Related Manuals for ABB XRC G5
Summary of Contents for ABB XRC G5
- Page 1 — ABB M E AS UR E M EN T & AN ALY TI C S | 2 1 0 6 0 2 6 M NA A XSeries User Manual /XRC Accurate, reliable, capable of measuring and monitoring gas flow to AGA, it is API, and ISO standard.
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Page 2: Table Of Contents
— List of figures ........................6 List of tables ......................... 9 Additional information ......................10 Safety ..........................11 Safety symbol conventions ....................11 Potential safety hazards for this equipment ................12 1 System Description ......................13 XSeries enhancements and backwards compatibility ........... 13 Embedded software (overview) ................... - Page 3 Pipe mount installation ....................29 Wall mount installation ....................30 Direct-mount installation .................... 31 6990 rack mount installation ................32 3.7.1 Overview ....................32 3.7.2 Termination panel ..................33 3.7.3 Rack mount enclosure .................. 33 Ground equipment ....................34 Leak-test manifold and tubing connections ..............34 3.10 Install the RTD ......................
- Page 4 Initial measurement application setup ................62 Configure communication ................... 64 8.7.1 Configure COM1 ................... 64 8.7.2 Configure COM2 ................... 67 8.7.3 Configure for network communication ............. 68 8.7.4 Enable and configure Ethernet ............... 68 8.7.5 Enable Wi-Fi ....................69 8.7.6 Enable Bluetooth ..................
- Page 5 10.4.4 Warm restart from PCCU entry mode ............109 10.4.5 Warm restart using terminal mode ............... 110 10.4.6 Cold restart with onboard COLDBOOT button ..........110 10.4.7 Cold restart from the device loader .............. 111 10.4.8 Cold restart from terminal mode ..............112 10.4.9 Restart using the factory configuration ............
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Page 6: List Of Figures
— List of figures Figure 1-1: XFC inside the enclosure ..................20 Figure 1-2: XRC inside the enclosure ..................20 Figure 1-3: Liquid Crystal Display and annunciators ..............20 Figure 1-4: XFC Electronic board ................... 21 Figure 1-5: XRC Electronic board ................... 21 Figure 3-1: Mounting pipe ....................... - Page 7 Figure 8-20: Communication Setup for Bluetooth ............... 72 Figure 8-21: Add/Assign Bluetooth application to Bluetooth interface ..........73 Figure 8-22: Verify Bluetooth application assignment ..............73 Figure 8-23: PCCU Connection Setup for Bluetooth ..............74 Figure 8-24: Flow computer with 5-valve manifold ..............75 Figure 9-1: Totalflow/TCP application instance with non-default TCP port ........
- Page 8 Figure 10-23: Change time/date factory defaults on a new board ..........118 Figure 10-24: XFC Display connector ..................119 Figure 10-25: XRC Display connector ................... 119 Figure 10-26: XFC COMM ports .................... 120 Figure 10-27: XRC COMM ports ................... 120 Figure 11-1: SP calibration pressure checks ................
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Page 9: List Of Tables
— List of tables Table 0-1: Related Documentation .................... 10 Table 1-1: XSeries product enhancements and backward compatibility ........13 Table 1-2: XFC applications ....................15 Table 1-3: XRC applications ....................15 Table 1-4: Applications available with XSeries ................17 Table 1-5: Default display parameters .................. -
Page 10: Additional Information
— Additional information Additional free publications for the device are available for download at www.abb.com/totalflow or by scanning this code: Table 0-1: Related Documentation Documents: Document number XSeries /XRC Quick Start Guide (QSG) 2106141 XSeries Startup Guide for XRC and XFC... -
Page 11: Safety
The content of these instructions is neither part of nor provided for changing a previous or existing agreement, promise, or legal relationship. All ABB obligations result from the respective sales contract, which also contains the full and solely valid warranty clauses. -
Page 12: Potential Safety Hazards For This Equipment
NOTICE – Equipment damage or loss of data. This symbol indicates a potential for equipment damage, loss of data or another unintended outcome. Failure to observe this information may result in damage to or destruction of the product and / or other system components. -
Page 13: System Description
— System Description This section introduces the Totalflow® fifth Generation XSeries flow computers (XFC ) and remote controllers (XRC The XSeries devices are low power, microprocessor-based units designed to meet a wide range of oil and gas applications. The devices have built-in, pre-engineered applications for data collection, trending and long-term data storage. -
Page 14: Embedded Software (Overview)
XSeries Enhancements/changes Backward compatibility/retained features System feature or component Real time clock With lithium battery Backup with lithium battery activated with backup onboard switch Without Lithium battery, clock keeps operating for up to 24-48 hours after power is removed and without lithium battery Memory backup Solid state persistent storage backup (by super capacitor) -
Page 15: Xrc G5 Functionality
Custom programming is supported with IEC 61131 applications. IMPORTANT NOTE: XSeries devices support several IEC application types. ABB-built IEC applications are available off-the-shelf or can be designed upon request. Customer-built IEC applications (developed by the customer or other third-party IEC programmers) are also supported. -
Page 16: Xseries G5 Calculation Methods
1.2.4 XSeries calculation methods The records and statistics generated are based on the following calculation methods of the XSeries Calculation of flow rates and volumes is in accordance with AGA 3-85, AGA 3-92, AGA 3-2012, AGA-7 or ISO-5167. Calculation of the flow rates and volumes is in accordance with AGA-8 92 Gross or Detail or NX-19 Supercompressibility Standards. -
Page 17: Display Application
Table 1-4: Applications available with XSeries Application XSeries - US XSeries- SU AGA-3 Measurement AGA-7 Measurement Alarm System Analysis Trend File API Liquid SU Communications Coriolis Interface Coriolis SU Display XSeries ENRON Interface Facility Management App Gas Lift Gas Orifice SU Gas Turbine SU Holding Registers Host Interface... -
Page 18: Configuration Files
display application manages the continuous display of operating parameters, status, alarm, or unusual conditions on the LCD. Displayed parameters and other indicators help operators obtain quick visual information on the status and health of the system. Displayed values scroll in the LCD at programmable time intervals and duration. -
Page 19: Customer Data Collection Files
Insert the key USB flash drive in one of the laptop’s USB ports. View available credits in the Key Credits window. If the credits on the device or the key are insufficient or not of the required type, call the ABB to purchase additional credits. See Contact us on the last page of this manual. -
Page 20: Hardware Overview
Programmable secure access to prevent unauthorized access to and configuration of the flow computer Internal 100-ohm platinum RTD resistance curve fit with user-programmable single point offset or 3/5-point user-calibration of the RTD input (XFC) Quick, simple calibration procedures for the transducer in the XFC ... -
Page 21: Electronic Board
IMPORTANT NOTE: For clarity, the XIMV is a multi-variable transducer (includes a static pressure cell, a differential cell and an RTD input). The XIMVs new technology offers high accuracy, better linearity and better overall performance over the previous equipment. 1.3.4 Electronic board The electronic board on the XSeriesG5 devices is mounted on the inside of the enclosure door. -
Page 22: Table 1-6: Local Communication Ports/Wireless Support (Local Operator Access)
IMPORTANT NOTE: External connectors (MMI, USB, Ethernet) are weather-proof only when not connected. Use these ports only for local communication for setup and maintenance purposes, never for permanent field connections. DANGER – Serious damage to health / risk to life. Do not use the MMI port, USB port or connect any USB dongle to the USB port when an explosive atmosphere is present. -
Page 23: User Interface Software Description: Pccu32
1.3.5.3 Network communication (Ethernet) The Ethernet interface can be configured for remote network communication. Ethernet connects the XSeries device to a communication network and allows remote access or management over that network. IMPORTANT NOTE: XSeries devices have only one Ethernet interface. If the device is configured and connected for network communication, direct connection to the Ethernet port for local access is not supported without disconnection from network. -
Page 24: Battery And Charger Power Configurations
The voltage range must be from 12Vdc to 14Vdc. IMPORTANT NOTE: Power supplies can be installed outside or inside of enclosures. Power supplies that are installed inside must be ABB-approved and must fit in the selected enclosure. Verify the options available for your enclosure size and requirements. - Page 25 2 1 0 60 26M NAA | XSER IE S | 2 5...
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Page 26: Site Planning And Requirements
Plan the installation based on enclosure dimensions and battery weight per model. For details on the enclosure weight and specifications, refer to the Data Sheets. Plan the power equipment installation based on the requirements for the power source selected. ABB- approved battery/charger systems and external power supplies are available. See section 1.5 Power... -
Page 27: Download Pccu
ABB makes the software available online in compressed format. You must download the software from the ABB library or as directed by ABB technical support personnel. PCCU must be installed in the laptop that will be used to connect to the device in the field. We recommend you obtain the software prior to field installation in case you are unable to access online ABB resources from the field. -
Page 28: Installation
— Installation The XFC can be pipe-mounted or wall-mounted, or direct-mounted to the meter run. and XRC IMPORTANT NOTE: Do not direct-mount the larger enclosures (for XFC – 6713, 6714 and for - 6790, 6890). The following is assumed: The XFC and XRC are designed to adapt to different site scenarios. -
Page 29: Unpack And Inspect
XRC exterior, LCD display, optional equipment if purchased. If there are missing, incorrect, damaged parts or noticeable defects, call the ABB main office number listed in Contact IMPORTANT NOTE: Do not return equipment to ABB without prior written consent. Returns are subject to the terms and conditions specified by ABB. -
Page 30: Wall Mount Installation
Figure 3-1: Mounting pipe Legend: Mounting pipe Meter run Saddle 2-inch x 40-inch Mounting pipe U Mounting bolt Screw the mounting pipe into the saddle until it is tight. Level the mounting pipe: a. Level and center the pipe and saddle on the top of the meter run. Tighten the saddle- mounting U-bolt. -
Page 31: Direct-Mount Installation
IMPORTANT NOTE: Large enclosures are heavy and bulky. More than one person may be required for installation. The following steps detail the procedures for wall-mounting the XFC or XRC by the meter run. Materials: One (1) enclosure mounting kit (includes instructions, brackets, U-bolts and fastening hardware) ... -
Page 32: Overview
NOTICE – Equipment damage. To avoid damage to the stainless-steel tubing, fittings, and valves, always use a backup wrench to stabilize and eliminate tension on both sides of the connection when tightening. Damaged connections may introduce leaks into the system resulting in inaccurate measurement. -
Page 33: Termination Panel
Figure 3-3:XRC 6990 rack mount 3.7.2 Termination panel User connections to the XRC 6990 are made on the termination panel on the rear of the enclosure. No internal wiring connections should have to be made by the user. Two termination panels are available, depending upon whether the user ordered a single XRC 6990 or a Dual Unit with two controller boards. -
Page 34: Ground Equipment
Figure 3-4: 6990 Rack mount enclosure Refer to the requirements of national and local electrical codes for the location. The grounding lug is located on the bottom front of the XFC or XRC enclosure. WARNING – Bodily injury / Equipment damage: The equipment must be bonded to an earthing terminal. -
Page 35: Install The Rtd
Figure 3-5: XFC with XIMV and 5-valve manifold Legend XFC with XIMV and 5-valve manifold High side equalizer valve XIMV Manifold vent valve Enclosure Low side equalizer valve Connect the pressure device to the test port. Apply pressure to the port based on the transducer range (100% of range). Squirt liquid leak detector onto the following connections: •... -
Page 36: Figure 3-6: Typical Rtd Installation
WARNING: Bodily injury. Install electrical wiring according to requirements for the area classification. Refer to the certification drawing indicated on the device’s name tag, and national and local codes. IMPORTANT NOTE: This procedure applies to the XFC only. The XRC does not have onboard support for RTD inputs. -
Page 37: Wire The Rtd To The Xfc
Screw the probe connector into the thermowell. IMPORTANT NOTE: Do not wrap the RTD cable around the pipeline. Run the RTD cable along the side of the process stream pipeline in a straight line. Use nylon tie wraps to secure the cable to the pipeline. -
Page 38: Install Antenna (For Wireless Functionality)
NOTICE – Equipment damage: Do not over-tighten the terminal connector screws as this may damage the wires. Reinsert the terminal connector in the J7 terminal block. IMPORTANT NOTE: The XSeries Wi-Fi Kit 2106049AIAB is required for antenna installation. Additional information. Install the antenna to support onboard Bluetooth ®... -
Page 39: Install Battery And Charger
— Install battery and charger Follow this procedure to install a battery and a solar panel charger if operating the XFC or XRC the battery mode configuration described in section 1.5.1.1 12-volt battery with solar panel configuration. IMPORTANT NOTE: If not using a solar panel as the charger, install the required charging source as required for your enclosure size. -
Page 40: Figure 4-1: Solar Panel
If the measured output voltage is within the manufacturer’s specification, as defined by the specification sheet supplied with the panel, continue with the installation. If the measured voltage is out of specification, contact ABB for a replacement panel. Install the mounting bracket on the solar panel using the provided hardware. - Page 41 Legend: Solar panel Pipe coupling Solar mounting bracket Extension pipe Solar panel cable U-bolts Flow computer In the northern hemisphere, position the solar panel facing south. In the southern hemisphere, position the solar panel facing north. IMPORTANT NOTE: Position the solar panel correctly before tightening the U-bolts. Tighten the solar panel mounting hardware.
- Page 42 Figure 4-2: CHRG terminal block on the XFC NOTICE – Equipment damage or loss of data. Do not over-tighten the terminal connector screws as this may damage the wires. NOTICE – Equipment damage or loss of data. Do not connect the solar panel to the electronic board before battery connection.
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Page 43: Wire Comm Ports
— Wire COMM ports Wire the XFC or XRC COMM ports to communicate with and power external devices. Wiring for communication depends on the type of serial interface required by the device. Wiring for power is required if there is no external supply powering the external device. Install the required communication modules in the correct slot on the XFC or XRC board. -
Page 44: Figure 5-1: Xfc G5 R-232 Comm1
Table 5-2: Serial communication specifications Type Maximum Length RS-232 50 feet (15 meters) RS-485 4000 feet (1220 meters) To wire equipment to the XFC serial communication ports, determine the COMM port to use, insert the correct communication module type in the available slot, then refer to the generic wiring drawings or pinout tables. -
Page 45: Figure 5-2: Xfc G5 R-232 Comm2
(COMM1) and Figure 5-4 (COMM2) show connection lines to a single device. RS-485 supports multiple devices per port. For additional wiring options, search additional user drawings at www.abb.com/upstream. 2 1 0 60 26M NAA | XSER IE S | 4 5... -
Page 46: Figure 5-3: Xfc G5 R-485 Comm1
Figure 5-3: XFC R-485 COMM1 IMPORTANT NOTE: Typically, only BUS+, BUS- and GND may be required to communicate with a third-party RS-485 device. The figure above illustrates all lines associated with the COMM1 or COMM2 RS-485 module. Figure 5-4: XFC R-485 COMM2 Table 5-4: XFC RS-485 COMM1 and COMM 2... -
Page 47: Xrc Comm Pinouts
Figure 5-6 (RS 485 COMM1) shows connection lines to a single device. RS-485 supports multiple devices per port. For additional wiring options, search additional user drawings at www.abb.com/upstream. 2 1 0 60 26M NAA | XSER IE S | 4 7... -
Page 48: Figure 5-6: Xrc Rs-485 Comm 1
Figure 5-6: XRC RS-485 COMM 1 Table 5-5: XRC COMM 1 and COMM 2 pinouts RS-232 RS-485 COMM 1 and 2 COMM 1 and 2 VBATT VBATT SW VBATT SW VBATT OPER OPER RRTS BUS- BUS- BUS+ BUS+ 4 8 | XSE RI ES G5 | 2 10 6 02 6MNAA... -
Page 49: Wire I/Os
The following table provides the I/O general description. For detailed specifications visit www.abb.com/upstream to review product datasheets. IMPORTANT NOTE: Onboard input/output information is also available in the PCCU online help topics. -
Page 50: Analog Inputs (Ai)
This can be set with the onboard IEC/STD switch. This switch selects the electrical voltage threshold point which defines when a DI state is either OPEN or CLOSED. IMPORTANT NOTE: The IEC mode supports the ABB Coriolis Master primary meter’s high-speed pulse output. 6.1.2.2 Debounce XSeries pulse inputs support debounce capability. -
Page 51: Digital Outputs (Do)
Debounce Yes, software selectable Yes, hardware selectable from user interface (PCCU): Debounce with onboard pins (J5, J9, J11, J12): can be enabled/disabled on each PI. Debounce on (default): Jumper pins Debounce off: Jumper pins 1 and 2 6.1.3 Digital outputs (DO) Digital outputs (DO) on XSeries devices are used to control external equipment. -
Page 52: Digital Input And Output (Di/Do) Pinouts Xfc Di/Do
Figure 6-2: XRC AI terminals and input mode selector jumpers Table 6-5: XRC AI Pinouts Input Description AI-1 (+) Input signal (COM) Input ground AI-2 (+) Input signal (COM) Input ground AI-3 (+) Input signal (COM) Input ground AI-4 (+) Input signal (COM) Input ground AI-5 (+) Input signal... -
Page 53: Di/Do
Pin J6 Description (+) Output signal (-) Output ground (+) Output signal (-) Output ground 6.3.1 DI/DO The XRC has four onboard digital outputs and four onboard digital inputs. Figure 6-4 shows the digital I/O terminals on the XRC , the input mode switches, and the debounce jumpers. The input mode switches support standard pulse inputs (STD) or pulse inputs from Coriolis (IEC). -
Page 54: Powering The Device
— Powering the Device Apply power to the XFC or XRC by making the correct connections for the power mode chosen. The XFC and XRC support two power modes: Battery mode: The primary power source is a 12-volt battery with a charger. ... -
Page 55: Connect The Battery (Dc Power)
7.3.1 Connect the battery (dc power) Connect the 12-volt SLA battery using the battery cable. WARNING– Bodily injury and property damage. Complete all wiring of peripheral or external devices to the controller before power is applied. Connect the battery before connecting the charger cable. Connect the battery: Connect the battery to the BATT terminals on the XFC (J1 as shown below) or XRC... -
Page 56: Power With External Power Supply
Figure 7-4: XFC charger connection 7.3.2.2 Connect another charger The charger can also be a power supply converting another voltage level to nominal 12 Vdc. The nominal 12 Vdc level must be between 14.5 Vdc to 15.5 Vdc to charge the battery and provide a voltage value that is safe for the device. -
Page 57: Enable Real Time Clock Backup
The lithium battery maintains operation of the real time clock. The lithium battery backup is recommended and can be set onboard with the backup jumper (J13). The two settings are: Enable – Jumper settings 1-2. The lithium battery backs up the real time clock. If power is lost or disconnected, the real time clock continues to operate until depletion of the lithium battery. -
Page 58: Basic Configuration And Startup
MMI or PCCU cable) (MMI) cable and connect to a USB port on the PC. The Digi® Edgeport®/1 converter is recommended and can be purchased from ABB (part number 1801382-001). Contact technical support to order or for more details. USB cable... -
Page 59: Figure 8-1: System Setup
Figure 8-1: System Setup Click Close. Connect to the device entry mode: On the PCCU32 tool bar, click Entry to connect to the device. Figure 8-2: PCCU32 Tool bar and Entry Legend: PCCU 32 Elements Number Element name Tool bar Entry button If the XFC or XRC... -
Page 60: G5 Or Xrc G5
Figure 8-3: PCCU32 Date/Time synchronization warning IMPORTANT NOTE: Click Help for more information. Click No to set the time and date later during the installation or click Yes to synchronize date and time now. When successfully connected to the XFC or XRC , the screen displays the device and measurement variables. -
Page 61: Station Setup
Figure 8-5: PCCU32 Views Click Yes at the warning notice and wait for the PCCU32 Entry mode screen to refresh. Wait for the Entry mode screen to reappear. Configure basic station parameters: At the PCCU32 Entry screen, click the station ID (TOTALFLOW) at the top of the navigation tree. -
Page 62: Change The Default Time And Date Format
Entry Format Description Date/ MM/DD/YYYY Date and time must be set correctly and should agree with the Time HH:MM: SS collection equipment if measurement tubes are instantiated. (24-hour clock) Verify the Lithium Battery Status is OK with a green bar, see Figure 8-6: Station Setup. -
Page 63: Figure 8-8: Flow Measurement Advanced Setup (Gas Orifice)
Figure 8-8: Flow Measurement Advanced Setup (Gas orifice). On the Setup tab, verify and change if necessary, the following settings: a. If receiving live flowing temperature values from an RTD, set the RTD Installed field to Yes. b. If using a fixed temperature value instead of live readings, set the Use Fixed Temperature field to Yes. -
Page 64: Configure Communication
Figure 8-10: Constants tab Verify or update the following: • For Barometric pressure, type the value, subtracted from the absolute pressure readings when calibrating in gauge pressure. IMPORTANT NOTE: Barometric pressure is area-dependent. Use the correct barometric pressure for the area or the contracted value. •... -
Page 65: Figure 8-11: Xfc G5 Comm Terminals (Module In Comm1 Slot Shown)
Install the communication module for the required serial interface type (RS-232 or RS-485) in the COMM1 slot on the XFC or XRC board. Figure 8-11: XFC COMM terminals (Module in COMM1 slot shown) Wire the communication equipment according to the type of serial interface required. See section 5 Wire COMM ports. -
Page 66: Figure 8-13: Verify The Communications Set Up For Comm1
Table 8-3: Communication setup parameters Timeouts and delays Serial port settings Parameter Default Parameter Default Ack timeout (s) Baud 9600 Response delay (ms) Parity None Xmit key delay (ms) Data bits Unkey delay (ms) Stop bits Power up delay (ms) For RS-485 communication, position the termination jumpers according to the following table: Table 8-4: RS-485 Termination on COMM1... -
Page 67: Configure Com2
IMPORTANT NOTE: This procedure assumes that the default generic serial communication configuration is used. Additional configuration options which optimize support for specific ABB products (for example, the XMV Interface application) are also available. For details about these options, click Help from the Communications Setup tab screen and configure the port as required by the external device. -
Page 68: Configure For Network Communication
Click Send changes to device when configuration is complete. Verify that the new port name displays under Communications on the navigation tree. 8.7.3 Configure for network communication The XFC and XRC can connect to several types of wired or wireless networks. The Ethernet port supports connection for both local and remote communication. -
Page 69: Enable Wi-Fi
Select the Enable Ethernet checkbox. If using static addresses, type the IP Address, Subnet Mask, and Default Gateway, provided by the IT administrator. If using DHCP for dynamic addressing, select the Enable DHCP checkbox. Figure 8-16: Enable and configure Ethernet communication Click Send. -
Page 70: Figure 8-17: Wi-Fi Tab Screen
Enable as a Wi-Fi Access Point: Install the antenna. (See section 3.12 Install antenna.) Configure the Network ID. On the PCCU Entry mode navigation tree, select Communications. Select the Wi-Fi tab. Figure 8-17: Wi-Fi tab screen Select the Enable Wi-Fi Access Point checkbox. Change the default security passcode, click Change. -
Page 71: Enable Bluetooth
Figure 8-18: Network connections When prompted, provide the security passcode and click OK. View the list of wireless networks again and verify that the client shows Connected. A connected status indicates that the Wi-Fi client has been authenticated and automatically assigned an IP address. -
Page 72: Figure 8-19: Enable Bluetooth
Figure 8-19: Enable Bluetooth Select the Communication Setup tab. The Bluetooth interface is unused in the port list. Figure 8-20: Communication Setup for Bluetooth Select Bluetooth (Unused). Select Add New Device/Application. See the figure below. 7 2 | XSE RI ES G5 | 2 10 6 02 6MNAA... -
Page 73: Figure 8-21: Add/Assign Bluetooth Application To Bluetooth Interface
Figure 8-21: Add/Assign Bluetooth application to Bluetooth interface Select Bluetooth. Click OK. Click Send Changes to device. On the Communication Setup tab, verify that the port list and the description both display Bluetooth. See the figure below. Figure 8-22: Verify Bluetooth application assignment Start a new instance of PCCU to test the Bluetooth connection or close the current connection: Start PCCU, from the top menu, and select Setup. -
Page 74: Commission The Device
Figure 8-23: PCCU Connection Setup for Bluetooth Click Close to exit PCCU connection setup. On the top PCCU menu, click Entry to connect to the XFC or XRC When the connection is successful, continue with configuration procedures or click Close to close the Bluetooth connection. -
Page 75: Optional Volume Reset (Recommended)
IMPORTANT NOTE: The following procedure is based on the flow computer attached to a 3-valve manifold. For all other applications, adapt these instructions to the specific manifold. Place the XFC in service: Close the high and low pressure tap valve connections on the stream to shut off the process flow. -
Page 76: Configure Security (Recommended)
— Configure security (recommended) To secure access to the XSeries devices, review the security features implemented. Totalflow user interfaces and host products support connection with the XSeries devices through several types of communication ports, protocols, and services. These constitute points of entry that could be subject to inexperienced, unauthorized or malicious access through a point-to-point connection or a connection established over a network. -
Page 77: Open Transmission Control Protocol (Tcp) Ports
Table 9-3: User-enabled services on XSeries Service Default Description Security feature available Name state SSH/SFTP Disabled Serves connection requests Authentication based on private-public Service for secure login shell and file key pairs, passphrase-protected keys transfer. Supports connection requests from third-party SSH/SFTP clients Totalflow Enabled Enables or blocks the ability... -
Page 78: Denial Of Service (Dos) Thresholds Rates
Figure 9-1: Totalflow/TCP application instance with non-default TCP port IMPORTANT NOTE: TCP port numbers from 0 to 1023 are universally reserved for well-known ports and should never be used. Protection of ports used for TCP/IP communication such as Ethernet, is very important. Several cybersecurity threats can make a device unavailable for connection. -
Page 79: Configure Bi-Level Security With Security Switch
Recommendation Description Secure access with Turn the onboard security switch on to enforce authentication through security switch bi-level security codes or RBAC. (See section 9.5 Configure bi-level security with security switch.) Configure Bi-level Change default security codes to private codes (the default security security codes code for both level 1 and level 2 is 0000). -
Page 80: Figure 9-2: S1 Security Switch
Figure 9-2: S1 Security switch Legend – S1 Security switch Battery Security switch Ensure the security switch is set to OFF. On the Station Setup tab, verify that the Security Switch Status field shows Off. Figure 9-3: Station Setup tab – Security switch status Type a four-digit security code for Security Code Level 1 (read only access). -
Page 81: Configure Role-Based Access Control (Rbac)
On the Station Setup tab, click Re-read and check that the security switch status is On. Enforcement of the security codes is in effect. IMPORTANT NOTE: The codes will be required the next time PCCU32 attempts to connect to the device. -
Page 82: Figure 9-4: Security Editor Screen
Figure 9-4: Security Editor screen In the Security Editor dialog box, create the RBAC administrator before creating any other users: a. Ensure that Role is set to Administrator in the Role Definition section. b. Click Add User on the RBAC Security Editor screen. Type the user name in the Name field in the User Name and Password dialog box. -
Page 83: Edit The Security File
9.6.3 Edit the security file To edit an existing security control file: From the Security Editor screen, click Open. Browse to PCCU > RBAC > [file name.rba]. Click Open. Make the necessary changes. Click Save As…. Type a password for the security file. Click OK. Click Save to keep the default file name, or change the name then click Save. -
Page 84: Enable Rbac Authentication On Communication Ports
Figure 9-6: User role assignment Repeat steps 1 through 5 for each user account Click Save As… to save and name the new security control file. Type a password for the security control file in the Current Password field and click OK. 9.6.5 Enable RBAC authentication on communication ports Enabling RBAC authentication on communication ports secures access to the device. -
Page 85: Use Default Rbac Credentials
Figure 9-7: Enable port authentication from RBAC security editor Click Save As… to save changes to the security control file. Type the password for the security control file for the Current Password and click OK. 9.6.5.2 Enable authentication from the Entry mode Enabling RBCA authentication from the Entry mode requires enabling one port at a time. -
Page 86: Figure 9-9: Login Dialog Box
Figure 9-9: Login dialog box The User name and Password may be set as default credentials in PCCU. When set as the default, the user name and password fields are automatically populated with the default credentials on subsequent logins. To create, change or disable the RBAC credentials in PCCU: Click the Setup icon on the main toolbar or click Operate >... -
Page 87: Secure The Ssh/Sftp Service
Authentication requires specific private-public key pairs for the type of access. Default private keys and passphrases are requested from ABB and kept by the customer. The default public keys are stored at the factory in a protected storage location in the device's flash. They remain unchanged by updates of any of the device software components. -
Page 88: Update Default Ssh/Sftp Keys
9.7.3 Update default SSH/SFTP keys ABB Totalflow generates default keys, but customers must generate their own private keys for security. Updating the private key requires the update of the corresponding public key stored on the XSeries device. This procedure describes how to regenerate a private key and update its corresponding public key on the device. -
Page 89: Figure 9-11: Puttygen Key Generator
Figure 9-11: Puttygen Key Generator Move the mouse to the Key blank field, under the progress bar (see highlighted area below). Figure 9-12: Puttygen Key Generator Key blank field 2 1 0 60 26M NAA | XSER IE S | 8 9... -
Page 90: Figure 9-13: New Public Key
Wait until the program completes the new key generation (the progress bar reaches 100 %). The Key field displays the new public key. Figure 9-13: New public key In the Key comment field: leave default (includes the date of key generation) or another preferred description In the Key passphrase and Confirm passphrase fields: create a strong private passphrase (a passphrase protects the use of the private key. -
Page 91: Figure 9-14: New Private Key And Passphrase
Figure 9-14: New private key and passphrase Click Save private key. Figure 9-15: Save private key and passphrase Type the file name and select the desired location to store the key file at file browser window. The private key file has the “. ppk” extension. This new private key along with its 2 1 0 60 26M NAA | XSER IE S | 9 1... -
Page 92: Figure 9-16: Select Location To Save Private Key File
passphrase would be used for accessing the accounts after its corresponding public key is updated on the device. Figure 9-16: Select location to save private key file Click Save. The file browser closes. Right-click on the Key field where the public key displays. Click Select All. IMPORTANT NOTE: Do not click Save public key for this process. -
Page 93: Figure 9-18: Copy Generated Public Key
Figure 9-18: Copy generated public key Create a new text file in your laptop or PC and paste the copied public key contents into this file. Save the text file using one of following names (choose the name based on the account type and on whether the keys will be added to or replace the existing keys on the device): A_userkey.txt: A key with this name is appended (A) to the available Totalflow- user public keys in the device. -
Page 94: Figure 9-19: Enable The Ssh/Sftp Service
Start PCCU and use Entry mode to connect to the device. Select Communications> Network. Select the SSH/SFTP service checkbox. Figure 9-19: Enable the SSH/SFTP service Click Send. Select Ethernet to enable, verify or configure valid IP parameters. The figure below shows an example of a valid IP configuration to access the device over a network. -
Page 95: Figure 9-21: Filezilla Site Manager Connection Setup
Click Browse to select the current private key. If the keys are being changed for the first time, use the default developer or tech-support private key provided by ABB. If the keys were previously updated, then use those keys instead. -
Page 96: Figure 9-22: Type Private Key Passphrase (Password)
Figure 9-22: Type private key passphrase (password) Verify that the connection with the device is established successfully when the FileZilla new site window displays. This window displays the file directories of the laptop or PC (on the left) and the device (on the right). Figure 9-23: FileZilla New Site window Navigate to and open the directory containing the newly created public key text file (on the left). -
Page 97: Figure 9-24: Open The /Flash/Appdata/.Ssh/ Directory
Figure 9-24: Open the /Flash/AppData/.ssh/ directory Right-click on the newly created public key file and select Upload from the drop-down menu. Figure 9-25: Upload public key from laptop to device Verify that the file is copied to the /Flash/AppData/.ssh/ directory. The name of the file should display under that directory when the upload is complete. -
Page 98: Figure 9-27: Restart Totalflow Device After Public Key Update
Restart the device for the public key update to take effect (Figure 9-27). Return to PCCU (if you remained connected via MMI or USB). Select View>Expert on the top PCCU menu. Wait for the view to change. Select the station name at the top of the navigation tree. ... - Page 99 IMPORTANT NOTE: Keep private key files stored in a safe location accessible only to authorized personnel and security managers. 2 1 0 60 26M NAA | XSER IE S | 9 9...
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Page 100: 10 Service And Maintenance
— 10 Service and maintenance The following chapter includes procedures required for the service and maintenance of the XSeriesG5 devices. These include: data and configuration backup, device software updates, part replacement (spare parts list included), real-time clock maintenance, device restart, and power removal and restoration. -
Page 101: Save The Device Configuration
Figure 10-1: Collect data On the navigation tree, select the tubes and applications for data collection. If collecting all device data, select all items. Select the outputs and data range. Click Collect. Click Close to exit data collection and return to the entry mode screen. 10.1.2 Save the device configuration The following procedures are required to save the configuration of the Totalflow device for backup... -
Page 102: Figure 10-2: Station Setup And Backup
Click the value for Update Cold Start Configuration and select Delete and Recreate TfCold. Click Send. Figure 10-2: Station Setup and Backup Click Close to terminate the Entry mode connection with the device and return to the main PCCU screen. Save the updated startup configuration. -
Page 103: Figure 10-3: 32Bit Loader Confirmation Pop-Up
Figure 10-3: 32Bit Loader confirmation pop-up Click Yes. The Connection setup window displays. Figure 10-4: Connection Setup Type the connection setup parameters and click Connect. When the connection is successful, the main loader screen displays. Click Services > Save from the menu bar on the main Loader screen. The Save Software from Device window displays. -
Page 104: Figure 10-5: Save Software From Device Window
Figure 10-5: Save Software from Device window To save only the configuration, clear all options except Config. Figure 10-6: Config checkbox Click Start. A browser window displays. Locate the destination folder for the configuration, type the file name, and click Save. Take note of the location of the configuration file. -
Page 105: Change The Xseries Clock
Figure 10-7: Select location to save config file Monitor progress in the Loader Status logs view. Verify that the configuration package is copied in the selected directory. Figure 10-8: Loader status logs Click Close to exit the Save window. Click Close to exit the 32-Bit Loader. When a measurement application is running, a clock change could affect the times when log period entries are made. -
Page 106: Backward Or Forward Clock Change Not Crossing An Hour Boundary
10.2.1 Backward or forward clock change not crossing an hour boundary When the clock is changed, and an hourly boundary is not crossed, an additional log period entry is not required. Example: If the present time is 4:15 p.m. and clock is changed to 4:05 p.m. of the same day, the daily flow record is the same. -
Page 107: Warm Restart With Onboard Reset Button
Only as part of a service or repopulates it using maintenance procedure or when 10.4.8 Cold restart from the startup (cold) specifically directed to by ABB terminal mode configuration. technical support. Restarts with startup A cold restart causes running (cold) configuration. -
Page 108: Warm Restart From The Device Loader
This procedure uses the RESET button on the electronic board to restart the device. It causes the device to restart using the running (warm) configuration. You must have physical access to the device and be able to open the enclosure door and access the electronic board. To restart with the reset button: Open the door to the unit. -
Page 109: Warm Restart From Pccu Entry Mode
Figure 10-11: Warm restart with device loader Click Help for more information. 10.4.4 Warm restart from PCCU entry mode This procedure restarts the device using the System Shutdown/Then reset function from the Station Setup screen in PCCU. It causes the device to restart with the running (warm) configuration. The procedure can be performed while on a local or remote PCCU connection. -
Page 110: Warm Restart Using Terminal Mode
Figure 10-12: Warm restart on the Station Setup tab (Expert view) 10.4.5 Warm restart using terminal mode This procedure performs the warm restart from the terminal mode. It causes the device to restart using the running (warm) configuration. The procedure can be performed while physically connected to the device or remotely. Terminal mode can be invoked from entry mode or from the PCCU splash screen. -
Page 111: Cold Restart From The Device Loader
Figure 10-13: XFC Onboard COLDBOOT button Figure 10-14: XRC Onboard COLDBOOT button Press and hold the COLDBOOT button and at the same time press and hold the RESET button for 10 seconds. The LCD displays “Loading Boot Loader”. Verify the Power On sequence is completed. If the display moves through the startup screens and begins cycling correctly, the COLDBOOT was successful. -
Page 112: Cold Restart From Terminal Mode
Figure 10-15: Cold restart using the device loader Click Help for more information. 10.4.8 Cold restart from terminal mode This procedure performs the cold start from the terminal mode. It causes the device to restart using the startup (cold) configuration. The procedure can be performed while on a local or remote connection, but it is highly recommended that the cold restart is performed locally. -
Page 113: Restart Using The Factory Configuration
Figure 10-16: Terminal menu option Type the command BOOT=COLD at the terminal prompt. Figure 10-17: Terminal screen – cold boot Press Enter. 10.4.9 Restart using the factory configuration This procedure restores the device's startup configuration to its factory defaults from the 32-bit loader. -
Page 114: Remove And Restore Power
Figure 10-18: Restart using factory configuration It might be necessary to remove power from an XSeries for maintenance. This procedure describes the removal and reconnection of power. For terminal block connectors, you do not need to remove individual wires. Remove the connector block to avoid rewiring. Figure 10-19: XFC Figure 10-20: XRC IMPORTANT NOTE: Do not remove power if the device does not have the lithium battery... -
Page 115: Reconnect Power To The Electronic Board
If information does not display after contrast adjustment, check the LCD ribbon cable connection. Ensure the connector is securely plugged into the onboard DISPLAY connector. If unable to see any information displayed after checking connection, call ABB technical support. Figure 10-21: LCD contrast adjustment... -
Page 116: Xseries Replacement Parts And Procedures
The following is a list of the XSeries replaceable parts. Part removal method depends on the part location and connections and enclosure type. Electronic board LCD assembly Lithium battery 12 V battery Complete XIMV assembly (Transducer) ... -
Page 117: Replace The Lithium Battery
IMPORTANT NOTE: To extend the life of the battery, fully charge the battery prior to installation. A system using solar panels may not fully charge the battery. Additionally, a fast charge, which the solar panel cannot provide, will improve the life of the battery. To recharge a battery, a quick charge will remove buildup in the battery much more effectively than a trickle charge. -
Page 118: Replace The Lcd Assembly
service, plan the replacement carefully and follow your company policies. See Additional information. Please review the following admonitions in this section before replacement. NOTICE – Equipment damage: The electronic board inside the XSeries housing is susceptible to damage by static electricity or improper handling. To prevent this, wear a grounding strap when handling the board. -
Page 119: Figure 10-24: Xfc G5 Display Connector
If the LCD does not display parameters after contrast adjustment and checking that the ribbon connector is firmly attached to the electronic board, call ABB technical support. If the LCD had displayed the startup sequence properly and begins to scroll parameters as programmed, tighten electronic board screws and close the enclosure door. -
Page 120: Replace Or Add Communication Modules (Comm Modules)
10.7.5 Replace or add communication modules (COMM modules) The XSeries devices support two serial communication interfaces. Communication modules are required to activate those interfaces. Each can be configured as either RS-232 or RS-485. Standard configuration may ship with a COMM1 module already installed. Use this procedure to replace or add new communication modules. -
Page 121: Replace The Transducer (Xfc Only)
10.7.5.3 Insert modules Insert the communication modules into the COMM1 (XA1) and COMM2 (XA2) slots: Remove modules from their package. Grasp each new module in the middle and align the pins with the slot. Module pin 1 (indicated by a dot mark on the flat side of the module) must connect to slot pin 1 indicated on the board. -
Page 122: 11 Calibration
Barometer or another means which can determine barometric pressure Nitrogen or compressed air source IMPORTANT NOTE: ABB Totalflow recommends performing a five-point calibration check before (as found) and after (as left) calibration. During normal operation, either cell could be knocked out of calibration (typically due to a slug of liquid). -
Page 123: Differential Pressure Checks
On the Checks tab, select SP from the Calibration drop-down menu. Define the SP display value: Absolute or Gauge (Figure 11-1: SP calibration pressure checks). IMPORTANT NOTE: Selecting Absolute will display the value with the barometric pressure added. Subsequent values require that the barometric pressure be added to the value before it is entered. -
Page 124: Figure 11-2: Dp Calibration Pressure Checks
As discussed in the previous section, it is recommended that DP calibration pressure checks be performed prior to and directly following calibration. A minimum of three (3) DP markers should be set; however, as many DP markers as are needed can be entered. -
Page 125: Calibrating Static Pressure
Connect the calibration standard to the calibration test port. Apply pressure to the next preferred verification pressure. After the current reading stabilizes, enter the pressure value from the calibration source, and click OK. After all the static pressure markers have been set, determine if calibration is required. Return the manifold to service before exiting Calibration mode if more calibration is not required. -
Page 126: Calibrating Differential Pressure (Dp)
Close both the downstream and upstream tap valves. Open the atmosphere vent valve. Click Low Cal Point. Verify the current reading is continuously updated. This should represent the lowest calibration point. When the current reading stabilizes, click OK; otherwise, enter a different value, and then click OK. -
Page 127: Zero Transducer
On the Calibration tab, select DP from the Calibration drop-down menu. Select either a 3- or 5-point calibration from the corresponding drop-down menu. Select the Range (URL) of the transducer DP pressure cell. The range should agree with the tag attached to the transducer and target values based on the URL will display in the Calibration table. -
Page 128: Static Pressure
IMPORTANT NOTE: Always follow the company recommended policies and procedures. The process of performing as found pressure checks records an event and manages the records in a manner that assures accountability and continuity. Follow the instructions in sections 11.1.1 Static pressure checks 11.1.2 Differential pressure checks. -
Page 129: Table 11-2: Rtd Wiring Pinouts
Table 11-2: RTD wiring pinouts Terminal Terminal SHLD VBAT SWVBAT Select either a 3- or 5-point calibration from the corresponding drop-down menu. Select the temperature Range (URL) of the RTD or edit and define a non-standard range. The range should agree with the tag attached to the transducer, and target values based on the range will display in the Calibration table. -
Page 130: Resistance Temperature Detectors (Rtd) Bias
After the last point is entered, PCCU32 will automatically calibrate the RTD. If electing to use bias as a calibration method, the RTD temperature will always be biased by this value. The bias does not affect the fixed temperature that is specified on the Setup tab. Place the flow computer in Hold mode by selecting Calibration on the tool bar. -
Page 131: Connect Calibration Equipment
IMPORTANT NOTE: For I/O calibration on TFIO modules refer to PCCU32 online help topics. Topics for calibration of each module type are available when you click Help on the applicable screens. 11.5.1 Connect calibration equipment A calibrator simulates the external device attached to the controller AI during analog input calibration. The calibrator applies the signal (voltage or current) values that would otherwise come from the external device. -
Page 132: Analog Input Calibration (Voltage Mode)
Figure 11-4: XRC Figure 11-5: XRC AIs and mode selector jumpers (default setting) To set the AI to voltage mode: If calibrating on the XFC: AIs support voltage mode by default. Ensure that there are no external resistors connected across the AI pins. If calibrating on the XRC: Verify that the mode selector jumper (J21, J22, J24, J25 or J26) is across pins 2 and 3 for the selected AI. -
Page 133: Figure 11-6: Ai Voltage Default Calibration Values
IMPORTANT NOTE: For illustrative purposes, the AI 1 is calibrated for an external device with a measurement range value of 100. To calibrate the analog input: Make sure the AI is set to voltage mode. Restore power to the XSeries Make sure that the calibrator is set to the voltage signal type. -
Page 134: Analog Input Calibration (Current Mode)
Figure 11-7: Low calibration value for voltage Click 100% Cal Point. The Enter 100% Calibration Value dialog box displays with the target high value automatically calculated. For example, the value is 100.000 for the range value of 100. Adjust the calibrator to apply the high value (100%) of the signal range. For example, if the signal range of the external device is 1-5 Vdc, apply 5 Vdc. -
Page 135: Figure 11-9: Ai Current Default Calibration Values
Low Cal Point 100% Cal Point 50% Cal Point These instructions can be adapted for a five (5) point calibration. The five pressure points display in calibration order: Low Cal Point 100% Cal Point 75% Cal Point ... -
Page 136: Verify Analog Input Calibration
Type the external device measurement range into the entry field and click OK. The values in the Target column of the table update to reflect the new range. Click Low Cal Point. The Enter Low Calibration Value dialog displays with the target low value automatically calculated. -
Page 137: Repeat Calibration In Case Of Errors
Figure 11-11: Low range value verification Adjust the calibrator to apply the high (100%) value of the signal range. Wait for the value in Current Value to stabilize. Verify that Current Value displays a value equal or close to the target range high (100%) value. - Page 138 Click Send. Click the Calibrate icon on the PCCU toolbar (the Calibrate icon shows tools). Click I/O Interface on the navigation tree. Repeat the calibration procedure in section 11.5.2 Set the AI to the correct input signal mode XSeriesG5 devices support voltage or current input signals from external devices. Before proceeding with the calibration or restoring power to the device, make sure you set the correct AI mode.
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Page 139: 12 Troubleshooting
— 12 Troubleshooting This section discusses a few potential issues during the initial startup of the flow computer. The LCD displays alarm conditions and status codes in the Annunciator area, see Figure 12-1: XSeriesG5 annunciators. IMPORTANT NOTE: Alarms are recorded in the Log period flow record. Status codes are not recorded in the Log period flow record. -
Page 140: Failure To Start
Indicator Description Measurement Applications Back Flow Condition: Visible only when DP variable is displayed Zero Flow Condition: Visible only when the flow rate is displayed Hold: Displayed when PCCU32 has entered hold Alarm Condition: Need to view alarm. Compare application limits to the current values to determine where the alarm condition is present. -
Page 141: Remote Communication Failure
If the display does not begin cycling correctly or locks up on one of the startup screens, contact technical support for additional instructions. IMPORTANT NOTE: To reach technical support, call the ABB Totalflow main office, listed under Contact us and select technical support from the menu options. -
Page 142: Appendix A Typographical Conventions
Cross-reference to Hyperlink to the website in blue, Go to the XSeries User Manual another document or with underline at abb.com. website Greater-than character Indicates that the following item is From the menu, locate and select (>) an additional menu selection Calibrate >... -
Page 143: Appendix B Cyber Security
ABB Inc. and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information. -
Page 144: Appendix C Compliance
— EU Directive 2012/19/EU – WEEE Waste Electrical and Electronic Equipment (WEEE) marked using the crossed-out wheeled bin symbol shall not be mixed with general household waste. Correct disposal at a recycling facility will help save valuable resources and prevent potential negative effects on health and the environment. -
Page 145: Contact Us
We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.