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
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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.