Emerson ROC809 User manual

Form Number A6175
Part Number D301217X012
November 2010
ROC800-Series Remote Operations Controller
Instruction Manual
ROC809
ROC827
Remote Automation Solutions

ROC800-Series Remote Operations Controller Instruction Manual
ii Revised Nov-10
Revision Tracking Sheet
November 2010
This manual may be revised periodically to incorporate new or updated information. The revision date
of each page appears at the bottom of the page opposite the page number. A change in revision date
to any page also changes the date of the manual that appears on the front cover. Listed below is the
revision date of each page (if applicable):
Page Revision
All pages Nov-10
All pages Jun-09
Initial issue Mar-06
NOTICE
Remote Automation Solutions (“RAS”), division of Emerson Process Management shall not be liable for technical or editorial errors in this
manual or omissions from this manual. RAS MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND, IN
NO EVENT SHALL RAS BE LIABLE FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT
NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING
WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF THIRD PARTIES.
Bristol, Inc., Bristol Canada, BBI SA de CV and Emerson Process Management Ltd, Remote Automation Solutions division (UK), are wholly
owned subsidiaries of Emerson Electric Co. doing business as Remote Automation Solutions (“RAS”), a division of Emerson Process
Management. FloBoss, ROCLINK, Bristol, Bristol Babcock, ControlWave, TeleFlow and Helicoid are trademarks of RAS. AMS, PlantWeb
and the PlantWeb logo are marks of Emerson Electric Co. The Emerson logo is a trademark and service mark of the Emerson Electric Co.
All other trademarks are property of their respective owners.
The contents of this publication are presented for informational purposes only. While every effort has been made to ensure informational
accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described
herein or their use or applicability. RAS reserves the right to modify or improve the designs or specifications of such products at any time
without notice. All sales are governed by RAS’ terms and conditions which are available upon request.
RAS does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and
maintenance of any RAS product remains solely with the purchaser and end-user.
© 2006-2010 Remote Automation Solutions, division of Emerson Process Management. All rights reserved.

ROC800-Series Instruction Manual
Contents
Chapter 1 – General Information 1-1
1.1 Scope of Manual ............................................................................................................................1-2
1.2 Series 1 versus Series 2 Architecture............................................................................................1-3
1.3 Hardware........................................................................................................................................1-5
1.3.1 Central Processor Unit (CPU)..........................................................................................1-8
1.3.2 Real-Time Clock (RTC)....................................................................................................1-9
1.3.3 Diagnostic Monitoring ......................................................................................................1-9
1.3.4 Options...........................................................................................................................1-10
1.4 FCC Information...........................................................................................................................1-10
1.5 Firmware ......................................................................................................................................1-11
1.5.1 Historical Database and Event & Alarm Log..................................................................1-15
1.5.2 Meter Runs and Stations ...............................................................................................1-15
1.5.3 ROC800 Flow Calculations............................................................................................1-16
1.5.4 ROC800L Flow Calculations..........................................................................................1-17
1.5.5 Automatic Self Tests......................................................................................................1-17
1.5.6 Low Power Modes .........................................................................................................1-18
1.5.7 Proportional, Integral, and Derivative (PID)...................................................................1-18
1.5.8 Function Sequence Table (FST)....................................................................................1-19
1.6 ROCLINK 800 Configuration Software ........................................................................................1-19
1.7 ROC800L Software......................................................................................................................1-21
1.8 DS800 Development Suite Software ...........................................................................................1-22
1.9 Expansion Backplane...................................................................................................................1-23
1.10 FOUNDATION™ Fieldbus Interface......................................................................................1-23
1.11 Additional Technical Information........................................................................................1-23
Chapter 2 – Installation and Use 2-1
2.1 Installation Requirements...............................................................................................................2-1
2.1.1 Environmental Requirements...........................................................................................2-2
2.1.2 Site Requirements ...........................................................................................................2-2
2.1.3 Compliance with Hazardous Area Standards..................................................................2-3
2.1.4 Power Installation Requirements.....................................................................................2-4
2.1.5 Grounding Installation Requirements ..............................................................................2-4
2.1.6 I/O Wiring Requirements..................................................................................................2-5
2.2 Required Tools...............................................................................................................................2-5
2.3 Housing..........................................................................................................................................2-5
2.3.1 Removing and Replacing End Caps................................................................................2-6
2.3.2 Removing and Installing Wire Channel Covers...............................................................2-6
2.3.3 Removing and Installing Module Covers.........................................................................2-7
2.4 Mounting the ROC800 on a DIN Rail.............................................................................................2-7
2.4.1 Installing the DIN Rail ......................................................................................................2-9
2.4.2 Securing the ROC800 to the DIN Rail.............................................................................2-9
2.4.3 Removing the ROC800 from the DIN Rail.....................................................................2-10
2.5 ROC800-Series Expansion Backplane (EXP) .............................................................................2-10
2.5.1 Attaching an Expansion Backplane...............................................................................2-11
2.5.2 Removing an Expansion Backplane..............................................................................2-12
2.6 Central Processing Unit (CPU) ....................................................................................................2-13
2.6.1 Removing the CPU Module ...........................................................................................2-16
2.6.2 Installing the CPU Module .............................................................................................2-17
Revised Nov-10 iii

ROC800-Series Instruction Manual
2.7 License Keys................................................................................................................................2-17
2.7.1 Installing a License Key.................................................................................................2-18
2.7.2 Removing a License Key...............................................................................................2-19
2.8 Startup and Operation..................................................................................................................2-19
2.8.1 Startup ...........................................................................................................................2-20
2.8.2 Operation.......................................................................................................................2-20
Chapter 3 – Power Connections 3-1
3.1 Power Input Module Descriptions..................................................................................................3-1
3.1.1 12-Volt DC Power Input Module (PM-12)........................................................................3-1
3.1.2 24-Volt DC Power Input Module (PM-24)........................................................................3-3
3.1.3 Auxiliary Output (AUX+ and AUX–).................................................................................3-4
3.1.4 Switched Auxiliary Output (AUXSW+ and AUXSW–)......................................................3-6
3.2 Determining Power Consumption..................................................................................................3-7
3.2.1 Tuning the Configuration ...............................................................................................3-11
3.3 Removing a Power Input Module.................................................................................................3-20
3.4 Installing a Power Input Module...................................................................................................3-21
3.5 Connecting the ROC800 to Wiring...............................................................................................3-22
3.5.1 Wiring the DC Power Input Module ...............................................................................3-22
3.5.2 Wiring the External Batteries.........................................................................................3-24
3.5.3 Replacing the Internal Battery .......................................................................................3-26
3.6 Additional Technical Information..................................................................................................3-27
Chapter 4 – Input/Output Modules 4-1
4.1 I/O Module Overview..................................................................................................................4-1
4.2 Installation...................................................................................................................................4-3
4.2.1 Removing and Installing Wire Channel Covers...........................................................4-4
4.2.2 Removing and Installing Module Slot Covers..............................................................4-4
4.2.3 Installing an I/O Module...............................................................................................4-5
4.2.4 Removing an I/O Module.............................................................................................4-6
4.2.5 Wiring I/O Modules......................................................................................................4-7
4.3 Analog Input (AI) Modules..........................................................................................................4-7
4.4 Analog Output (AO) Modules......................................................................................................4-9
4.5 Discrete Input (DI) Modules......................................................................................................4-10
4.6 Pulse Input (PI) Modules ..........................................................................................................4-12
4.7 Discrete Output (DO) Modules .................................................................................................4-14
4.8 Discrete Output Relay (DOR) Modules ....................................................................................4-15
4.9 Resistance Temperature Detector (RTD) Input Modules.........................................................4-17
4.10 Advanced Pulse Module (APM)................................................................................................4-18
4.11 Thermocouple (TC) Input Module.............................................................................................4-22
4.12 Highway Addressable Remote Transducer (HART).................................................................4-25
4.13 Multi-Variable Sensor Input/Output (MVS I/O) .........................................................................4-28
4.14 Alternating Current Input/Output (AC I/O) Module ...................................................................4-32
4.15 Additional Technical Information ..............................................................................................4-35
Chapter 5 – Communications 5-1
5.1 Communication Ports and Modules Overview............................................................................5-1
5.2 Installing Communication Modules.............................................................................................5-3
5.3 Removing a Communication Module..........................................................................................5-4
5.4 Wiring Communication Modules.................................................................................................5-5
5.5 Local Operator Interface (LOI)....................................................................................................5-5
5.5.1 Using the LOI.................................................................................................................5-7
iv Revised Nov-10

ROC800-Series Instruction Manual
5.6 Ethernet Communication............................................................................................................5-7
5.7 EIA-232 (RS-232) Serial Communication...................................................................................5-9
5.8 EIA-422/485 (RS-422/485) Serial Communications Module....................................................5-10
5.8.1 EIA-422/485 (RS-422/485) Jumpers & Termination Resistors....................................5-11
5.9 Dial-up Modem Communication Module ..................................................................................5-13
5.10 Multi-Variable Sensor (MVS) Interface Module........................................................................5-14
5.11 Additional Technical Information...............................................................................................5-15
Chapter 6 – Troubleshooting 6-1
6.1 Guidelines ......................................................................................................................................6-1
6.2 Checklists.......................................................................................................................................6-2
6.2.1 Serial Communications....................................................................................................6-2
6.2.2 I/O Point...........................................................................................................................6-3
6.2.3 Software...........................................................................................................................6-3
6.2.4 Powering Up.....................................................................................................................6-4
6.2.5 MVS or MVS I/O Module..................................................................................................6-4
6.3 Procedures.....................................................................................................................................6-4
6.3.1 Preserving Configuration and Log Data...........................................................................6-5
6.3.2 Restarting the ROC800....................................................................................................6-5
6.3.3 Troubleshooting Analog Input Modules...........................................................................6-6
6.3.4 Troubleshooting Analog Output Modules ........................................................................6-7
6.3.5 Troubleshooting Discrete Input Modules.........................................................................6-9
6.3.6 Troubleshooting Discrete Output Modules ......................................................................6-9
6.3.7 Troubleshooting Discrete Output Relay Modules..........................................................6-10
6.3.8 Troubleshooting Pulse Input Modules ...........................................................................6-10
6.3.9 Troubleshooting RTD Input Modules.............................................................................6-11
6.3.10 Troubleshooting Thermocouple Input (T/C) Modules....................................................6-12
6.3.11 Troubleshooting Advanced Pulse Modules ...................................................................6-13
Chapter 7 – Calibration 7-1
7.1 Calibration Overview......................................................................................................................7-1
7.2 Calibration Frequency....................................................................................................................7-1
7.3 Preparing for Calibration................................................................................................................7-2
Appendix A – Glossary A-1
Appendix B – Wiring Diagrams B-1
B.1 Daniel Senior Sonic Meter to PI Module........................................................................................B-1
B.2 Daniel 1818A and 1838 Turbine Pre-Amp to PI Module................................................................B-2
B.3 Micro Motion RFT9739 & 2400S Transmitters to PI Module.........................................................B-3
B.4 Micro Motion RFT9739 & 2400S Transmitters to APM Module.....................................................B-4
B.5 3- and 4-Wire RTD to RTD Module................................................................................................B-5
B.6 Daniel Senior Sonic Meter to APM Module....................................................................................B-6
B.7 Daniel 1818A and 1838 Dual Turbine Pre-Amp to APM Module...................................................B-7
B.8 Daniel 1818A and 1838 Turbine Pre-Amp to APM Module...........................................................B-8
B.9 Two-Stage Valve with Two Limit Switches to ACIO Module..........................................................B-9
Index I-1
Revised Nov-10 v

ROC800-Series Instruction Manual
vi Revised Nov-10
[This page is intentionally left blank.]

ROC800-Series Instruction Manual
Chapter 1 – General Information
This manual focuses on the hardware aspects of the ROC809 and
ROC827 Remote Operations Controllers – also known as the ROC800-
Series controllers (“ROC800”) – and the ROC800-Series expansion
backplanes (“EXPs”), that attach only to the ROC827 and provide
increased I/O capabilities.
For technical information on the ROC800s, refer to the technical
specifications ROC800:809, ROC800:827, and ROC800:FW1 (available
at www.EmersonProcess.com/Remote). For information about the
software you use to configure the ROC800-Series, refer to the
ROCLINK™800 Configuration Software User Manual (for ROC800-
Series) (Form A6218).
ROC800L This manual also discusses the hardware for the ROC800L, a
ROC800-Series device that is factory-loaded with specific firmware
and software designed to measure and manage the flow of liquid
hydrocarbons.
For technical information on the ROC800L, refer to the technical
specifications ROC800:809L,ROC800:827L, and ROC800:SW1. For
information about the software you use to configure the ROC800L, refer
to the ROCLINK 800 Configuration Software User Manual (for
ROC800L) (Form A6214).
ROC800 or
ROC800L? The ROC800-Series (ROC809 and ROC827) are principally designed
to measure the flow of natural gas in accordance with AGA and other
standards. Firmware and user programs enhance that functionality.
To meet market demands, Remote Automation Solutions initially
developed user programs to perform flow calculations for certain
liquids. These programs grew to encompass flow and volume
corrections for most liquid hydrocarbons (as defined by the API in the
Manual for Petroleum Measurement Systems, or MPMS). Finally, to
modularize these capabilities and ensure the integrity of the AGA
calculations, we developed a suite of user programs enabled by a license
key.
This chapter details the structure of this manual and provides an
overview of the ROC800 and its components.
In This Chapter
1.1 Scope of Manual....................................................................................1-2
1.2 Series 1 versus Series 2 Architecture ...................................................1-3
1.3 Hardware ...............................................................................................1-5
1.3.1 Central Processor Unit (CPU)...................................................1-8
1.3.2 Real-Time Clock (RTC) ............................................................1-9
1.3.3 Diagnostic Monitoring...............................................................1-9
1.3.4 Options....................................................................................1-10
1.4 FCC Information...................................................................................1-10
1.5 Firmware..............................................................................................1-11
Revised Nov-10 General Information 1-1

ROC800-Series Instruction Manual
1.5.1 Historical Database and Event & Alarm Log..........................1-14
1.5.2 Meter Runs and Stations........................................................1-15
1.5.3 ROC800 Flow Calculations ....................................................1-16
1.5.4 ROC800L Flow Calculations ..................................................1-17
1.5.5 Automatic Self Tests...............................................................1-17
1.5.6 Low Power Modes..................................................................1-18
1.5.7 Proportional, Integral, and Derivative (PID)............................1-18
1.5.8 Function Sequence Table (FST) ............................................1-19
1.6 ROCLINK 800 Configuration Software................................................1-19
1.7 ROC800L Software..............................................................................1-21
1.8 DS800 Development Suite Software...................................................1-22
1.9 Expansion Backplane..........................................................................1-23
1.10 Foundation™ Fieldbus Interface .........................................................1-23
1.11 Additional Technical Information .........................................................1-23
The ROC800 is a microprocessor-based controller that provides the
functions required for a variety of field automation applications. It is
ideal for applications requiring general logic and sequencing control;
historical data archiving; multiple communication ports; Proportional,
Integral, and Derivative (PID) control; and flow measurement on up to
twelve meter runs.
1.1 Scope of Manual
This manual contains the following chapters:
Chapter 1
General Information Provides an overview of the hardware and
specifications for the ROC800 and the ROC800-
Series expansion backplanes (EXPs).
Chapter 2
Installation and Use Provides information on installation, tools, wiring,
mounting the ROC800, and other essential elements
of the ROC800 and EXPs.
Chapter 3
Power Connections Provides information on the Power Input modules
available for the ROC800 base unit and provides
worksheets to help determine power requirements for
the ROC800 configurations.
Chapter 4
Input/Output (I/O)
Modules
Provides information for the Input/Output (I/O)
modules available for the ROC800 and EXPs.
Chapter 5
Communications Provides information for the built-in communication
capabilities and the optional communication modules
available for the ROC800.
Chapter 6
Troubleshooting Provides information on diagnosing and correcting
problems with the ROC800.
Chapter 7
Calibration Provides information for calibrating Analog Inputs,
HART®Inputs, RTD Inputs, and MVS Inputs for the
ROC800.
Glossary Provides generalized definitions of acronyms and
terms.
Wiring Diagrams Provides diagrams that show how to wire the
modules to various industry-standard devices.
Index Provides an alphabetic listing of items and topics
1-2 General Information Revised Nov-10

ROC800-Series Instruction Manual
contained in this manual.
1.2 Series 1 versus Series 2 Architecture
The Series 2 ROC800 architecture incorporates a redesigned CPU
module and redesigned expansion I/O backplanes to provide major
system advancements. These include an increase in processor speed
(from 50MHz to 65MHz), an increase in SRAM for User C programs
(20K to 100K), an increase in flash memory (4Mb to 16Mb), an
increase in DRAM (8Mb to 16Mb), and greater general flexibility in
module placement. For easy visual identification, the printed circuit
board (PCB) for the Series 2 CPU module, the PCB for the Series 2 base
unit and expansion backplanes, and the Series 2 ROC800 ABS plastic
housing are all black. Additionally, the Series 2 CPU module is labeled
CPU Series 2 (see Figure 1-1).
Note: In the Series 1 ROC800, the PCBs for the CPU module, the base
unit, and the backplanes are green; the ABS plastic housing is
gray.
What’s
Compatible? In the Series 2 ROC827, you cannot insert a Series 1 CPU module
into a Series 2 base unit or attach Series 1 expansion backplanes to
Series 2 base units or expansion backplanes. Firmware is not available
to upgrade a Series 1 CPU module to the new functionally. To obtain
the Series 2 enhancements, you must obtain and use a Series 2 CPU
module.
The architecture of the ROC809’s fixed backplane allows you to insert a
black Series 2 CPU module into a Series 1 (green) base unit. However,
firmware is not available to upgrade a Series 1 CPU module to the new
functionality. To obtain the Series 2 enhancements, you must obtain and
use a Series 2 CPU module.
Note: The ROC800L functions only on the Series 2 hardware
platform.
Module Placement Table 1-1 compares module placement in the ROC809, based on the
installation of a Series 1 or Series 2 CPU. Table 1-2 compares module
placement in the ROC827, based on the installation of a Series 1 or
Series 2 CPU.
Table 1-1. ROC809 Module Placement (Series 1 vs. Series 2)
Module ROC809 Series 1 ROC809 Series 2 Module Color
AI-12 Any Any Grey
AI-16 Any slot with firmware
version 2.13 Any Black
AO Any Any Grey
APM Any Any Grey
Revised Nov-10 General Information 1-3

ROC800-Series Instruction Manual
1-4 General Information Revised Nov-10
Module ROC809 Series 1 ROC809 Series 2 Module Color
RS-485 1st three slots 1st three slots Grey
RS-232 1st three slots 1st three slots Grey
Dial-up Modem 1st three slots 1st three slots Grey
MVS1 1st three slots 1st three slots Grey
MVS I/O1 1st three slots Any Black
DI Any Any Grey
HART Any Any Grey
DO Any Any Grey
DOR Any Any Grey
RTD Any Any Grey
TC Any None Grey
PI Any Any Grey
1The ROC809 supports a maximum of two MVS modules.
Table 1-2. ROC827 Module Placement (Series 1 vs. Series 2)
Module ROC827 Series 1 ROC827 Series 2 Module Color
AI-12 Any Any Grey
AI-16 Any slot with firmware
version 2.13 Any Black
AO Any Any Grey
APM 1st three slots Any Grey
RS-485 1st three slots 1st three slots Grey
RS-232 1st three slots 1st three slots Grey
Dial-up Modem 1st three slots 1st three slots Grey
MVS1 1st three slots 1st three slots Grey
MVS I/O1 1st three slots Any Black
DI Any Any Grey
HART 1st three slots Any Grey
DO Any Any Grey
DOR Any Any Grey
RTD Any Any Grey
TC Any None Grey
PI Any Any Grey
1The ROC827 supports a maximum of two MVS modules.
Note: For further information, refer to the technical specifications
ROC800:809, ROC800:827, ROC800:809L, and
ROC800L:827L. For further information on compatibility and
migration issues, refer to the Remote Automation Solutions
Technical Support White Paper WP0800004R1.

ROC800-Series Instruction Manual
1.3 Hardware
The ROC809 and ROC827 are highly innovative and versatile units
with an integrated backplane to which the central processor unit (CPU),
power input module, communication modules, and I/O modules
connect. The ROC809 (see Figure 1-1) has nine module slots, of which
three can house communication modules. The ROC827 base unit
(shown on the left-hand side of Figure 1-2) has three I/O module slots.
The ROC800-Series expansion backplanes (EXPs) attach to the
ROC827 base unit (see Figure 1-2). Each EXP provides six additional
I/O module slots. The ROC827 can support up to four EXPs, for a total
of 27 I/O module slots (six slots per EXP plus the three I/O slots on the
ROC827 base unit).
The ROC800s use a Power Input module to convert external input
power to the voltage levels required by the electronics and to monitor
voltage levels to ensure proper operation. Two Power Input modules—
12 Volts dc (PM-12) and 24 Volts dc (PM-24)—are available. For more
information on the Power Input modules, refer to Chapter 3, Power
Connections.
The ROC800s support a variety of communication protocols: ROC Plus,
Modbus, Modbus TCP/IP, Modbus encapsulated in TCP/IP, and
Modbus with Electronic Flow Measurement (EFM) extensions.
Figure 1-1 shows the housing, typical I/O modules, and communication
modules installed in a ROC809. The patented ABS (Acrylonitrile
Butadiene Styrene) plastic housing has wire covers to protect the wiring
terminals. The housing includes DIN rail mounts for mounting the unit
on a panel or in a user-supplied enclosure. Patent 6,771,513 covers the
ROC800 enclosure (refer to www.uspto.gov).
Revised Nov-10 General Information 1-5

ROC800-Series Instruction Manual
Power Supply Module
Module (1 of 9 max)
CPU Wire Channel Cover
LOI (Local Port)
EIA-232 (RS-232D)
Right End Cap
Built-in Ethernet
(Comm1)
Built-in EIA-232
(RS-232C) (Comm2)
Figure 1-1. ROC809
Module Placement The left-most slots in the ROC809 (Figure 1-1) accommodate the
Power Input module and the CPU module. The remaining nine slots
can accommodate either communication modules or I/O modules (see
Table 1-1).
Note: If you use the optional communications modules, you can only
place those modules in the three slots (1, 2, or 3) immediately to
the right of the Power Input and CPU modules. Place I/O
modules in any available slot.
Figure 1-2 shows a ROC827 base unit (left) and a typical expansion
backplane (EXP) (right) populated with a full complement of six I/O
modules. Each EXP is composed of the same plastic housing as the
ROC827, contains six I/O slots, and has a powered backplane that easily
attaches to the ROC827 and other EXPs.
1-6 General Information Revised Nov-10

ROC800-Series Instruction Manual
Power Supply Module
Module (1 of 27 max)
CPU Wire Channel Cover
LOI (Local Port)
EIA-232 (RS-232D) Right End Cap
Built-in Ethernet
(Comm1)
Figure 1-2. ROC827 Base Unit with One Expansion Backplane (separated for clarity)
Built-in EIA-232
(RS-232C) (Comm2)
I/O Modules The ROC800 and EXPs support various types of Input/Output (I/O)
modules, which can satisfy a wide variety of field I/O requirements
(refer to Chapter 4, Input/Output Modules). You can place I/O
modules in any available slot. I/O modules include:
Analog Inputs (AI).
Analog Outputs (AO).
Discrete Inputs (DI).
Discrete Outputs (DO).
Digital Relay Outputs (DOR).
Advance Pulse Module (APM).
Alternating Current I/O (ACIO).
Multi-variable Sensor (MVS I/O).
Highway Addressable Remote Transducer (HART®) Module.
Pulse Inputs (PI) – High/Low Speed.
Resistance Temperature Detector Inputs (RTD).
Thermocouple (T/C) Inputs.
Communication Ports
and Modules The ROC800 provides up to six communication ports (refer to
Chapter 5, Communications). Three communication ports are built-in:
Local Operator Interface (LOI) – Local Port EIA-232 (RS-232D).
Ethernet – Comm1 Port for use with the DS800 Development Suite
Software.
EIA-232 (RS-232C) – Comm2 Port for point-to-point asynchronous
serial communications.
Revised Nov-10 General Information 1-7

ROC800-Series Instruction Manual
Communication modules (which you install only in slots 1 [Comm3], 2
[Comm4], or 3 [Comm5] in the ROC800) provide additional ports for
communicating with a host computer or other devices. Modules include:
EIA-232 (RS-232C) – Point-to-point asynchronous serial
communications include Data Terminal Ready (DTR) support,
Ready To Send (RTS) support, and radio power control.
EIA-422/EIA-485 (RS-422/RS-485) – Point-to-point (EIA-422) or
multiple-point (EIA-485) asynchronous serial communications.
Multi-Variable Sensor (MVS) – Interfaces with MVS Sensors (up
to two modules per ROC800).
Dial-up modem – Communications over a telephone network
(14.4K V.42 bis with throughput up to 57.6K bps).
Caution The design of ROC800-Series communications and I/O modules
supports “hot-swapping” (replacing similar modules in the same slot)
and “hot-plugging” (inserting modules into an empty slot) while the
ROC800 is powered. However, it is a good safety practice with any
electrical device to first remove power before you make internal
connections. If you find it necessary to hot-swap or hot-plug a module,
first review the most current specification sheet for that module to
ensure both your safety and the integrity of data that module may
provide.
FOUNDATION™Fieldbus
Interface The FOUNDATION Fieldbus Interface (FFI) is a ROC800-based
solution that enables a ROC800 to support bi-directional multi-drop
digital communications between fieldbus devices.
While you can implement the FFI as a stand-alone device, you can also
install it as an integral part of the ROC827 housing, since the FFI is
based on a standard Series 2 EXP. However, the FFI does not expand
the I/O capability of the ROC827 beyond the 27 module-limit.
For technical information on the FFI, refer to the technical
specifications ROC800:FFI or the FOUNDATION Fieldbus Interface
Instruction Manual (Form A6259). For information about the software
you use to configure the FFI, refer to the Field Interface Configurator
User Manual (Form A6250).
1.3.1 Central Processor Unit (CPU)
The CPU contains the microprocessor, the firmware, connectors to the
backplane, the three built-in communication ports (two with LEDs), a
LED low power wakeup button, a RESET button, the application
license key connectors, a STATUS LED indicating system integrity, and
the main processor.
CPU components include:
32-bit Motorola MPC862 Quad Integrated Communications
Controller (PowerQUICC) PowerPC processor. Bus clock frequency
at 65 MHz with a watchdog timer.
1-8 General Information Revised Nov-10

ROC800-Series Instruction Manual
Flash ROM (Read-Only Memory).
SDRAM (Synchronous Dynamic Random Access Memory).
Diagnostic monitoring.
Real-Time Clock.
Automatic self-tests.
Power saving modes.
Local Operator Interface (LOI) EIA-232 (RS-232D) Local Port.
EIA-232 (RS-232C) serial Comm2 port.
Ethernet Comm1 port.
1.3.2 Real-Time Clock (RTC)
You can set the ROC800’s real-time clock (RTC) for year, month, day,
hour, minute, and second. The clock provides time stamping of the
database values. The battery-backed clock firmware tracks the day of
the week and corrects for leap year. The time chip automatically
switches to backup power when the ROC800 loses primary input power.
The internal Sanyo 3-volt CR2430 lithium battery provides backup for
the data and the RTC when the main power is not connected. The
battery has a one-year minimum backup life with the battery installed,
the jumper disengaged, and no power applied to the ROC800. The
battery has a ten-year backup life with the backup battery installed and
power applied to the ROC800 or when the battery is removed from the
ROC800.
Note: If the real-time clock does not keep the current time when you
remove power, replace the lithium battery.
1.3.3 Diagnostic Monitoring
The ROC800 has diagnostic inputs incorporated into the circuitry for
monitoring system integrity. Use ROCLINK 800 software to access the
System Analog Inputs (on the directory tree, double-click I/O, System
Analog Input, and #1, Battery to open the System Analog Input
screen). Refer to Table 1-3.
Table 1-3. System Analog Inputs
System AI
Point Number PM-12 Function PM-24 Function
1 Battery Input Voltage Module Voltage
2 Charge in Voltage Module Voltage
3 Module Voltage Module Voltage
4 Not Used Not Used
5 On Board Temperature On Board Temperature
Revised Nov-10 General Information 1-9

ROC800-Series Instruction Manual
Note: The PM-24 module’s DC-to-DC converter supplies
approximately 12 volts to the backplane, which is reflected in
the on-screen values for points 1 through 3.
1.3.4 Options
The ROC800 allows you to choose from a wide variety of options to
suit many applications.
Optional communication modules include EIA-232 (RS-232) serial
communications, EIA-422/485 (RS-422/485) serial communications,
Multi-Variable Sensor (MVS), dial-up modem communications, and the
HART module (refer to Chapter 5, Communications).
The ROC800 can handle up to two MVS interface modules. Each
module can provide power and communications for up to six MVS
sensors, for a total of up to 12 MVS sensors per ROC800 (refer to
Chapter 5, Communications).
Optional I/O modules include Analog Inputs (AI), Analog Outputs
(AO), Discrete Inputs (DI), Discrete Outputs (DO), Discrete Output
Relays (DOR), Pulse Inputs (PI), Resistance Temperature Detector
(RTD) Inputs, Thermocouple (T/C) Inputs, Advanced Pulse (APM), and
Alternating Current I/O (ACIO) (refer to Chapter 4, Input/Output
Modules).
The optional application license keys provide extended functionality,
such as the use of the DS800 Development Suite Software (the IEC
61131-3 compliant programming environment) and various user
programs, and enable embedded meter runs. For example, you need to
install a license key with the proper license in the ROC800 to perform
AGA calculations. Refer to Section 1.6, DS800 Development Suite
Software.
The Local Operator Interface (LOI local port) communications terminal
requires the installation of an LOI cable between the ROC800 and your
PC. The LOI port uses an RJ-45 connector with a standard EIA-232
(RS-232D) pin out.
1.4 FCC Information
This equipment complies with Part 68 of the FCC rules. Etched on the
modem assembly is, among other information, the FCC certification
number and Ringer Equivalence Number (REN) for this equipment. If
requested, this information must be provided to the telephone company.
This module has an FCC-compliant telephone modular plug. The
module is designed to be connected to the telephone network or
premises’ wiring using a compatible modular jack that is Part 68-
compliant.
1-10 General Information Revised Nov-10

ROC800-Series Instruction Manual
The REN is used to determine the quantity of devices that may be
connected to the telephone line. Excessive RENs on the telephone line
may result in the devices not ringing in response to an incoming call.
Typically, the sum of the RENs should not exceed five (5.0). Contact
the local telephone company to determine the total number of devices
that may be connected to a line (as determined by the total RENs).
If this equipment and its dial-up modem causes harm to the telephone
network, the telephone company will notify you in advance that
temporary discontinuance of service may be required. However, if
advance notice is not practical, the telephone company will notify the
customer as soon as possible. In addition, you will be advised of your
right to file a complaint with the FCC if you believe it necessary.
The telephone company may make changes to its facilities, equipment,
operations, or procedures that could affect the operation of the
equipment. If this happens, the telephone company will provide advance
notice so you can make the necessary modifications to maintain
uninterrupted service.
If you experience trouble with this equipment or the dial-up modem,
contact Emerson Process Management’s Remote Automation Solutions
(at 641-754-3923) for repair or warranty information. If the equipment
harms the telephone network, the telephone company may request that
you disconnect the equipment until the problem is resolved.
1.5 Firmware
The firmware that resides in Flash Read-Only Memory (ROM) contains
the operating system, ROC Plus communications protocol, and
application software. The CPU module provides battery-backed Static
Random Access Memory (SRAM) for saving configurations, storing
events, alarms, and the historical logs.
ROC800 or ROC800L The ROC800-Series supports either of two sets of firmware. The
original ROC800 firmware is designed primarily to support gas flow
measurements. The ROC800L firmware is designed to support both
liquids and gas flow measurements.
Note:To convert a ROC800 to a ROC800L, refer to the ROC800L
Field Conversion Guide (Form A6305).
The ROC800-Series Operating System firmware provides a complete
operating system for the ROC800. The firmware in the ROC800 is
field-upgradeable using a serial connection or the Local Operator
Interface (LOI) local port. For more information, refer to the ROCLINK
800 Configuration Software User Manual (for ROC800-Series) (Form
6218) or ROCLINK 800 Configuration Software User Manual (for
ROC800L) (Form 6214)
The firmware supports:
Revised Nov-10 General Information 1-11

ROC800-Series Instruction Manual
Input/Output Database.
Historical Database.
Event and Alarm Log Databases.
Applications (PID, AGA, FST, and such).
Measurement Station Support.
Determining Task Execution.
Real-Time Clock.
Establishing and Managing Communications.
Self-Test Capability.
The firmware makes extensive use of configuration parameters, which
you configure using ROCLINK 800 software.
RTOS The ROC800-Series firmware uses a pre-emptive, multi-tasking,
message-based Real-Time Operating System (RTOS) with hardware-
supported memory protection. Tasks are assigned priorities and, at any
given time, the operating system determines which task will run. For
instance, if a lower priority task is executing and a higher priority task
needs to run, the operating system suspends the lower priority task,
allows the higher priority task to run to completion, then resumes the
lower priority task’s execution. This is more efficient than a “time
sliced” architecture type.
TLP The ROC800 reads data from and writes data to data structures called
“points.” A “point” is a ROC Plus Protocol term for a grouping of
individual parameters (such as information about an I/O channel) or
some other function (such as a flow calculation). Points are defined by
a collection of parameters and have a numerical designation that
defines the type of point (for example, point type 101 refers to a
Discrete Input and point type 103 refers to an Analog Input).
The logical number indicates the physical location for the I/O or the
logical instance for non-I/O points within the ROC800. Parameters are
individual pieces of data that relate to the point type. For instance, the
raw A/D value and the low scaling value are parameters associated with
the Analog Input point type, 103. The point type attributes define the
database point to be one of the possible types of points available to the
system.
Together, these three components—the type (T), the logical (L), and the
parameters (P)—can be used to identify specific pieces of data that
reside in a ROC800’s data base. Collectively, this three-component
address is often called a “TLP.”
I/O Database The Input/Output database contains the input and output points the
operating system firmware supports, including the System Analog
Inputs, Multi-Variable Sensor (MVS) inputs, and Input/Output (I/O)
modules. The firmware automatically determines the point type and
point number location of each installed I/O module. It then assigns
each input and output to a point in the database and includes user-
1-12 General Information Revised Nov-10

ROC800-Series Instruction Manual
defined configuration parameters for assigning values, statuses, or
identifiers. The firmware scans each input, placing the values into the
respective database point. These values are available for display and
historical archiving.
SRBX Spontaneous-Report-by-Exception (SRBX or RBX) communication
allows the ROC800 to monitor for alarm conditions and, upon
detecting an alarm, automatically reports the alarm to a host computer.
Any kind of communications link—dial-up modem or serial line—can
perform SRBX as long as the host is set up to receive field-initiated
calls.
Protocols The firmware supports both the ROC Plus protocol and the Modbus
master and slave protocol. ROC Plus protocol can support serial
communications and radio or telephone modem communications to
local or remote devices, such as a host computer.
The firmware also supports the ROC Plus protocol over TCP/IP on the
Ethernet port. The ROC Plus protocol is similar to the ROC
300/400/500 protocol, since it used many of the same opcodes.
For more specific information refer to the ROC Plus Protocol
Specifications Manual (Form A6127) or the ROC800L Protocol
Specifications Manual (A6294), or contact your local sales
representative.
The ROC800-Series firmware also supports Modbus protocol as either
master or slave device using Remote Terminal Unit (RTU) or American
Standard Code for Information Interchange (ASCII) modes. This allows
you to easily integrate the ROC800 into other systems. Extensions to the
Modbus protocol allow the retrieval of history, event, and alarm data in
Electronic Flow Metering (EFM) Measurement applications.
Note:In Ethernet mode, the firmware supports Modbus both in master
and slave mode.
Security The ROCLINK 800 software also secures access to the ROC800. You
can define and store a maximum of 16 case-sensitive user identifiers
(User IDs). In order for the ROC800 to communicate, a case sensitive
log-on ID supplied to the ROCLINK 800 software must match one of
the IDs stored in the ROC800.
The operating system firmware supports the application-specific
firmware supplied in the Flash ROM. The application firmware includes
Proportional, Integral, and Derivative (PID) Control; FSTs;
Spontaneous-Report-By-Exception (SRBX) Communications
Enhancement; optional American Gas Association (AGA) Flow
calculations with station support; and optional IEC 61131-3 language
programs (using DS800 Development Suite software). Applications
reside in the firmware, so you do not need to re-build and download the
firmware for changes in calculation method.
Input Module The Series 1 ROC800 defaults to 16-point addressing, but
Revised Nov-10 General Information 1-13

ROC800-Series Instruction Manual
Addressing automatically switches to 8-point addressing if you add a fourth or
fifth expansion backplane.
The Series 2 ROC800 defaults to 8-point addressing. To switch to 16-
point addressing, you must manually select this option.
Note: To change input module addressing, select ROC > Device
Information in ROCLINK 800. On the Device Information
screen’s General tab, select either 8-Points Per Module or 16-
Points Per Module in the Logical Compatibility Mode frame
and click Apply.
The difference between 16-point and 8-point addressing becomes
critical when you have a host device reading data from specific TLPs.
For example, under 16-point addressing, channel 2 for a DI module in
slot 2 is referenced by TLP 101,33,3. Under 8-point addressing, channel
2 for a DI module in slot 2 is referenced by TLP 101,17,23. Table 1-4
illustrates the difference between 8-point and 16-point addressing.
Table 1-4. 16-Point vs. 8-Point Addressing
Slot Number Logicals (16 pt) Logicals (8 pt)
0 0–15 0–7
1 16–31 8–15
2 32–47 16–23
3 48–63 24–31
4 64–79 32–39
5 80–95 40–47
6 96–111 48–55
7 112–127 56–63
8 128–143 64–71
9 144–159 72–79
10 N/A 80–87
11 N/A 88–95
12 N/A 96–103
13 N/A 104–111
14 N/A 112–119
15 N/A 120–127
16 N/A 128–135
17 N/A 136–143
18 N/A 144–151
19 N/A 152–159
20 N/A 160–167
21 N/A 168–175
22 N/A 176–183
23 N/A 184–191
24 N/A 192–199
25 N/A 200–207
26 N/A 208–215
27 N/A 216–223
ROC800L The ROC800L firmware provides many of the same capabilities as the
ROC800 firmware. We recommend, however, that the ROC800L
supports only six gas runs (using a single AGA key). History stored in
1-14 General Information Revised Nov-10