Emerson FloBoss S600 User manual

Flow Computer Division
Website: www.EmersonProcess.com/flow
Form A6115
Part Number D301150X412
September 2004
FLOBOSS™ S600 Flow Manager
Instruction Manual

FloBoss S600 Instruction Manual
ii Rev Sep/04
Revision Tracking Sheet
September 2004
This manual is 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 Pages Sep/04
All Pages 8/01
FloBoss and ROCLINK are marks of one of the Emerson Process Management companies. The Emerson logo is a trademark
and service mark of Emerson Electric Co. All other marks are the property of their respective owners.
© Fisher Controls International, LLC. 2001-2004. All rights reserved.
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 S600 Instruction Manual
Rev Sep/04 Table of Contents iii
TABLE OF CONTENTS
SECTION 1 – GENERAL INFORMATION....................................................................................1-1
1.1 Scope of Manual........................................................................................................................1-1
1.2 FloBoss S600 Flow Computer...................................................................................................1-2
1.3 Config 600 Software..................................................................................................................1-5
1.4 FloBoss S600 Specifications.....................................................................................................1-7
SECTION 2 – INSTALLATION .......................................................................................................2-1
2.1 Preparing for Installation...........................................................................................................2-1
2.2 Environmental Considerations ..................................................................................................2-2
2.3 Required Tools for Installation..................................................................................................2-2
2.4 Installing the FloBoss S600.......................................................................................................2-3
2.5 Installation and Removal of the Boards ....................................................................................2-7
SECTION 3 – CPU..............................................................................................................................3-1
3.1 P152 CPU Board .......................................................................................................................3-1
3.2 Power Supply.............................................................................................................................3-2
3.3 Communication Ports................................................................................................................3-4
3.4 CPU On-Board Connectors.......................................................................................................3-8
3.5 CPU Bit Links (Jumpers) ..........................................................................................................3-8
3.6 Dual Ethernet LAN Port..........................................................................................................3-10
SECTION 4 – I/O ................................................................................................................................4-1
4.1 P144 I/O Board..........................................................................................................................4-1
4.2 P154 Prover Board ..................................................................................................................4-17
4.3 P188 HART Board..................................................................................................................4-24
SECTION 5 – FRONT PANEL..........................................................................................................5-1
5.1 Description ................................................................................................................................5-1
5.2 Front Panel Port.........................................................................................................................5-2
5.3 Keypad.......................................................................................................................................5-2
5.4 Alarm LED and Alarm Keys.....................................................................................................5-3
5.5 Display.......................................................................................................................................5-4
5.6 Navigating the Display..............................................................................................................5-5
5.7 Entering Data.............................................................................................................................5-6
5.8 Assigning a Default Page ..........................................................................................................5-8
5.9 Assigning a Page to a Function Key..........................................................................................5-8
5.10 Using the Exponential Key........................................................................................................5-8
5.11 Using the Print Key...................................................................................................................5-9
SECTION 6 – WEB SERVER ACCESS...........................................................................................6-1
6.1 How to Access the FloBoss S600..............................................................................................6-1
6.2 How to Navigate the Web Server Interface...............................................................................6-2
SECTION 7 – STARTUP ...................................................................................................................7-1
7.1 Starting the FloBoss S600.........................................................................................................7-1
7.2 Warm Start.................................................................................................................................7-1

FloBoss S600 Instruction Manual
Rev Sep/04 Table of Contents iv
7.3 Cold Start...................................................................................................................................7-1
7.4 Startup Menu..............................................................................................................................7-3
7.5 Network Setup ...........................................................................................................................7-3
SECTION 8 – TROUBLESHOOTING.............................................................................................8-1
8.1 Troubleshooting Guidelines.......................................................................................................8-1
8.2 Troubleshooting Checklists .......................................................................................................8-1
8.3 Procedures..................................................................................................................................8-3
APPENDIX A – FRONT PANEL NAVIGATION..........................................................................A-1
A.1 Main Menu................................................................................................................................A-1
A.2 Flow Rates Menu......................................................................................................................A-2
A.3 Totals Menu..............................................................................................................................A-3
A.4 Operator Menu..........................................................................................................................A-4
A.5 Plant I/O Menu..........................................................................................................................A-6
A.6 System Settings Menu...............................................................................................................A-8
A.7 Tech/Engineer Menu.................................................................................................................A-9
A.8 Calculations Menu..................................................................................................................A-10
GLOSSARY........................................................................................................................................ G-1
INDEX...................................................................................................................................................I-1

FloBoss S600 Instruction Manual
Rev Sep/04 Information 1-1
1 SECTION 1 – GENERAL INFORMATION
This section includes the following information:
Section Page Number
1.1 Scope of Manual 1-1
1.2 FloBoss S600 Flow Computer 1-2
1.3 Config 600 Software 1-5
1.4 FloBoss S600 Specifications 1-7
1.1 Scope of Manual
This manual describes the FloBoss™ S600 Flow Computer. This manual describes the installation and
startup procedures. Basic maintenance, operation, and troubleshooting information is also provided.
The information in this manual is arranged as follows:
♦Section 1 – General Information provides an overview of the FloBoss S600 and Config 600
software.
♦Section 2 – Installation provides instructions on installing the FloBoss S600 housing and includes
information on installation preparation and panel mounting procedures. This section also describes
the installation and removal of the plug-in boards.
♦Section 3 – CPU describes the use of the communications and power connector blocks, field
wiring configuration, and bit link settings for the plug-in CPU board. It also describes the optional
second Ethernet communications port.
♦Section 4 – I/O describes the use of the plug-in connector blocks, field wiring configuration, and
bit link settings for the optional plug-in I/O boards.
♦Section 5 – Front Panel describes the front panel keypad, communications port, and display area.
This section also shows how to access the FloBoss S600 through the front panel display. This
includes keypad functions, screen displays, display navigation basics, data entry, and printing
reports.
♦Section 6 – Web Server Access shows how to access the FloBoss S600 through a web server
interface. This includes screen displays and interface navigation basics.
♦Section 7 – Startup describes how to initiate a warm start or cold start.
♦Section 8 – Troubleshooting provides maintenance and troubleshooting procedures, including the
basic board-level test procedures.
♦Appendix A – Front Panel Display Navigation lists the default front panel display screens. This
appendix is intended as a navigation reference aid.
♦Glossary defines terms and abbreviations used in this manual.

FloBoss S600 Instruction Manual
Rev Sep/04 Information 1-2
Figure 1-1. The FloBoss S600 Flow Manager
1.2 FloBoss S600 Flow Computer
The FloBoss S600 Flow Manager is a panel-mount flow computer designed specifically for hydrocarbon
liquid and gas measurement where versatility and accuracy matter. The standard features of the unit make
it ideal for fiscal measurement, custody transfer, batch loading and meter proving applications. The unit
allows multi-stream, multi-station applications to be configured, enabling you to simultaneously meter
liquids and gasses.
The FloBoss S600 Flow Manager is designed for use either as a stand-alone flow computer or as a system
component. The intelligent I/O boards fit both gas and liquid applications and support two streams and a
header. Adding I/O boards (maximum 3) allows you to configure up to six streams and two headers.
Orifice, ultrasonic, turbine, positive displacement, Coriolis, annubar & V-Cone flow meter types are all
supported.
The analog performance of the FloBoss S600 is of the highest order, allowing longer intervals between
calibration checks.
The FloBoss S600 Flow Manager offers multiple communication interfaces:
♦One LAN port for Ethernet 10 baseT connectivity (using FTP and TCP/IP protocols). An optional
second Ethernet port can be added if required.
♦HART communication is facilitated by way of a 12 channel I/O board. Point to point and multi-drop
architectures are supported (up to 50 Transmitters).
♦An embedded web-server allows remote access to the flow computer. Security is provided by way of
user name and password protection with a detailed event log for audit purposes (supports Windows®
Internet Explorer®version 6 or greater).

FloBoss S600 Instruction Manual
Rev Sep/04 Information 1-3
♦Two EIA-232 (RS-232) serial ports for connection to a printer or RTU.
♦Three EIA-422/485 (RS-422/RS485) serial ports (up to 38400 bps baud) for connection to a Modbus
SCADA data network or DCS Supervisory System.
♦One dedicated configuration port for connection to the Config 600 Software.
The FloBoss S600 uses distributed processing to achieve maximum performance. The main CPU
incorporates a hardware floating point processor. Each additional card also has local processing to convert
inputs and output from engineering units to field values and vice-versa, as well as running background tests
and PID loops.
All metering calculations are performed using 64 bit (double) precision floating point numbers for the
highest accuracy. Cumulative totals are stored in three separate memory locations (Tri-reg format) for
maximum integrity. The user language Logicalc™ also allows double precision mathematical functions to
be performed on the database objects.
Figure 1-2. CPU Board

FloBoss S600 Instruction Manual
Rev Sep/04 Information 1-4
Figure 1-3. Intelligent I/O Board
Configuration can be set through the front panel interface, the Config 600 Lite software interface, or the
Config 600 Pro software interface. The IPL600, Config 600 Lite and Config 600 Pro interfaces allow both
sending (download) of new or modified configurations and receiving (upload) of existing configuration
from the FloBoss S600. The front panel interface consists of a backlit LCD display, 29-button keypad, and
an alarm status LED.
The FloBoss S600 Flow Manager provides the following functions through the Config 600 configuration
tool:
♦Stream and station totalization.
♦Batch totalization and correction.
♦3-term PID control.
♦Flow balancing.
♦Flow scheduling.
♦Automatic proving sequence.
♦K factor linearization.
♦Valve monitor/control.
♦Sampler control.
♦Station densitometer.
♦Station gas chromatograph.
♦Forward, reverse and error totals.
♦Comprehensive maintenance mode.

FloBoss S600 Instruction Manual
Rev Sep/04 Information 1-5
1.3 Config 600 Software
Config 600 Configuration Software is a suite of editors that provide the capability to monitor, configure,
and calibrate FloBoss S600 Flow Managers. Config 600 Pro software provides a full workbench for
configuration building. Config 600 Lite software allows sending, receiving and editing of existing
configurations. Config 600 Lite is suggested for users whose configurations have been initially created by
their local sales channel, integrator, or the factory. IPL600 software allows only configuration transfer and
communication port configuration.
1.3.1 IPL 600
The IPL 600 software is the “Interactive Program Loader” (available separately). The IPL 600 software
sends VxWorks firmware and receives and sends configurations. In Config Lite and Config Pro, this
interface is referred to as the Transfer Editor.
NOTE: The FloBoss S600 will not operate until a configuration has been sent from the host PC.
1.3.2 Config 600 Lite
The Config 600 Lite editors can be used to modify pre-developed configurations, transfer configurations,
edit items on the front panel display, and edit report formats.
NOTE: Config 600 Lite is used to custom configure a new FloBoss S600 during installation.
Config 600 Lite allows you to perform the following functions:
♦Edit initialization process data, including orifice size, analog input scaling, alarm limits, and keypad
values.
♦Build and customize Modbus slave maps, Modbus master polling sequences, front panel displays,
and period report formats.
♦Customize the alarm system, including alarm groups, suppression, and inhibits.
♦Configure system security by setting user names and passwords, and assigning access levels for
each data object on the displays.
♦Specify the engineering units and totalization rollover value.
♦Reflash the CPU module firmware with software upgrades and transfer configurations via the
Transfer Editor.
1.3.3 Config 600 Pro
The Config 600 Pro editors allow you to configure the FloBoss S600 from a PC.
NOTE: The Config 600 Pro is used to create and develop new FloBoss S600 applications.
Config 600 Pro allows you to perform the following functions:
♦Create a new application from base templates for gas, liquid, and prover applications.

FloBoss S600 Instruction Manual
Rev Sep/04 Information 1-6
♦Edit process configuration data, including orifice size, analog input scaling, alarm limits, and
keypad values.
♦Build and customize Modbus slave maps, Modbus master polling sequences, front panel displays,
and period report formats.
♦Specify the engineering units and totalization rollover value.
♦Customize the alarm system, including alarm groups, suppression, text, and inhibits.
♦Configure system security by setting user names and passwords, and assigning access levels for
each data object.
♦Add and remove objects from the database.
♦Program special features using Logicalc.
♦Reflash the CPU module firmware with software upgrades and transfer configurations via the
Transfer Editor.
For more details on using Config 600 Lite and Config 600 Pro software, refer to the appropriate Config
600 Software User Manual or on-line help.

FloBoss S600 Instruction Manual
Rev Sep/04 Information 1-7
1.4 FloBoss S600 Specifications
Specifications
I/O CAPABILITY
Analog Inputs: 0 to 5.2 V dc or 0 to 22 mA, >16
bits.
Analog Outputs: 0 to 21 mA, 12 bit minimum.
4-Wire RTD: PT100 (-100 to 200°C).
Digital Input: 30 V max optically isolated.
Digital Output: Open Collector, 36 V max, 100 mA.
Dual Pulse Inputs: DC to 10 KHz, IP252/76, ISO
6551:1996, andAPI Chapter 5.5 LevelA, B or E.
Pulse Outputs: Open Collector, dc to 100 Hz.
Prover Pulse Bus: Open Collector, dc to 5 KHz.
Sphere Switches: Supports 1, 2, or 4 switch mode.
Frequency Input: DC to 10 KHz, 3 V pk-pk.
CPU CAPABILITY
50 MHz 486DX2. 16 MB DRAM.
1 MB SRAM (Battery Backed). 4 MB Flash.
Form ‘C’ Watchdog relay. Real-Time Operating
System Windriver VxWorks.
Real-time Clock battery supported calendar clock
chip, maintains system time during power loss.
CIRCUIT BOARDS
Eurocard-compatible. Slide in and out from rear of
case.
CALCULATIONS
Gas: ISO 5167, ISO 6976, NX 19, SGERG, GPA
2172 & 2145, PTZ, GOST 8.563.1 & 2 (97),AGA 3,
AGA 5, AGA 7, AGA 8.
Liquid: API 2540, API 11-2-1, API 11-2-2.
Prover: Compact, Uni-directional, Bi-directional,
Master Meter, Dual Chronometry, Pulse
Interpolation.
POWER REQUIREMENTS
Supply Voltage: 20-32 V dc, 24 W (nominal).
Protection: 2.5 AAnti-surge fuse.
Supply Isolation: Galvanically isolated from unit to
earth ground, 50 V.
Transducer Outputs: 24 V dc, 500 mA;
15 V dc, 100 mA.
ENVIRONMENTAL
Operating Temperature: 0 to 60°C.
Storage Temperature: -40 to 70°C.
Operating Humidity: To 90% non-condensing.
WEIGHT
4.3 kg approx. with single I/O board.
DIMENSIONS
Case Depth: 304 mm. Allow an extra 300 mm
clearance for board extraction and connectors.
Front Panel: 85 mm W x 270 mm H.
ENCLOSURE
Painted, welded steel outer case with plastic front
panel.
APPROVALS AND COMPLIANCES
Available with European CE Mark.
OIML R117 compliant.
EN12405 For EFM devices compliant.
Approved by NMI (Netherlands Measurement
Institute, CMI (Czech Metrology Institute), and OMH
(Hungarian National Office of Measure).
OMNL (Algeria).

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-1
2 SECTION 2 – INSTALLATION
This section provides instructions on installing the FloBoss S600 unit, including installation preparation,
panel mounting procedures, and the installation and removal of the plug-in boards.
This section includes:
Section PageNumber
2.1 Preparing for Installation 2-1
2.2 Environmental Considerations 2-2
2.3 Required Tools for Installation 2-2
2.4 Installing the FloBoss S600 2-3
2.5 Installation and Removal of the Boards 2-7
2.1 Preparing for Installation
Installation of the FloBoss S600 must conform to all applicable local codes and regulations. All
installation procedures should be in accordance with normal practices of good workmanship. Although the
FloBoss S600 shipped to you may not include all of the hardware options described in this manual, the
procedure for the basic installation of the unit remains the same.
Note: It is strongly recommended that you familiarize yourself with the procedures described in
this section before you begin to install the FloBoss S600.
The FloBoss S600 uses a modular design that provides maximum flexibility and ease of installation. The
basic panel-mounted version consists of three major components:
♦Fabricated metal case, complete with pre-installed PSU/backplate and four card slots for the plug-in
cards (comprising a dedicated CPU slot and three I/O slots).
♦Removable front panel comprising the LCD display and keypad assembly.
♦Plug-in boards, one CPU board and one I/O board are supplied for a basic configuration (two
blanking plates are supplied to cover the unused slots).
Figure 2-1 shows the FloBoss S600 system components with the appropriate user-provided tools.

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-2
Figure 2-1. FloBoss S600 System Components
2.2 Environmental Considerations
The FloBoss S600 panel mount is designed for use within the control room and should be placed in a
position that provides ease of use, comfort, and safety for operators and maintenance personnel. The
optimum height for viewing and using the display and keypad is at operator eye level.
Where one or more units are installed in a confined space or with other heat producing
equipment, special attention should be given to the combined heating effect. This combined
heat could increase the environmental temperature beyond its acceptable threshold, thereby
impacting performance.
2.3 Required Tools for Installation
Before attempting any installation of the FloBoss S600 hardware, ensure you have the following tools:
♦Small flat-blade screwdriver suitable for the slot headed captive screws on the rear of the case that
secure each plug-in board into the case.
♦5.5 mm (5 BA) hex or small adjustable crescent wrench for the front panel bosses.
♦2.5 mm Allen wrench suitable for the hex cap screw on the front face of the front panel to secure
the front panel molding to the case.

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-3
2.4 Installing the FloBoss S600
Refer to the following procedures for installing the various FloBoss S600 components, including the front
panel, panel-mounted unit, and plug-in boards.
2.4.1 Unpacking the FloBoss S600
Unpack the FloBoss S600 carefully and inspect parts for visual damage.
Note: Do not discard packaging material until all pieces of the shipment have been identified and
you are confident that all parts are working correctly.
2.4.2 Removing the Front Panel
To begin the mounting process, remove the front panel from the FloBoss S600 as follows:
1. Ensure power has been removed from the FloBoss S600.
2. Use a 2.5 mm Allen wrench to remove the hex cap screw from the bottom center of the front
panel. Refer to Figure 2-2.
Figure 2-2. Removing the Front Panel
3. Carefully slide the FloBoss S600 face up 4 mm (0.15 in) to allow it to clear the retaining groove
at the top of the case, and then allow the face to come forwards to clear the panel case
completely. Refer to Figure 2-3.

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-4
Figure 2-3. Lift Front Panel
4. Disconnect the ribbon cable from the back of the front panel at the blue connector. Refer to
Figure 2-4. Observe the orientation of the connector with its mating keyway. The ribbon cable
must be correctly re-inserted at the end of the installation process.
Do not remove the ribbon cable from the FloBoss S600 housing entrance. This might cause
damage to the unit.
Figure 2-4. Remove Connector
Disconnect
Here

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-5
5. Remove the top and bottom bosses from the unit housing, using a 5.5 mm (5 BA) hex wrench.
Table 2-1. Mounting Dimensions
Part Dimensions
Display Keypad Moulding 85 mm (3.35") width x 269 mm (10.59") height x 28 mm (1.10") deep
Case 84.5 mm (3.327") width x 270 mm (10.63") height x 303.8 mm (11.94") deep
Panel Cutout 66 mm (2.6") width x 150 mm (5.9") height
Pitch Between Cases 110 mm (4.33") giving 25 mm (0.98") air gap
Max Panel Thickness 10 mm (0.39")
Access Allow 300 mm (11.81") clearance directly behind case for maintenance
Figure 2-5. Panel Mount Dimensions
2.4.3 Installing the Panel-Mounted Unit
After removing the front panel, you can install the panel-mounted unit as follows:
1. Keeping the environmental considerations in mind, construct the framework of the cubicle to
support the operating panel.
Note: A standard 483 mm (19 in.) rack that is 311 mm (12.25 in.) high will accommodate up to
four FloBoss S600 flow computers with the rear of the case supported.
2. Refer to Figure 2-6 and Table 2-1 for position details for two 7 mm (0.276 in.) holes and a
cutout. The panel cut out should be rectangular in shape for each FloBoss S600 unit. A
tolerance of +/- 3 mm (0.12 in.) is allowed on each axis.

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-6
Figure 2-6. Panel Cutout Dimensions
3. Panel thickness should be at least 3 mm (0.12 in) to prevent distortion. Thinner panels can be
used, but these require the rear of the case to be supported. Refer to Figure 2-7.
It is recommended that a rear support or anchor is always used to prevent twisting and other
distortion effects during installation and maintenance.
Figure 2-7. Panel Mount

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-7
4. Place the front of the case against the rear of the prepared cutout.
5. Re-install the top and bottom bosses, and tighten with a 5.5 mm (5 BA) hex wrench.
6. When the rear support is fitted, you should use a self-tapping screw to secure the case to the
rear support. The maximum depth of the screw inside the case should be 3 mm (0.12 in.).
2.4.4 Re-installing the Front Panel
The final stage of the installation process is to re-install the front panel on the FloBoss S600 as follows:
1. Connect the ribbon cable (from the front of the case) to the connector on the front panel.
Observe the orientation of the connector with its mating keyway. The ribbon cable must be
correctly inserted. Do not use excessive force to refit the cable.
2. Place the top of the front panel over the retaining groove on the top boss and slide downwards.
3. To secure the front panel, place the hex cap screw into its recess in the bottom center of the
front panel.
4. Use a 2.5 mm Allen wrench to tighten the screw finger-tight. Turn an additional 180 degrees to
complete the installation.
Take care not to over-tighten the screw. Over-tightening may cause damage to the panel face.
2.5 Installation and Removal of the Boards
The FloBoss S600 unit will be shipped with the boards already installed. If you need to remove the boards
for maintenance or upgrade reasons, please follow the procedures in this section.
The CPU board is dedicated to the left-most rear slot of the case. The remaining slots can be populated
with plug-in I/O boards, or they can be left blank and covered with the blank plates designed for the
purpose.
Ensure suitable electrostatic discharge precautions are taken prior to removing any of the
plug-in boards.
The terminals on some boards may be wired to electrical potentials sufficiently high to cause
electrical shock and injury. Make sure the power sources of any connected devices are
turned off and discharged before performing any installation or repairs.
To remove the plug-in boards:
1. Ensure the FloBoss S600 is powered-down before attempting to extract a plug-in board.
2. Unscrew the retention screws before attempting to remove a board to avoid damage to the pull
tabs. Refer to Figure 2-8.

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-8
Figure 2-8. Unscrewing the Retention Screws
3. Unlatch the pull-tabs for the appropriate board and pull the board clear of the case. Some
rocking of the board may be required to release the connector. Refer to Figure 2-9 and Figure
2-10.
Figure 2-9. Using the Pull Tabs

FloBoss S600 Instruction Manual
Rev Sep/04 Installation 2-9
Figure 2-10. Board Ready for Removal or Final Insertion
To install the plug-in boards:
1. Install the plug-in boards with care by aligning them in the guides (located at top and bottom of
the case). Gently slide the board until it mates fully with the appropriate connector on the
backplane.
2. Each plug-in board has two “pull tabs” on the backplate. These should be pressed securely in
place upon insertion.
The insertion and location of the plug-in boards along the guides does not require excessive
force. Take care not to twist or otherwise distort the boards during installation.
3. Secure the board in the case with the retention screws (two per board).