TotalFlow uFLO User manual

2100890-001 (AB)
TOTALFLOW®
µFLO Computer
User’s Manual

Copyright Notice
©2003 by ABB ,Inc., Totalflow Products, Bartlesville, Oklahoma 74006, U.S.A. All rights reserved.
This publication is for information only. The contents are subject to change without notice and should not
be construed as a commitment, representation, warranty, or guarantee of any method, product, or device
by Totalflow.
Inquiries regarding this manual should be addressed to ABB, Inc., Totalflow Products, Technical
Communications, 7051 Industrial Blvd., Bartlesville, Oklahoma 74006, U.S.A.

i
Table of Contents
Introduction................................................................................................................. ix
About the Manual......................................................................................................................... ix
Key Symbols ................................................................................................................................ ix
Getting Help .................................................................................................................................. x
Safety Practices and Precautions ................................................................................................. x
Chapter 1 System Description .................................................................................1-1
Overview ....................................................................................................................................1-1
µFLO Computer Hardware ........................................................................................................1-6
µFLO General Specifications ....................................................................................................1-9
µFLO 2100767 Board..............................................................................................................1-10
Integral Multivariable Transducer (IMV) Specifications............................................................1-10
Functions of the µFLO.............................................................................................................1-11
Log Period Records .................................................................................................................1-12
Display Function.......................................................................................................................1-14
Status and Alarm Conditions....................................................................................................1-15
Chapter 2 Installation ...............................................................................................2-1
Overview ....................................................................................................................................2-1
Unpacking & Inspection .............................................................................................................2-2
Meter Run Installation Overview ................................................................................................2-2
Pipe Mount Installation...............................................................................................................2-4
Wall Mount Installation...............................................................................................................2-8
Direct Mount Installation...........................................................................................................2-10
Manifold Input Lines.................................................................................................................2-12
RTD Probe Installation.............................................................................................................2-13
Battery Pack Installation...........................................................................................................2-16
Solar Panel Installation ............................................................................................................2-16
AC Charging Unit Installation...................................................................................................2-18
Chapter 3 µFLO Startup...........................................................................................3-1
Overview ....................................................................................................................................3-1
Laptop Computer running PCCU32 ...........................................................................................3-2
FS/2 Handheld PCCU ................................................................................................................3-2

ii
Setting up the µFLO.............................................................................................................. 3-3
Overview....................................................................................................................................3-3
Station ID ...................................................................................................................................3-3
Location .....................................................................................................................................3-3
Date/Time ..................................................................................................................................3-3
Security System .........................................................................................................................3-4
Configuring the µFLO........................................................................................................... 3-5
Contract Hour ............................................................................................................................3-5
Volume Calculation Period ........................................................................................................3-5
Log Period .................................................................................................................................3-5
Calculation Type ........................................................................................................................3-5
Constants...................................................................................................................................3-7
Super Compressibility Calculation (Fpv).................................................................................... 3-8
Alarm Limits ...............................................................................................................................3-9
Reset Volume ............................................................................................................................3-9
Startup µFLO ....................................................................................................................... 3-11
Put µFLO On Line...................................................................................................................3-11
Volume Reset ..........................................................................................................................3-11
µFLO Standard Displays .................................................................................................... 3-13
Program Display ......................................................................................................................3-13
Chapter 4 Maintenance & Troubleshooting............................................................ 4-1
Overview....................................................................................................................................4-1
Maintenance ........................................................................................................................... 4-3
Backing up Configuration Files ..................................................................................................4-3
Changing µFLO Clock .............................................................................................................. 4-3
Replacing µFLO Battery Pack ..................................................................................................4-4
Replacing Liquid Crystal Display (LCD) Board ..........................................................................4-8
Replacing Integral Multivariable Transducer (IMV).................................................................... 4-9
Callibration Overview ...............................................................................................................4-12
Checking Static Pressure (SP) ................................................................................................ 4-13
Calibrating Static Pressure (SP) ..............................................................................................4-13
Checking Differential Pressure (DP)........................................................................................4-14
Calibrating Differential Pressure (DP)...................................................................................... 4-14

iii
Setup RTD ...............................................................................................................................4-14
How to Change Orifice Plate....................................................................................................4-15
Zero Transducer.......................................................................................................................4-16
Troubleshooting................................................................................................................... 4-17
Reset Procedures ....................................................................................................................4-17
Visual Alarm Codes..................................................................................................................4-21
Troubleshooting Alarms ...........................................................................................................4-22
Communications Overview ......................................................................................................4-24
RS-232 Communications .........................................................................................................4-24
RS-485 Communications .........................................................................................................4-26
RS-422 Communications .........................................................................................................4-28
Wake-Up ..................................................................................................................................4-30
Chapter 5 Totalflow®Definitions and Acronyms....................................................5-1
Chapter 6 Drawing & Diagrams ...............................................................................6-1

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v
Table of Figures
Figure 1–1 µFLO 6213 Dimensions ...........................................................................................1-2
Figure 1–2 µFLO 6210 Dimensions ...........................................................................................1-3
Figure 1–3 Bottom View µFLO 6213..........................................................................................1-4
Figure 1–4 Bottom View µFLO 6210..........................................................................................1-4
Figure 1–5 Integral Multivariable Transducer (IMV)...................................................................1-5
Figure 1–6 µFLO 2100767 Board, Complete Overview .............................................................1-7
Figure 1–7 µFLO Comm Board .................................................................................................1-8
Figure 1–8 Liquid Crystal Display and Indicators.....................................................................1-15
Figure 2–1 Bottom View of µFLO 6213 with IMV ......................................................................2-3
Figure 2–2 Bottom View of µFLO 6210 with IMV ......................................................................2-3
Figure 2–3 Typical Pipe Installation ...........................................................................................2-4
Figure 2–4 Typical Pipe Saddle Installation...............................................................................2-5
Figure 2–5 µFLO Pipe Mounted ................................................................................................2-6
Figure 2–6 µFLO 6213 Pipe Mounted........................................................................................2-7
Figure 2–7 µFLO 6213 Wall Mounted........................................................................................2-9
Figure 2–8 µFLO 6213 Direct Mounted....................................................................................2-11
Figure 2–9 µFLO Computer IMV Ports....................................................................................2-12
Figure 2–10 RTD Probe Wiring................................................................................................2-13
Figure 2–11 µFLO 2100767 Board Cutout, Installation...........................................................2-15
Figure 2–12 Typical Solar Panel Installation............................................................................2-18
Figure 2–13 Mounting AC Charger ..........................................................................................2-20
Figure 4–1 µFLO 2100767 Board Cutout, Maintenance............................................................4-5
Figure 4–2 µFLO 6210 Component/Cable Locations.................................................................4-6
Figure 4–3 µFLO 6213 Component/Cable Locations.................................................................4-7
Figure 4–4 Flow Computer with Discrete Manifold ..................................................................4-10
Figure 4–5 µFLO 2100767 Board with Communication Configurations...................................4-19
Figure 4–6 Liquid Crystal Display and Indicators.....................................................................4-21

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vii
List of Tables
Table 1–1 µFLO 2100767 Board Identifications, Complete Overview.......................................1-7
Table 1–2 Typical µFLO Display Options................................................................................1-14
Table 1–3 µFLO Status and Alarm Description.......................................................................1-15
Table 2–1 µFLO 2100767 Board Identifications, Installation...................................................2-15
Table 3–1 Configurable Calculation Factors..............................................................................3-6
Table 3–2 Gas Orifice Constants...............................................................................................3-7
Table 3–3 Fpv Analysis Data .....................................................................................................3-8
Table 3–4 Alarm Limits ..............................................................................................................3-9
Table 3–5 µFLO Displayed Items............................................................................................3-13
Table 4–1 µFLO 2100767 Board Identifications, Maintenance .................................................4-5
Table 4–2 µFLO 6210/6213 Component Identifications ............................................................4-8
Table 4–3 Calibration Configurable Parameters ......................................................................4-12
Table 4–4 µFLO 2100767 Board with Communication Configurations ...................................4-20
Table 4–5 Visual Alarm Codes.................................................................................................4-21
Table 4–6 Troubleshooting Alarm Codes.................................................................................4-22
Table 4–7 Troubleshooting RS-232 Serial Communication .....................................................4-24
Table 4–8 Troubleshooting RS-485 Communications .............................................................4-26
Table 4–9 Troubleshooting RS-422 Communications .............................................................4-28

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ix
Introduction
About the Manual
This manual is written to provide an experienced flow meter technician with the requirements necessary
to install, setup and operate a Totalflow Flow Computer System.
Organization &
Style
Each of the chapters in this manual presents information in an organized and concise
manner. Readers are able to look at the headings and get a broad picture of the
content without reading every word. Also, there are overviews at the beginning of
each chapter that provides you with an idea of what is in the chapter, and how it fits
into the overall manual.
Highlights This manual provides the following information:
Chapter Description
1. System Description Provides a description of the Totalflow µFLO system
components, specifications, and description of flow
computer computation methods.
2. Installation Includes unpacking and detailed procedures for setup
and installation.
3. µFLO Operation Provides you with a tutorial on how to get a newly
installed µFLO system up and running.
4. Maintenance &
Troubleshooting
Provides instructions on how to remove and replace
major modules, a description of the µFLO front panel
error messages and provides a troubleshooting chart on
how to correct most problems.
5. Definitions &
Acronyms
Provides quick access to the majority of terms and
acronyms, as well as their definitions.
6. Drawings Provides a place to put drawings that accompany a unit.
Key Symbols
The following symbols are used frequently in the manual. These are intended to catch your eye and draw
your attention to important information.
Intended to draw your attention to a statement that might clarify a point made earlier.
Intended to draw your attention to a statement that might keep you from making a
mistake, keep you from destroying equipment or parts, or keep you from personal
injury.
Intended to draw your attention to a fact that may be useful or helpful.

x
Getting Help
At Totalflow, we take pride in the on going support we provide our customers. When you purchase a
product, you receive documentation which should answer your questions; however, your Totalflow
technical support provides you an 800 number as an added source of information.
If you require assistance, call:
USA: [phone] or International: 001-918-338-4888
Before You Call • Know your Totalflow’s serial number. Serial numbers can be found on the
escutcheon plate located on the side of each unit.
• Be prepared to give the customer service representative a detailed description of
the problem.
• Note any alarms or messages as they appear on the PCCU or front panel LCD.
• Prepare a written description of problem.
• Know your software version, board and IMV part numbers.
Safety Practices and Precautions
This manual contains information and warnings which have to be followed by the user to ensure safe
operation and to retain the product in a safe condition.
Safety First WARNING statements identify conditions or practices that could result in personal
injury or loss of life.
CAUTION statements identify conditions or practices that could result in damage to
the equipment or other property.
Symbols in
This Manual
This symbol indicates where applicable safety, cautionary or other
information is to be found.
Terms as
Marked on
Equipment
DANGER indicates a personal injury hazard immediately accessible as one reads the
markings.
CAUTION indicates a personal injury hazard not immediately accessible as one reads
the markings, or a hazard to property, including the equipment itself.
Symbols
Marked on
Equipment Protective ground (earth) terminal
Grounding the
Product
If a grounding conductor is required, it should be connected to the grounding terminal
before any other connections are made.
Correct
Operating
Voltage
Before switching on the power, check that the operating voltage listed on the
equipment agrees with the power being connected to the equipment.
Continued on Next Page

xi
Safety Practices and Precautions, Continued
Danger
Arising
From Loss of
Ground
A grounding conductor may or may not be required depending on the hazardous
classification. If required, any interruption of the grounding conductor inside or outside
the equipment or loose connection of the grounding conductor can result in a
dangerous unit. Intentional interruption of the grounding conductor is not permitted.
Safe
Equipment
If it is determined that the equipment cannot be operated safety, it should be taken
out of operation and secured against unintentional usage.
Fuse
Replacement
Fuses used on the µFLO electronic boards are surface mount and field repair should
not be attempted. Most fuses automatically reset themselves, but if a know problem
exists, the Measurement Unit Assembly should be sent in for repair or replacement.
Safety
Guidelines
DO NOT open the equipment to perform any adjustments, measurements,
maintenance, parts replacement or repairs until all external power supplies have been
disconnected.
Only a properly trained technician should work on any equipment with power still
applied.
When opening covers or removing parts, exercise extreme care "live parts or
connections can be exposed".
Capacitors in the equipment can still be charged even after the unit has been
disconnected from all power supplies.

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1-1
Chapter 1
System Description
Overview
This Chapter introduces you to the TOTALFLOWµFLO 6200 series flow computers. µFLO computers
are low power, microprocessor based units designed to meet a wide range of measurement, monitor
and alarming applications for remote gas systems.
Model µFLO 6213 is packaged in a light weight enclosure that can accommodate the µFLO 2100767
Board (main electronic board), a variety of remote communications options and batteries (See Figure
1–1).
Model µFLO 6210, is also packaged in a small light weight enclosure which can only accommodate the
µFLO 2100767 board. All power supply and radio communication applications must be housed in
separate accommodations (See Figure 1–2).
In both models, the µFLO IMV (Integral Multivariable Transducer) unit and Main Board are a single unit
and are mounted underneath (See Figures 1-3 and 1-4) the enclosure with the top portion inserted into
the enclosure where all field wiring takes place (See Figure 1-5). This µFLO IMV unit is factory sealed
and is currently not field repairable.
The symbol µstands for the Greek word meaning micro or mu and the letters FLO is short for flow. As
it’s name implies, it is a flow computer designed to meet basic needs, eliminating many of the features
on our more expandable Flow Computers. Based on ABB Totalflow XSeries technology, it is designed
to provide a cost effective alternative to the multi-feature, multi-tube XSeries Flow Computer.
Highlights This Chapter covers the following topics:
Topic See Page
µFLO Computer Hardware 1-6
µFLO General Specifications 1-9
µFLO 2100767 Board 1-10
Integral Multivariable Transducer (IMV) Specifications 1-10
Functions of the µFLO 1-11
Log Period Records 1-12
Display Function 1-14
Status and Alarm Conditions 1-15
Continued on Next Page

1-2
FLO 6213
Figure 1–1 µFLO 6213 Dimensions

1-3
4.186
3.141
4.355
9.359
3.23
12.602
8.647
9.992 9.367
13.206
Figure 1–2 µFLO 6210 Dimensions

1-4
Figure 1–3 Bottom View µFLO 6213
9.367
9.992
8.647
Figure 1–4 Bottom View µFLO 6210

1-5
(+)
(-)
Figure 1–5 Integral Multivariable Transducer (IMV)
Overview, Continued
Capabilities The µFLO defaults to retention of daily and log period records for 40 days and
retention of 200 events. These defaults can be extended, limited only by the file
space on the device.
This model may be used in conjunction with the handheld FS/2 and/or a laptop
computer running PCCU32 software. The FS/2 can do basic procedures, but
PCCU32 is required for many of the initial setup features of the device.
The µFLO maintains a history of alarms as well as average differential pressure
(DP), average static pressure (SP), average flowing temperature (Tf), accumulated
volume and energy and an average extension.
The µFLO can be programmed to calculate flow rates and volumes in accordance
with either AGA 3-85, AGA 3-92.
Supercompressibility calculations can be performed in accordance with either NX-19
or AGA 8-92, gross or detail.

1-6
µFLO Computer Hardware
The Totalflow® µFLO 6200 Computers are housed in a lightweight single compartment aluminum case.
It’s components are:
• Aluminum enclosure
• µFLO 2100767 Board
• Integral Multivariable Transducer
• Liquid Crystal Display (LCD)
• Resistive Temperature Detector (RTD)
• Battery Compartment Shelf (Model 6213 only)
• Communication Area(Model 6213 only)
• Charger or Solar Panel(Model 6213 only)
Enclosure The enclosure consists of hinged-door box. The door provides a watertight,
corrosion resistant seal between the outside elements and the µFLO
components. It is NEMA 4X rated. Opening the door’s latch allows access to
electronics and Integral Multivariable Transducer (IMV) components.
µFLO 2100767
Board
The µFLO 2100767 Board is mounted directly on the Integral Multivariable
Transducer (IMV). All user connections to the board are mounted directly on the
face of the board. The µFLO 2100767 Board uses a low power processor
running at 11.0592 MHz with Data stored in 512K SRAM. RAM memory has
lithium backup battery. The applications programs are stored in 512K Flash, the
flash loader is stored in 512 K PROM, and Registry and Configuration files are
stored in 32K E2PROM. Other circuitry processes the inputs from the IMV and
provides interfaces to the LCD and the PCCU. Remote communications are
handled by the µFLO Communications Connector J3 (See Figure 1–6, Item #1
and Table 1-1).
Integral
Multivariable
Transducer (IMV)
The IMV contains circuitry for processing all measurements and provides the
primary measurement capability for the µFLO (See Figure 1-6). The unit is
designed to provide EMI/RFI protection of the low level signals, and to protect
the circuitry from other environmental effects.
Because the IMV is characterized over temperature at the factory the unit is not
field repairable. All repairs should be done at an authorized Totalflow depot
service center or returned to the factory. The IMV is characterized over
temperature so that any changes occurring in the IMV or in the electronics can
be compensated.
Resistive
Temperature
Detector (RTD)
An optional 100-ohm platinum RTD measures real-time flowing temperature of
the gas. The standard RTD is provided with a 10-foot cable. Other lengths of
cable are available upon request.
Battery
Compartment Shelf
The battery compartment shelf (6213 only) will house various optional battery
packs that are available for the µFLO; from 8 ampere hours up to 26 ampere
hours. Installation of the battery is discussed in detail in Chapter 4,
Maintenance & Troubleshooting.
Continued on Next Page