Make sure the input power has the correct polarity.
♦Make sure the input power is at least 12.5 volts (unless Switch S1 on the termination board of
newer FloBoss units—see Section 2—is depressed during power-up).
CAUTION
Check the input power polarity before turning on the power. Incorrect polarity can
damage the ROC/FloBoss.
CAUTION
When installing units in a hazardous area, ensure components selected are labeled
for use in such areas.
1.6.1 Startup
Observe cautions above, and then apply power to the FloBoss 407. After the FloBoss completes start-
up diagnostics of Random Access Memory (RAM) and other internal checks, the STATUS LED on the
processor board turns on. This LED should turn on, and stay on, to show that the FloBoss 407
completed a valid reset sequence. If the LED indicator does not come on, refer to the Troubleshooting
and Repair paragraphs in Section 2 of this manual for possible causes.
1.6.2 Operation
Once startup is successful, it is necessary to configure the FloBoss 407 to meet the requirements of the
application. The manual that comes with the configuration software describes in detail the procedures
for configuring the FloBoss and calibrating the I/O. Once the FloBoss is configured and calibrated, it
can be placed into operation.
CAUTION
Configuration of the FloBoss must be performed only in an area known to be non-
hazardous.

FloBoss 407 Instruction Manual
1-14 Rev 5/00
1.7 KEYPAD OPERATION
Table 1-3 provides a brief description of the keypad functions and the expected displays. For a detailed
description, refer to Section 5 of this manual.
To activate the display, press any key, for example I/O SUMMARY. This returns a password prompt to
the display. Enter the numeric password with the keypad and press ENTER. A date and time message
shows on the LCD. Refer to Section 5.5 concerning password security.
Select one of the categories to view from the keypad. The information scrolls on the LCD. Press HOLD
DISPLAY to stop the list from scrolling on the LCD. The FloBoss 407 continuously updates the current
display until the HOLD DISPLAY key is pressed again to return the list to the scroll mode.
Table 1-3. FloBoss 407 Keypad Functions
KEY DISPLAY
Log On Press Any Key Password prompt
Enter Password Date and time
I/O SUMMARY Tag, value, and alarm for each I/O point
ALT, I/O DETAIL Parameters for selected I/O point
FLOW RATES Flow parameters for selected meter run
ALT, COMM PORTS Parameters for selected communications port
FLOW COMP Gas composition for selected meter run
Parameter ALT, SYS PARAM System parameters: address, contract hour, etc.
Lists METER CONFIG Meter configuration for selected meter run
ALT, TIME Date and time
CONTROL Parameters for selected PID loop
ALT, FST Parameters for selected FST
USER LIST 1,2,3 User defined parameter list 1, 2, or 3
ALT, CALIBRATE Calibration procedure
ALARMS Alarm log
ALT, MIN/MAX Minimum and maximum history log
History ALT, MINUTE HIST Minute history log
Functions ALT, HOURS HIST Hours history log
ALT, DAY HIST Day history log
Display UP, DOWN Manually scrolls parameter list
Control ALT, PREV/NEXT SET Selects previous or next set of parameters
HOLD DISPLAY Stops scroll; updates value; press again to resume
EDIT Allows edit of current parameter; enter to save
Keypad BACKSPACE Edit mode backspace erase
Control CANCEL Stops edit mode; resumes list display
ALT, CANCEL Cancels the operation in progress
QUIT ALT, PASSWORD Logs out current user; displays password prompt
ALT, DISPLAY OFF Logs out current user; shuts the display off