ABB Totalflow mflo Series User guide

FLO SERIES

FLO

Start-Up Guide

Introduction:

This startup guide is to assist in the startup of the

FLO series flow

computer. Through this guide will be references to status codes that are

displayed in different annunciator positions on the unit’s display. Since

assignments can now be made to any of the eight annunciators, there is

no specific annunciator for a specific code. However, for those of you

familiar with previous assignments, units are typically shipped with the

assignments defaulted as you are accustomed to seeing. This pertains

more to communication’s ports since users may have custom

applications assigned to the other annunciators.

Recommended Start-Up Sequence

HINT: Step 1 thru 22 is a recommended start-up sequence and some of

the steps do not go into any great detail. Some steps because detail is

not needed and some because more information is available later in the

Start-Up Guide. For example there are later topics for installing and

wiring the RTD, installing the main battery, solar panel installation plus

other information. So, scan through the guide to see what information is

available before you begin the installation. Also keep in mind that units

on a RS485 bus may not have a battery or solar panel since they can be

powered from a remote power source such as another

FLO, which

does contain a battery and solar panel.

Physical mounting and piping:

1. Unpack

2. Inspect for damage and missing or incorrect components.

3. Determine where to mount the

FLO.

4. Install bracing for µFLO (pipe saddle, direct mount, pipe driven in

ground). Attach U-bolts to 2” pipe using silicone spray or Teflon tape

to prevent galling. (See Figures 1 & 2)

5. Mount manifold to bottom of the µFLO. Since the µFLO can be

ordered with the flow going left to right or right to left, verify direction

of flow by looking at the transducer tag that shows a (+) and (-).

Plus(+) indicates the high side (upstream side), therefore flow is from

(+) to (-). For direct mount manifolds, the direction is very important.

(See Figure 3 for a typical manifold configuration)

6. Connect stainless steel tubing from manifold to orifice tap valves.

With the manifold equalized to avoid damaging the µFLO’s

transducer, apply pressure to the manifold and check for leaks. For

best measurement, use large bore, short, equal length gage lines

with a downward slope to taps (at least 1" per 3 feet).

2" x 40"

Mounting Pipe

Meter Run

"U" Mounting

Bolt

Saddle

Figure 1 (Saddle Mount)

Flat and lock washers

2 " Mounting Pipe

U - Bolt

with 9/16" bolt

Figure 2 (Pipe Mount)

Figure 3 (Typical Manifold Mount)

Install RTD Probe:

7. Install RTD and connect wiring to connector block J9. (See Page 6

and Figure 5)

Install Battery(s):

8. Verify that the Memory Backup is Enabled. This is J1, terminals 1 &

2. (See Page 7 and Figure 5)

9. Mount and connect a fully charged battery to the battery connector

J6. (See Page 7 and Figure 5)

10. The display should go quickly through the startup routine then start

scrolling through the default display items. (If not, see Tip on Page

19) This typically insures that the components and wiring are good.

Refer to “Standard Displays" on page 15 for typical default displays.

Refer to “Visual Alarm & Status Codes" on page 16 for location,

symbols, and descriptions. You should see a LC code in the A7

annunciator (See Figure 10) since the charging source has not been

connected. This is the typical annunciator for the I/O Subsystem

application but could vary on different systems.

Install Solar Panel:

11. Assemble, mount, and connect solar panel or AC charger. NEVER

CONNECT CHARGER WITH THE MAIN BATTERY PACK

DISCONNECTED. (See pages 8 & 9) The LC code should go away

after the charging source is connected. Solar powered units will

naturally depend on available sunlight.

Setup:

12. Connect FS/2 or laptop running PCCU32 to the unit. To use an FS/2,

the µFLO must have been ordered from factory with FS/2 support.

PCCU32 must have software Version 4.3 or higher and the FS/2

must be 2018583-007 or higher.

13. Configure µFLO: Set date/time, ID, location, AGA setup, using Entry

Mode in PCCU32 or an FS/2.

14. In Calibration Mode, verify registers for Static pressure, Differential

pressure and Temperature. (PCCU32 Only)

15. In Calibration Mode, select RTD Installed, un-check Use Fixed TF,

and adjust RTD Bias if a temperature standard is used.

16. In Calibration Mode, perform as found calibration checks.

17. If calibration is needed, calibrate static pressure first, then differential

pressure, using a deadweight tester or acceptable standard. Insure

that both orifice taps are closed and bypass valves are open during

AP calibration to avoid a false DP. Make sure there are no leaks in

the manifold or test equipment.

18. Perform as left calibration checks as needed.

19. Place Flow Computer on line: To avoid inducing toggle and/or a

calibration shift, close vent valve, open both bypass valves, then

open orifice tap valves SLOWLY (high pressure side first). Once both

orifice tap valves are fully opened, the bypass valves can be closed.

20. Verify that the unit is calculating volume correctly. Watch the display

or look at the Current Values in the Entry Mode of PCCU32.

21. Collect data and review the event and characteristic files to insure all

parameters are set properly.

22. Optional: When you are reasonably sure that all setup and

calibration is complete and the unit is on line calculating volume, it is

recommended that a Reset Volume command be sent from the

PCCU32 Entry Mode. This allows the unit to have what might be

considered as an official starting point for good live data. The Reset

Volume will be recorded in the Events file to mark the date and time.

Installing and Wiring RTD and Probe

The RTD measures flowing gas temperature. Procedures presented in

this section enable the user to install the RTD into the meter run and wire

leads to the main electronics board.

Totalflow Materials Supplied

•RTD Probe with 10’ of cable. Optional lengths 15’, 25’, 30’, 40’,

and 50’.

•One (1) thermowell with ¾" NPT threads. Optional threads are

½" and 1".

•Nylon tie wraps

Customer Materials Supplied

•Customer must specify or provide Thermowell "U" length.

•Teflon tape

1. Install thermowell into meter run.

2. Using snap ring pliers, adjust probe length

so that it is spring loaded against bottom

of thermowell.

3. Remove one of the hole plugs from the

FLO enclosure and install cord connector.

Remove nut, sealing ring and rubber

grommet from cord connector. Slide nut,

sealing ring and grommet over RTD cable and insert cable through

body of cord connector. Allow enough cable to extend into unit for

connecting wires to RTD termination block J9. (See Figure 5)

4. Secure the cable with the grommet sealing ring and nut.

Note: Charging source and Power should be removed from unit

before performing any field wiring.

5. Connect RTD probe to the

FLO’s RTD connector as follows:

Before making connections to terminal block, remove spade lugs if

attached and trim wire ends back 1/4". Remove J9 terminal block

from the

FLO’s main electronics board. (See Figure 5)

6. Loosen terminal block securing screws, insert wire, and then

retighten. Reinstall terminal block with wires attached.

Battery Installation

1. To extend the life of the battery pack, fully charge the battery prior to

installation. A system using solar panels may not fully charge the

battery. Also a fast charge, which the solar panel can’t provide,

improves the life of the battery. (See tip below)

2. Insert the battery pack into the battery compartment with its long

dimension facing outward.

3. Connect battery pack connector to main electronics board Battery

connector J6. (See Figure 5)

4. Observe LCD, the display should power up displaying Warm Start

information and begin scrolling through the default display items.

Caution: Do not connect solar panel power cable to the unit

unless the main battery pack is connected.

TIP: To recharge a battery, a quick charge will remove the buildup in

the battery much more effectively than a "trickle charge". A

battery slowly drained by low light conditions on a solar charged

system or setting in storage for instance, will be less likely to

recover than a battery pack that was quickly discharged from a

short for instance. Store batteries in a cool environment for less

drainage.

Lithium Battery

1. Verify that the Memory Backup is Enabled with a jumper on the

upper two pins (1 & 2) of J1. J1 is located just beneath and a little left

of the RTD connector. (See Figure 5)

2. Verify that the LL (low lithium alarm) is not being displayed on the A7

annunciator (default). This alarm indicates the Lithium battery is

below 2.5 volts and should be replaced.

Solar Panel Installation

Totalflow

Materials

Supplied

•One Solar Panel and Cable

•Two U-Bolts and fastening hardware

•One Solar Panel Bracket

Customer

Materials

Supplied

•Cable Ties

•One 9-inch or greater extension of 2-inch pipe

•One 2-inch collar

Procedure:

Note: Step 1 and 2 are not required if pipe is tall enough without the

extension.

1. Attach 2-inch pipe collar to top end of

FLO mounting pipe.

Securely tighten. (See Figure 4)

2. Install a 2-inch pipe extension into collar and securely tighten.

3. Install Solar Panel on mounting bracket with provided hardware.

4. Attach Solar Panel mounting plate to top end of 2-inch pipe with U-

bolts and associated mounting hardware. Do not tighten U-bolts until

Solar Panel has been correctly oriented.

5. If needed, connect Solar Panel power cable to Solar Panel connector

on back of unit. DO NOT connect the other end of cable to

FLO

unit until all steps are complete AND main battery pack has been

connected.

6. Position Solar Panel to face south in the northern hemisphere and

north in the southern hemisphere. Tighten U-bolts securely to avoid

movement by wind or vibration.

7. Check solar panel polarity using digital voltmeter to insure (+) and (-)

wires are properly identified.

8. The Solar Panel power cable connects to terminal block J7 Charger

Input terminals (See Figure 5). Remove one of the hole plugs from

the

FLO enclosure and install cord connector. Remove nut,

sealing ring and rubber grommet from cord connector. Slide nut,

sealing ring and grommet over cable and insert cable through body

of cord connector. Allow enough power cable to extend into the unit

for connection to Charger Input +/- terminals.

9. Secure Solar Panel cable using grommet, sealing ring and nut.

TIP: To prevent moisture from entering the

FLO, allow cable to

"dip" below, and then rise to access hole. This will provide a path

for rainwater away from the access hole.

Solar Panel

Mounting Bracket

2 " Collar

2 " Extension Pipe

Flow Computer

Cable

Solar Panel

U - Bolts

Figure 4 (Solar Panel Mounting)

(+)

(-)

Figure 5 (

FLO Board Layout)

NOTE: For orientation purposes, only connectors and major

components are shown.

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