TotalFlow XSeries User manual

2100802-001 (AB)
TOTALFLOW®
XSeries Remote Controller
User's Manual

Intellectual Property & Copyright Notice
©2002, 2007 by ABB Inc., Totalflow (“Owner”), Bartlesville, Oklahoma 74006, U.S.A. All
rights reserved.
Any and all derivatives of, including translations thereof, shall remain the sole property of
the Owner, regardless of any circumstances.
The original US English version of this manual shall be deemed the only valid version.
Translated versions, in any other language, shall be maintained as accurately as possible.
Should any discrepancies exist, the US English version will be considered final.
Notice: 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 Owner.
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
Getting Help..................................................................................................................x
Key Symbols.................................................................................................................x
Safety Practices and Precautions................................................................................ xi
Chapter 1 System Description............................................................................1-1
Overview................................................................................................................... 1-1
XSeries Remote Controller Hardware ...................................................................... 1-2
Standard Enclosure .................................................................................................. 1-4
Rack Mount Enclosure.............................................................................................. 1-7
XRC General Specifications ..................................................................................... 1-8
XRC-195 Electronic Board Specifications ................................................................ 1-9
XSeries On-board Input/Output .............................................................................. 1-11
Digital Output.......................................................................................................... 1-13
Analog Inputs.......................................................................................................... 1-14
Display Function ..................................................................................................... 1-15
Functions of the XRC.............................................................................................. 1-16
Display Annunciators.............................................................................................. 1-17
Laptop Computer running PCCU32........................................................................ 1-20
FS/2 Handheld PCCU............................................................................................. 1-20
Optional Equipment .................................................................................................. 1-21
Key Pad .................................................................................................................. 1-21
Totalflow Input/Output Modules.............................................................................. 1-24
Chapter 2 Installation ..........................................................................................2-1
Overview................................................................................................................... 2-1
Unpacking & Inspection ............................................................................................ 2-1
Pipe Saddle Mount Installation ................................................................................. 2-2
Wall Mount Installation.............................................................................................. 2-6
Battery Pack Installation ........................................................................................... 2-8
Solar Panel Installation........................................................................................... 2-10
AC Charging Unit Installation.................................................................................. 2-12
XRC6990 Rack Mount Installation.......................................................................... 2-15
XRC Communication, Jumper Settings and Field Wiring ....................................... 2-17
Chapter 3 XRC Startup ........................................................................................3-1
Overview................................................................................................................... 3-1
PCCU32 Installation and Setup................................................................................ 3-2
Connecting To Local Port ......................................................................................... 3-2
Setting up the XRC...................................................................................................... 3-4
Overview................................................................................................................... 3-4

ii
Station ID.................................................................................................................. 3-4
Device ID / Application ID......................................................................................... 3-4
Location .................................................................................................................... 3-5
Date/Time ................................................................................................................. 3-5
Program Display ....................................................................................................... 3-5
Security System........................................................................................................ 3-6
On Board I/O Calibration ............................................................................................ 3-8
Overview................................................................................................................... 3-8
Analog Input Calibration ........................................................................................... 3-8
Pulse and Digital Input Calibration ......................................................................... 3-10
Chapter 4 Maintenance ....................................................................................... 4-1
Overview................................................................................................................... 4-1
Backing up Configuration Files................................................................................. 4-2
Changing XRC Clock................................................................................................ 4-2
Downloading a New Flash........................................................................................ 4-3
Components and Spare Parts .................................................................................. 4-4
Replacing XRC Battery Pack.................................................................................... 4-8
Replacing Liquid Crystal Display (LCD) Board....................................................... 4-13
Chapter 5 Troubleshooting ................................................................................ 5-1
Overview................................................................................................................... 5-1
Troubleshooting Visual Alarm Codes ....................................................................... 5-4
Overview................................................................................................................... 5-4
Troubleshooting a Blank LCD Screen ...................................................................... 5-5
Troubleshooting a Low Lithium Alarm (LL)............................................................... 5-6
Troubleshooting a Low Charger Alarm (LC)............................................................. 5-7
Troubleshooting a Analog to Digital Failure Alarm (AD)........................................... 5-7
Resistive Temperature Detector (RTD) Continuity Test ........................................... 5-9
RTD Current Source (Resistive) Test..................................................................... 5-10
RTD Impedance Test ............................................................................................. 5-11
Power Troubleshooting ............................................................................................ 5-12
Overview................................................................................................................. 5-12
Power Supply Test ................................................................................................. 5-13
Solar Panel Charging System Test ........................................................................ 5-13
AC Charging System Test ...................................................................................... 5-15
Auxiliary Equipment Isolation Test ......................................................................... 5-16
TFIO Module Isolation Test .................................................................................... 5-17
SLEEP Mode .......................................................................................................... 5-18
Reset Procedures................................................................................................... 5-19
Troubleshooting Communications.......................................................................... 5-21
Communications Overview..................................................................................... 5-21
Transceiver Supply Voltage Test............................................................................ 5-23

iii
12V Communication Supply Voltage Test .............................................................. 5-23
Transceiver Check.................................................................................................. 5-25
RS-232 Communication Test.................................................................................. 5-25
RS-485 Communication Test.................................................................................. 5-27
RS-485 Communication Test.................................................................................. 5-27
Appendix A Register Documents ...................................................................... A-1
Standard Registers .....................................................................................................A-1
Alarm System Application Registers (Rev AB) ......................................................... A-1
Display Application Registers (Rev AA).................................................................... A-5
Holding Register Application (Rev AA)..................................................................... A-7
Operations Application Registers (Rev AB).............................................................. A-8
System Application Registers (Rev AD) ................................................................. A-21
Trend System Application Registers (Rev AA) ....................................................... A-24
Communication Registers........................................................................................A-26
Communication Application Registers (Rev AA) .................................................... A-26
FS2 Application Registers (Rev AA)....................................................................... A-28
XMV Interface Application Registers (Rev AC) ...................................................... A-33
Therms Master Application Registers (Rev AB) ..................................................... A-37
Therms Salve Application Registers (Rev AA) ....................................................... A-52
I/O Subsystem ...........................................................................................................A-57
I/O Subsystem Data Array Registers...................................................................... A-57
Tube Applications .....................................................................................................A-66
AGA3 Tube Application Registers (Rev AM) .......................................................... A-66
AGA7 Tube Application Registers (Rev AH) .......................................................... A-82
Enron Tube Registers (Rev AA) ............................................................................. A-98
Selectable Units.......................................................................................................A-122
AGA3 Selectable Units Tube Registers (Rev AE) ................................................ A-122
AGA7 Selectable Units Tube Registers (Rev AD) ................................................ A-142
Enron AGA3 Selectable Units Tube Registers (Rev AA)...................................... A-164
Appendix B Definitions & Acronyms ................................................................ B-1
Appendix C Drawing & Diagrams ...................................................................... C-1

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Table of Figures
Figure 1–1 Model XRC6490.............................................................................................. 1-4
Figure 1–2 Model XRC6790.............................................................................................. 1-5
Figure 1–3 Model XRC6890.............................................................................................. 1-6
Figure 1–4 XRC6990 Rack Mount .................................................................................... 1-7
Figure 1–5 Complete View XRC-195 Board ................................................................... 1-10
Figure 1–6 Liquid Crystal Display and Indicators............................................................ 1-18
Figure 1–7 Optional Keypad (P/N 2100652-xxx) ............................................................ 1-22
Figure 1–8 XRC6490 with Optional Key Pad .................................................................. 1-22
Figure 1–9 XRC6790 With Optional Keypad................................................................... 1-23
Figure 1–10 XRC6890 With Optional Keypad................................................................. 1-23
Figure 1–11 XRC6990 with Dual Keypads...................................................................... 1-24
Figure 1–12 TFIO Module Housing................................................................................. 1-25
Figure 1–13 XRC6490 Inside View ................................................................................. 1-25
Figure 1–14 XRC6790 Inside View ................................................................................. 1-26
Figure 1–15 XRC6890 Inside View ................................................................................. 1-26
Figure 1–16 XRC6990 Inside View ................................................................................. 1-27
Figure 2–1 Typical Pipe Saddle Installation...................................................................... 2-3
Figure 2–2 Model XRC6490, Pipe Mounted ..................................................................... 2-4
Figure 2–3 Model XRC6790, Pipe Mounted ..................................................................... 2-4
Figure 2–4 Model XRC6890, Pipe Mounted ..................................................................... 2-5
Figure 2–5 XRC Pipe Mounting ........................................................................................ 2-5
Figure 2–6 Model XRC6490, Wall Mounted...................................................................... 2-7
Figure 2–7 Model XRC6790, Wall Mounted...................................................................... 2-7
Figure 2–8 Model XRC6890, Wall Mounted...................................................................... 2-8
Figure 2–9 XRC-195 Board Battery and Charger Input Connections ............................... 2-9
Figure 2–10 Typical Solar Panel Installation................................................................... 2-10
Figure 2–11 Mounting AC Charger ................................................................................. 2-13
Figure 2–12 DC Wiring Instructions ................................................................................ 2-14
Figure 2–13 AC Wiring Instructions ................................................................................ 2-14
Figure 2–14 XRC6990 Rack Mount ................................................................................ 2-15
Figure 2–15 Single and Dual Unit Termination Panels ................................................... 2-16
Figure 2–16 XRC Standard Communication Wiring........................................................ 2-17
Figure 2–17 XRC Panel Mount Field Wiring Diagram..................................................... 2-18
Figure 2–18 XRC Main Electronic Board Jumper Configuration..................................... 2-20
Figure 2–19 Other Field Wiring I/O Connections ............................................................ 2-21
Figure 3–1 RS-232 MMI Communication Cables.............................................................. 3-3
Figure 3–2 XRC-195 Board- Analog Input Calibration Points ........................................... 3-9
Figure 3–3 195 Board- Analog Input Calibration Points.................................................. 3-10
Figure 4–1 XRC6490 Component/Cable Locations.......................................................... 4-4
Figure 4–2 XRC6890 Component/Cable Locations.......................................................... 4-5
Figure 4–3 Memory Backup Enable Jumper..................................................................... 4-8
Figure 4–4 XRC Battery and Charger Connections .......................................................... 4-9

vi
Figure 4–5 XRC Board Connections................................................................................4-12
Figure 5–1 Troubleshooting Flowchart ..............................................................................5-3
Figure 5–2 Liquid Crystal Display and Indicators...............................................................5-4
Figure 5–3 Battery Charger and Battery Pack Connections ..............................................5-6
Figure 5–4 Power Troubleshooting Flowchart .................................................................5-12
Figure 5–5 AC-DC Charger Wiring Instructions...............................................................5-16
Figure 5–6 Current Measurement Troubleshooting Cable...............................................5-17
Figure 5–7 Lithium Battery Backup Enable/Disable.........................................................5-20
Figure 5–8 Communication Troubleshooting Flow Chart.................................................5-22
Figure 5–9 XRC-195 Communication Wiring...................................................................5-24

vii
List of Tables
Table 1–1 XRC Board Component Descriptions............................................................. 1-11
Table 1–2 Typical XRC Display Options ......................................................................... 1-16
Table 1–3 Status and Alarm Description......................................................................... 1-18
Table 2–1 XRC Main Electronic Board to Termination Panel Correlation Chart............. 2-16
Table 2–2 XRC On-Board Jumper Settings .................................................................... 2-19
Table 3–1 XRC Displayed Items ....................................................................................... 3-5
Table 4–1 XRC6490 and 6890 Component Identifications............................................... 4-6
Table 4–2 Additional Spare Parts ..................................................................................... 4-7
Table 5–1 Visual Alarm Codes.......................................................................................... 5-4
Table 5–2 Specifications for Solar panels....................................................................... 5-15
Table 5–3 RS-232 Field Wiring on XRC-195 Board........................................................ 5-25
Table 5–4 RS-485 Field Wiring on XRC-195 Board........................................................ 5-27
Table 5–5 RS-485 Terminations ..................................................................................... 5-27
Table A–1 Discovery information for hardware drivers installed. .................................... A-64
Table A–2 Discovery PCU32 Ini Partnumbers. ............................................................... A-65
Table A–3 Discover Firmware number and revision of IO modules................................ A-65

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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 XSeries Remote
Controller 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, XSeries
system components and specifications.
2) Installation Includes unpacking and detailed procedures for
setup and installation.
3) XRC Startup Provides you with a tutorial on how to get a
newly installed XRC system up and running.
4) Maintenance Provides instructions on how to remove and
replace major modules.
5) Troubleshooting Provides a description of the XRC front panel
error messages and provides a troubleshooting
chart on how to correct most problems.
Appendix A: Modbus
Register Table
Provides a listing of all valid Modbus Registers.
Appendix B: Definitions
& Acronyms
Provides quick access to the majority of terms
and abbreviations, as well as their definitions.
Appendix C: Drawings Provides a place to put drawings that
accompany a unit.

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, Totalflow Technical Support provides you an 800 number as an added source of
information.
If you require assistance, call:
USA: [phone] International: 001-918-338-4888
Before You
Call
•Know your Totalflow’s model and serial number. Serial numbers can
be found on a plate located on each unit.
•Be prepared to give the customer service representative a detailed
description of the problem.
•Note any alarms or messages as they appear.
•Prepare a written description of problem.
•Know your software version, board and optional part numbers.
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 useful information or to clarify a
statement made earlier.
Intended to draw your attention to a fact that may be useful or helpful in
understanding a concept.
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 creating a situation that could cause personal injury if caution
is not used. Please refer to the “Safety Practices and Precaution”
section for additional information.
Intended to draw your attention to a statement regarding the likelihood of
personal injury or fatality that could result from improper access or
techniques used while working in hazardous locations. Please refer to
the “Safety Practices and Precaution” section for additional information.

xi
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. Installation, maintenance
and repairs should only be performed by a trained and qualified technician. Please refer to
Certification Drawings shipped with this unit for specific guidelines. Extra copies of the
certification drawings, referenced on the unit Name Tag, can be obtained, free of charge, by
contacting Totalflow Technical Support at the number listed in the “Getting Help” section.
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".
•Installation and maintenance must be performed by person(s) qualified
for the type and area of installation according to National and Local
codes.
•Capacitors in the equipment can still be charged even after the unit
has been disconnected from all power supplies.
Safety First Various statements in this manual identified as conditions or practices that
could result in equipment damage, personal injury or loss of life will be
highlighted using the following Icons.
Exercise caution while performing this task. Carelessness
could result in damage to the equipment, other property
and personal injury.
Stop. Do not proceed without first verifying that a
hazardous condition does not exist. This task may not be
undertaken until proper protection has been accomplished,
or the hazardous condition has been removed. Personal
injury or fatality could result. Examples of these warnings
include:
•Removal of enclosure cover(s) in a hazardous location
must follow guidelines stipulated in the Certification
Drawings shipped with this unit.
•If unit is installed or to be installed in a hazardous
location, technician must follow the guidelines
stipulated in the Certification Drawings shipped with
this unit.
•Access to unit via PCCU cable in a hazardous location
must follow guidelines stipulated in the Certification
Drawings shipped with this unit.
•Connecting or disconnecting equipment in a
hazardous location for installation or maintenance of
electric components must follow guidelines stipulated
in the Certification Drawings shipped with this unit.
Continued on Next Page

xii
Safety Practices and Precautions, Cont.
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.
Equipment
Markings 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.
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.
Danger 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 XSeries Model electronic boards are surface mount and
field repair should not be attempted. Most fuses automatically reset
themselves, but if a know problem exists, the board should be sent in for
repair or replacement.

1-1
Chapter 1
System Description
Overview
This Chapter introduces you to the Totalflow®XSeries Remote Controllers (XRC). The
XSeries are low power, microprocessor based units designed to meet a wide range of
automation, monitor, control, alarming and measurement applications. Four models are
available: Models XRC6490, 6790, 6890 and 6990.
The letters XRC stand for Extendable Remote Controller. As their name implies, they are
expandable to meet your needs, while maintaining backward compatibility with legacy
Totalflow systems.
Each model is packaged in an enclosure that can accommodate the Main Electronic Board
(XRC-195 Board), Liquid Crystal Display, a variety of batteries, remote communication
device (except 6990), and additional I/O Modules. The XRC6490 can accommodate up to
3 I/O Modules, the XRC6790 can accommodate up to 6 I/O Modules, the XRC6890 can
accommodate up to 14 I/O Modules and Rack Mount XRC6990 can accommodate up to 6
I/O modules per Main Electronic Board.
The XRC is powered by a battery system, which can be charged using; either solar panel,
24Vdc or 120/240 VAC chargers. It is optimized for extremely low power consumption and
is primarily designed for remote operation in harsh environments.
Highlights This Chapter covers the following topics:
Topic See Page
XSeries Remote Controller Hardware 1-2
Standard Enclosure 1-4
Rack Mount Enclosure 1-7
XRC General Specifications 1-8
XRC-195 Electronic Board Specifications 1-9
XSeries On-board Input/Output 1-11
Digital Output 1-13
Analog Inputs 1-14
Display Function 1-15
Functions of the XRC 1-16
Display Annunciators 1-17
Laptop Computer running PCCU32 1-20
FS/2 Handheld PCCU 1-20
Optional Equipment 1-21
Key Pad 1-21
Totalflow Input/Output Modules 1-24
Continued on Next Page

1-2
Overview, Cont.
Functionality The XRC system has built-in, pre-engineered applications for data
collection, trending and long term data storage. The XRC can be used for
oil and gas production, transmission and distribution site monitoring and
control, water and waste system monitoring and control, etc.
This system can be programmed for advanced control or shutdown logic
using the IEC 61131 Control Language. An extensive applications library
is available from Totalflow Projects Engineering as needed, or new
application programs can be developed for you by Totalflow.
It is also possible for experienced IEC 61131 programmers in your
company, or other companies, to design application programs for any
XRC device.
XSeries Remote Controller Hardware
The Totalflow® XSeries Remote Controller (XRC) Models are housed in an aluminum
case. With the exception of the size of the cases all models use identical components.
These are the components of the XRC:
•Enclosure
•XRC-195 Board (Model 6990 may have up to two)
•Battery Compartment
•Communication Compartment
•Liquid Crystal Display (LCD) (Model 6990 may have up to two)
•Charger or Solar Panel
•Optional Modular I/O
•Optional Keypad (Model 6990 may have up to two)
XRC-195 Board The XRC-195 board is mounted on the inside of the door. All XRC on
board input and output connections are made with snap-in connector
terminals mounted directly on the board. The board uses a low power
processor running at 11.0592 MHz with 512 K SRAM and 512 KPROM
and 32K E2PROM. Other circuitry processes the inputs from the on
board I/O and provides the interface to the LCD as well as the PCCU
and optional key pad. Remote communications are handled by the
RS232 and RS485 communication modules that plug directly into the
board. The following XRC-195 Board drawing shows all the major
functional parts and their locations when mounted.
Communication
Enclosure
A removable communications enclosure can be provided that has been
pre-drilled for mounting of many popular communications devices such
as radios, cellular phones, modems, etc. This feature is not available in
the XRC6990.
Continued on Next Page

1-3
XSeries Remote Controller Hardware, Cont.
Battery
Compartment
The XRC system houses an internal main battery.
•XRC6490: The battery sets in a central compartment directly
behind the removable battery plate.
•XRC6790: The battery sets in a central compartment directly
behind a hinged cover plate holding the DIN rail and installed
modular components.
•XRC6890: The battery sets on the floor of the main compartment
and houses the various optional battery packs that are available for
the XRC; from one 8 ampere hours up two 70 ampere hour
batteries.
•XRC6990: The 30 ampere hour battery sets on the floor of the
enclosure.
Solar Panel The XRC is configurable for a 10-Watt, 20-Watt or 30-Watt solar panel.
The panel is designed for mounting on a 2-inch extension pipe above
the XRC, on top of or the side of a meter house. As the XRC6990 is not
designed for outside installations, Solar Panel chargers must be
configured to mount outside of the building.
Additional
Features
Additional features of the Totalflow System enabling its flexibility
include the following:
•Programmable bi-level security system prevents unauthorized
communication and configuration of the XRC (See Chapter 3)
•Internal crystal controlled clock providing a highly stable time base
for the system
•Optional battery packs to extend operation for longer periods
without power
•Three available charging sources
External solar panel (standard)
External AC power
External 24/12 VDC power
•LCD (liquid crystal display) programmable to allow monitoring of
operations (for example, displays flow rate, volumes, etc.)
•Rugged, aluminum, powder coated, NEMA 4X enclosure, lockable
to prevent internal access
•Optional ability to allow rapid data collection over several
communication links.
•Additional I/O for valve control, pressure, level monitoring, remote
communication, etc.
•Optional Keypad

1-4
Standard Enclosure
The standard enclosure consists of hinged-door box in varying sizes for the XRC6490,
6790 and 6890 (see Figure 1–1 through Figure 1–3). The door provides a watertight,
corrosion resistant seal between the outside elements and the XRC components. It is
designed to meet Class I, Division 2, Groups C&D and is NEMA 4X rated. It is designed for
mounting in harsh environments (cold, hot, wet and salty). Opening the door’s latch(s)
allows access to electronics, battery, radio and modular components. This door may be
locked for security purposes.
XRC 6490
(11.52)
(14.81)
(10.269)
(12.55)
(10.27)
Figure 1–1 Model XRC6490
Continued on Next Page

1-5
Standard Enclosure, Cont.
RC 6790
X
Figure 1–2 Model XRC6790
Continued on Next Page

1-6
Standard Enclosure, Cont.
(18.00)
(15.52)
RC 6890 X
(28.81)
(15.52)
(28.00)
(20.09)
(18.70)
Figure 1–3 Model XRC6890