Thermo Scientific AutoPILOT PRO User manual

Part of Thermo Fisher Scientific
AutoPILOT PRO & PRO XL
Six-Run Gas Flow Computer &
Remote Telemetry Unit
User Guide
P/N 1-0500-005
Revision N

© 2019Thermo Fisher Scientific Inc.All rights reserved.
“Honeywell” isa trademark or registered trademark of Honeywell International Inc., or its subsidiaries or
affiliates.
“Rosemount” isa registered trademark of Rosemount Inc.
“Bluetooth” is a trademark orregistered trademark ofBluetooth SIG, Inc.
All other trademarks are the property of Thermo Fisher Scientific Inc. and its subsidiaries.
Thermo Fisher Scientific Inc. (Thermo Fisher)makes every effort to ensure the accuracy and completeness of this
manual. However, we cannot be responsible for errors, omissions, or any loss ofdata asthe result of errors or
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any timewithout notice.
The material in this manual is proprietary and cannot be reproduced inany form without expressed written
consent from Thermo Fisher.

Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
v
Revision History
Revision Level
Date
Comments
A 09-2008 Initial release (ERO 6565).
B 12-2008 Revised per ECO 6718.
C 02-2009 Revised per ECO 6802.
D 10-2009 Revised per ECO 7133.
E 03-2010 Revised per ECO 7309.
F 11-2010 Revised per ECO 7569.
G 08-2011 Revised per ECO 7805.
H 02-2013 Revised per ECO 8097.
J 04-2014 Revised per ECO 8389.
K 11-2014 Revised per ECO 8484.
L 10-2016 Revised per ECO 8934.
M 04-2017 Revised per ECO 9158.
N 07-2019Revised per ECO 9808.

Thermo Fisher Scientific

Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
vii
FCC Notification
The Thermo Scientific AutoPILOT PRO flow computer complies with
part 15 oftheFCC rules.
Caution The AutoPILOT PRO flow computer must be operated as
supplied. Any changes ormodifications made to the device without the
express written approval of ThermoFisher Scientific can void theuser’s
authority tooperate the equipment. 
Note This equipment has been tested and found to comply with thelimits
for a Class A digital device, pursuant to part 15of the FCC rules. These
limits are designed toprovide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the user
manual, maycause harmful interference to radio communications.
Operation ofthis equipment in a residential area is likely to cause harmful
interference, in which case the user will berequired to correct the
interference at the user’s own expense. 

Thermo Fisher Scientific

Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
ix
Contents
Product Overview ....................................................................................1-1
Basic System ..................................................................................................... 1-1
Enclosure ........................................................................................................ 1-1
Power Supply ................................................................................................. 1-1
Main Board .................................................................................................... 1-2
Expansion .......................................................................................................... 1-3
Radio / Host Port Options ................................................................................. 1-3
Using this Manual ............................................................................................. 1-4
Hardware Description: Basic System .......................................................2-1
The Enclosure .................................................................................................... 2-1
Power................................................................................................................. 2-3
External Power Source .................................................................................. 2-3
Internal Battery & Solar Charger Controller .................................................. 2-3
The Main Board ................................................................................................. 2-4
Jumper Settings & Connections ................................................................... 2-4
Lithium Backup Battery .................................................................................. 2-4
Transducer Inputs .......................................................................................... 2-5
RTD Connection ............................................................................................. 2-6
Discrete Outputs ............................................................................................ 2-7
Discrete Inputs ............................................................................................... 2-8
Pulse Inputs.................................................................................................... 2-9
Local Serial Communication Port ................................................................ 2-11
Radio Power Supply Output ......................................................................... 2-11
Solar Charger Power Input .......................................................................... 2-12
System Power Supply Input......................................................................... 2-12
MEB Interface .............................................................................................. 2-12
SIB Interface ................................................................................................ 2-12
Host Communication Port ............................................................................ 2-13
Ethernet Port ................................................................................................ 2-15
Honeywell Smart Transducer Connection ................................................... 2-15
USB Port ....................................................................................................... 2-15
Installing the Basic System......................................................................3-1
General .............................................................................................................. 3-1
NEMA 4X / IP65 ............................................................................................. 3-1
Mounting the Enclosure onto the Transducer .................................................. 3-2
Pole Mounting ................................................................................................... 3-6
Chapter 1
Chapter 2
Chapter 3
Security Consideration....................................................................................... 1-4

Contents
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AutoPILOT PRO Flow Computer User Guide Thermo Fisher Scientific
External Power Supply ................................................................................... 3-6
Flow Computer Enclosure .............................................................................. 3-7
Wiring ................................................................................................................ 3-8
Installing the Internal Battery ......................................................................... 3-11
Hazardous Area Installations .......................................................................... 3-13
Marking ........................................................................................................ 3-14
Repair ........................................................................................................... 3-16
MEB Options ...........................................................................................4-1
General .............................................................................................................. 4-1
MEB Interface Connections ........................................................................... 4-1
Location of MEBs in the Enclosure ................................................................ 4-5
Installation ......................................................................................................... 4-7
2-DI/DO MEB ..................................................................................................... 4-8
Address Jumpers ........................................................................................... 4-8
Connection to MEB Terminal Block ................................................................4-9
Discrete Inputs ................................................................................................4-9
Discrete Outputs ...........................................................................................4-10
4-DI MEB ...........................................................................................................4-11
Address Jumpers ..........................................................................................4-11
Connection to MEB Terminal Block ..............................................................4-11
Discrete Inputs ..............................................................................................4-11
4-DO MEB .........................................................................................................4-12
Address Jumpers ..........................................................................................4-12
Connection to MEB Terminal Block ..............................................................4-12
Discrete Outputs ...........................................................................................4-12
2-PI MEB .......................................................................................................... 4-13
Address Jumpers ......................................................................................... 4-13
Connection to MEB Terminal Block ............................................................. 4-13
Pulse Inputs .................................................................................................. 4-14
Switch Configurations.................................................................................. 4-15
2-D/A MEB ....................................................................................................... 4-15
Address Jumpers ......................................................................................... 4-16
Connection to MEB Terminal Block ............................................................. 4-16
Analog Outputs ............................................................................................ 4-16
Other I/O Expansion Options ....................................................................5-1
General .............................................................................................................. 5-1
The I/O Expansion Backplane ............................................................................ 5-1
Analog Input Expansion Option ......................................................................... 5-2
Installation ..................................................................................................... 5-2
Analog Inputs ................................................................................................. 5-4
Communication Expansion Option .................................................................... 5-4
Installation ..................................................................................................... 5-5
Connections & Jumper Settings .................................................................... 5-7
Chapter 4
Chapter 5
Modifying MEB Power Wiring for 24 Vdc System ............................................4-2

Contents
Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
xi
AutoMITTER SIB Option ...........................................................................6-1
General .............................................................................................................. 6-1
CSA Certified Systems ...................................................................................... 6-2
Installation ..................................................................................................... 6-3
ATEX or Brazilian Certified Systems ................................................................. 6-7
Hazardous Area Installations ........................................................................ 6-7
Wiring Overview ............................................................................................ 6-9
Installation ................................................................................................... 6-10
Radio Options ..........................................................................................7-1
MDS Radio Option ............................................................................................ 7-1
Installation ..................................................................................................... 7-2
AutoWAVE Radio Option .................................................................................. 7-5
Installation ..................................................................................................... 7-5
General .............................................................................................................. 8-1
212A Modem Option ................................................................................8-1
Installation ........................................................................................................ 8-2
Front Panel Interface ...............................................................................9-1
Using the Keypad .............................................................................................. 9-1
Contrast Adjustment ......................................................................................... 9-2
Getting Started .................................................................................................. 9-2
Functional Description ........................................................................... 10-1
Flow Computer Tasks ...................................................................................... 10-1
Meter Types ................................................................................................. 10-1
Equations ..................................................................................................... 10-1
Averaging Techniques ................................................................................. 10-3
Calibration/As Found/As Left ...................................................................... 10-3
Historical Data ............................................................................................. 10-4
Security............................................................................................................ 10-8
Communication Functions ............................................................................... 10-9
Maintenance ......................................................................................... 11-1
Replacing the Main Board .............................................................................. 11-1
Replacing Option Boards................................................................................. 11-4
Replacing the Backup Battery ......................................................................... 11-4
Upgrading the Firmware ................................................................................. 11-5
Getting Help .......................................................................................... 12-1
Contact Information ........................................................................................ 12-1
Warranty ......................................................................................................... 12-2
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Chapter 10
Chapter 10
Chapter 11

Contents
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AutoPILOT PRO Flow Computer User Guide Thermo Fisher Scientific
Ordering Information .............................................................................. A-1
Replacement Parts ........................................................................................... A-1
Transducer Options .......................................................................................... A-2
Kits .................................................................................................................... A-3
Specifications ......................................................................................... B-1
Main Board Jumper Settings & Connections ........................................... C-1
Jumper Settings ................................................................................................ C-1
Factory Settings ............................................................................................. C-1
Other Settings ................................................................................................ C-3
Connectors ......................................................................................................... C-4
Wiring Quick Start .................................................................................. D-1
Index ................................................................................................................I-1
Appendix A
Appendix B
Appendix C
Appendix D

Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
1-1
Chapter 1
Product Overview
The Thermo Scientific AutoPILOT PRO flow computer is the flagship
product in the Thermo Scientific flow computer product line. The
AutoPILOT PRO flow computer combines Thermo Fisher Scientific’s
long legacy of flow computer knowledge with all the latest technology –
low power, high speed data, connectivity, and high accuracy. The
functionality of the flow computer is scalable from a single run application
requiring measurement only to a six-run application with full station and
well head control. The flow computer also incorporates Thermo Fisher’s
self-tuning plunger lift algorithms that have been proven to increase natural
gas production.
The basic AutoPILOT PRO system consists of an enclosure, an external
power supply, and the main board.
Three types of enclosures are offered with the AutoPILOT PRO flow
computer. The NEMA 4X enclosure is available in fiberglass, aluminum, or
stainless steel. The NEMA 4 enclosure (AutoPILOT PRO XL) is a carbon
steel powder painted inside and out, type NEMA 4 / IP66 design. The
IP65 enclosure is available in aluminum or stainless steel. All enclosures
come standard with display and keypad.
The standard instrument is powered by an external 10–30 Vdc power
supply. The power supply is protected against high surge voltages and
designed to meet UL and ATEX requirements (reference the appropriate
certification tag for specific ratings).
Optionally, the instrument can be powered by an internal 12 V, 28 AH
rechargeable lead acid battery.
General
Basic System
Enclosure
Power Supply

Product Overview
Basic System
1-2
AutoPILOT PRO Flow Computer User Guide Thermo Fisher Scientific
The main board contains the primary logic functions of the flow computer
and has the following features:
Interface to the display
Flash memory for program storage and data storage, 2 M x 16
SRAM memory for data storage, 1 M x 16, battery backed
Real-time clock (RTC)
Lithium backup battery; voltage monitor for the RTC and SRAM
circuits allows for data and configuration retention in the event of
power failure
Local I/O consisting of:
-Three analog inputs
- One 100-ohm Pt RTD input
- Two discrete outputs
- Two discrete inputs
-Two pulse inputs
-One local Honeywell smart transducer connection
-One local serial communication port
-One RS232/RS485 host serial communication port
- Connection for AutoMITTER safety interface board (SIB) for
communication with multiple remote transducers controlled by a
Thermo Scientific AutoMITTER PRO transmitter
-Connection for optional modular expansion boards (MEBs)
- Two +12 V power supply outputs for wireless communication
devices: One for wireless radio and one for a Bluetoothwireless
module (future)
-One Ethernet communication port with ESD protection for
connection to the Internet
-One USB port (future)
Power consumption of 1 W (3.6 W with full connections)
Main Board

Product Overview
Expansion
Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
1-3
The capacity of the basic AutoPILOT PRO flow computer can be
expanded through optional I/O boards mounted in the enclosure. See
Appendix B for board specifications.
Note
One AutoPILOT PRO flow computer supports up to 12 expansion
boards in any combination, as long as the maximum number of boards
listed below is not exceeded. 
Table 1–1.
Maximum number of optional I/O boards per unit
I/O Board
Maximum # installed per unit
2-DI/DO MEB 6
4-DI MEB 6
4-DO MEB 6
2-PI MEB 4
2-D/A (Dual Analog Output) MEB 4
AI Expansion Expansion option consists of 1 AI expansion board
and up to 4 AI terminal boards.
Comm. Expansion Option Expansion option consists of 1 comm. expansion
board and up to 4 comm. terminal boards.
AutoMITTER SIB 1
If the host communication port on the main board is not being used
internally, it may be used to interface with an RS232 compatible device.
The following radio and host port options are available for use with the
AutoPILOT PRO flow computer:
MDS 9810 radio
Thermo Scientific AutoWAVE radio
Thermo Scientific 212A modem
Expansion
Radio / Host Port
Options

Product Overview
Using this Manual
1-4
AutoPILOT PRO Flow Computer User Guide Thermo Fisher Scientific
Using this
Manual
This manual provides a technical description of theproduct and
available options,installation and mounting instructions, basic
keypad operating procedures, and maintenance and troubleshooting
procedures. For instructions onhow to use theThermo Scientific
AutoCONFIG™ instrumentation configuration software with this
instrument, refer to the AutoCONFIG software startup guide (p/n
1-0485-068) and the AutoCONFIG software help system.
The information in this manual is designed to aid personnel to
correctly and safely install, operate, and / or maintain the system
described; however, personnel are still responsible for considering all
actions and procedures for potential hazards orconditions that may
not have been anticipated inthe written procedures. If a procedure
cannot be performed safely, it must not be performed until
appropriate actions can betaken to ensure thesafety ofthe
equipment and personnel. The procedures in this manual are not
designed to replace or supersede required or common sense safety
practices. All safety warnings listed in any documentation applicable
to equipment and parts used in orwith the system described in this
manual must be read and understood prior to working on or with
any part of the system.
The following admonitions are used throughout this manual to alert
users to potential hazards orimportant information. Failure to heed
the warnings andcautions inthis manual can lead to injury or
equipment damage.
Warning Warnings notify users of procedures, practices, conditions,
etc. which mayresult ininjury or death ifnot carefully observed or
followed. The triangular icon displayed varies depending on the
type ofhazard
(electrical, general). 
Caution Cautions notify users ofoperating procedures, practices,
conditions, etc.,which may result in equipment damage if not
carefully observed or followed. 
Note Notes emphasize important or essential information or a
statement of company policy regarding anoperating procedure,
practice, condition, etc. 
Tip Tips mayalso beused in this manual. They are suggestions or
things to consider that will help you use theinstrument or this
manual. 
Security
Consideration
Warning ThermoFisher Scientific strongly recommends
changing passwords before first use/login on this equipment. 

Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
2-1
Chapter 2
Hardware Description: Basic System
The basic AutoPILOT PRO system consists of the enclosure, the power
supply, and the main board.
Three types of enclosures are offered with the AutoPILOT PRO flow
computer. The NEMA 4X enclosure is available in fiberglass, aluminum, or
stainless steel. The IP65 enclosure is available in aluminum or stainless
steel. The NEMA 4 enclosure (AutoPILOT PRO XL) is a carbon steel
powder painted inside and out, type NEMA 4 / IP66 design. All enclosures
come standard with display and keypad.
Figure 2–1.
Dimensions: NEMA 4X & IP65 metal enclosures
The Enclosure

Hardware Description: Basic System
The Enclosure
2-2
AutoPILOT PRO Flow Computer User Guide Thermo Fisher Scientific
Figure 2–2.
Dimensions: NEMA 4X fiberglass enclosure
Figure 2–3.
Dimensions: NEMA 4 enclosure

Hardware Description: Basic System
Power
Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
2-3
The standard instrument is powered by an external 10–30 Vdc power
supply. Alternatively, the instrument may be powered by an internal
rechargeable battery. Power is connected to the flow computer through the
power distribution terminal block (TB1), located on the door panel of the
enclosure.
Power consumption of the basic AutoPILOT PRO flow computer is about
1 W for a typical unit; however, overall power consumption depends upon
the I/O configuration and is determined on an individual basis. Every
effort has been made to keep power consumption to a minimum.
The voltage range of the standard external power supply is 10–30 Vdc. If a
wireless radio is included in the system, the power supply should be able to
provide a current greater than 2.5 A.
See Chapter 3 for installation and wiring instructions.
If the internal battery option is used, the instrument is powered by a
rechargeable battery assembly that sits in a bracket fastened to the
instrument’s internal bracket. This battery is charged by an external solar
panel and incorporates a solar charger controller (SCC) that employs a
three-state solar charger algorithm: the bulk charge, the controlled
overcharge, and the float charge state.
When the battery capacity is 90% or less, the charger enters the bulk charge
state, providing the maximum and constant charge current to the battery.
Once the battery is close to being fully charged, the SCC enters the
controlled over-charging state. In this state, the SCC over-charges the
battery to ensure it is fully charged. Once the over-charging current reaches
its set point, the SCC switches to the float charge state, providing moderate
charging current to maintain the battery at its fully charged voltage level.
The charging cycle repeats when the battery capacity drops below 90%.
The SCC internal reference voltage is characterized with a negative
temperature coefficient matching that of a lead acid battery. The charger
voltage is automatically adjusted. Charging voltage increases at lower
ambient temperatures in order to maintain a fully charged battery. At
higher ambient temperatures, charging voltage is scaled off to help extend
the battery life.
The SCC dissipates its charging process heat through the main board
chassis. For proper operation, the main board must be mounted on its
bracket and the main board transistor Q12 must be attached to the chassis
bracket by a screw (see Figure 11–1 for an illustration).
Power
External Power
Source
Internal Battery &
Solar Charger
Controller

Hardware Description: Basic System
The Main Board
2-4
AutoPILOT PRO Flow Computer User Guide Thermo Fisher Scientific
The SCC accepts up to 20 W solar panels. TB10 on the main board is the
solar charger power input. For instructions on how to install the optional
internal battery, refer to “Installing the Internal Battery” in Chapter 3.
Table 2–1.
SCC specifications
Input solar panel voltage 12 V, 20 W max.
Output float charge voltage ~13.6 V
Output overcharge voltage ~14.7 V
Ambient temperature -40°C to +70°C
Input reverse voltage protection Yes
Shorted battery protection Yes
A set of the illustrations provided in this chapter and additional wiring
diagrams are provided in Appendix D.
The jumper settings and connector descriptions for the main board
discussed in this section are provided in Appendix C.
A Lithium backup battery is installed on the main board (BT1) to maintain
configuration, memory, and the real-time clock when power is removed
from the unit. The in-circuit connection of the Lithium battery is set by
installing a jumper at J39 pins 11–12 on the main board.
Tip
Loss of configuration or historical data with the backup battery jumper
installed may indicate that the Lithium battery needs to be replaced. 
Tip
The Lithium battery is a field replaceable item. Refer to “Replacing the
Backup Battery” in Chapter 11 for replacement instructions. 
Warning
The Lithium battery may explode if mistreated. Do not attempt
to recharge, disassemble, or burn it. 
The Main Board
Jumper Settings &
Connections
Lithium Backup
Battery

Hardware Description: Basic System
The Main Board
Thermo Fisher Scientific AutoPILOT PRO Flow Computer User Guide
2-5
The main board provides three analog inputs for single low-power
transducers (0–5 Vdc maximum range). Other transducers with voltage
output ranges such as 0.8–3.2 V or 1–5 V units may be used with software
scaling provided the 0–5 V limits are not exceeded. Use of 4–20 mA
current loop transmitters is not recommended for units powered from
small battery sources.
The analog inputs have been evaluated as non-incendive field circuits for
use with the following analog transmitters (differential pressure, static
pressure, and temperature):
Druck static pressure transmitter, Model PDCR143-8003 (25–3000
psi range)
Rosemountstatic pressure transmitter, Model 3051C Low Power
(3626 psi maximum)
Rosemountdifferential pressure transmitter, Model 2024 (2000 psi
maximum)
Rosemountdifferential pressure transmitter, Model 3051C Low
Power (3626 psi maximum)
Thermo Scientific RTD temperature transmitter, Model 465A
The transmitters may be connected to the flow computer using standard
cabling and optional flexible conduit. All transmitters are wired to TB1
through TB3 on the main board or to analog input channels 1 through 16
on the optional analog input expansion / terminal boards. Maximum cable
length between the flow computer and each transmitter is 25 feet.
Each local analog input provides transmitter power (XPWR) at a nominal
+12 V that power cycles with the unit, a transmitter signal input (IN), and
a transmitter power return (AGND). The analog inputs on the main board
are identified in the following table.
Table 2–2.
Analog inputs on the main board
Input
In
AGND
XPWR
AI1 TB1-1 TB1-2 TB1-3
AI2 TB2-1 TB2-2 TB2-3
AI3 TB3-1 TB3-2 TB3-3
Transducer Inputs