Emerson FloBoss 104 Quick guide

Safe Use Instructions –Emerson FloBoss 104 Flow Manager

Part D301733X012

February 2018

Remote Automation Solutions

Safe Use Instructions:

Emerson FloBoss™ 104 Flow Manager

Safe Use Instructions

Anleitung zur sicheren Verwendung

Consignes de sécurité

Instruções para uso seguro

安全使用说明

Istruzioni per l’uso sicuro

Instructies voor veilig gebruik

Instrucciones para un uso seguro

Safe Use Instructions –Emerson FloBoss 104 Flow Manager

Part D301733X012

February 2018

Safe Use Instructions –Emerson FloBoss 104 Flow Manager

Part D301733X012

February 2018

Remote Automation Solutions

Emerson FloBoss™ 104 Flow Manager

Figure 1. FloBoss 104 Flow Manager Nameplate

(ATEX Version shown)

Use this safe use instructions (SUI) document with the

FloBoss 103 and FloBoss 104 Flow Manager Instruction

Manual (part D301153X012). For full cautions and

descriptions of installation and troubleshooting

procedures, refer to this manual. If you require training for

this product, contact your local sales office.

The FloBoss 103 Flow Manager with ATEX or IECEx

flameproof approvals may be ordered with optional EIA-

232 (RS-232) communications, dial-up modem

communications, or Pulse Interface module (PIM).

FloBoss 104 special conditions for Safe Use

▪Operating Ambient Temperature: 40°C to +75°C.

▪Ensure that the thermal fluid transfer does not

overheat the equipment to a temperature

corresponding to the spontaneous combustion

temperature of surrounding gas.

Declaration of Conformity

Hereby, Remote Automation Solutions declares that the

FloBoss 103 products are in compliance with the essential

requirements and other relevant provisions of European

Directives 2004/108/EC (EMC), 94/9/EC (ATEX), and

97/23/EC (PED).

DANGER

When installing units in a hazardous area, make sure

all installation components selected are labeled for use

in such areas. Installation and maintenance must be

performed only when the area is known to be non-

hazardous. Installation or maintenance in a hazardous

area could result in personal injury or property

damage.

Always turn off the power to the FloBoss before you

attempt any type of wiring. Wiring powered

equipment could result in personal injury or property

damage.

To avoid circuit damage when working inside the unit,

use appropriate electrostatic discharge precautions,

such as wearing a grounded wrist strap.

Do not open covers unless area is known to be non-

hazardous.

Connecting the FloBoss 104 to a continuous high

wattage power source without removing the battery

charger module may result in battery overcharging

and failure. See Section 3.5.1, Overcharging Potential

in the FloBoss 103 and 104 Flow Manager Instruction

Manual (part D301153X012).

Safe Use Instructions –Emerson FloBoss 104 Flow Manager

Part D301733X012

February 2018

2www.Emerson.com/RemoteAutomation

Specifications

POWER

External Power Charging Input: 8-28 V dc, reverse

polarity protection.

Input Current: 10-15 mA nominal. 20 mA at 100% duty

cycle (battery charging not included).

ENCLOSURE

Housing and Cap: Die-cast aluminum alloy with iridite

plating and paint. Stainless steel (CF8M) version

available.

ENVIRONMENTAL

Operating Ambient Temperature: -40 to +75C.

LCD Display: -20 to +75C.

Storage Temperature: -50 to +85C.

Operating Humidity: 5 to 95%, non-condensing.

WEIGHT

4.30 kg (9.5 lbs) (aluminum)

APPROVALS:

ATEX Version (Flameproof & Type n)

Evaluated per Approval standards:

(Flameproof) (Type n)

EN 60079-0 (2012) EN 60079-0 (2012)

EN 60079-1 (2007) EN 60079-15 (2010)

IEC 60529 IEC 60529

Certified by LCIE as Model W40116.

ATEX Cert LCIE 03ATEX6221 X/06

ATEX Cert LCIE 13ATEX1033 X/01

Product Markings for Hazardous Locations:

Ex d IIB T5 Gb (-40°C ≤ Tamb ≤ +75°C), IP66

Ex nA IIB T3 Gc (-40°C ≤ Tamb ≤ +75°C), IP66

II 2/3 G. 0081

Specifications

IECEx Version (Flameproof and Type n)

Evaluated per Approval standards:

IEC 60079-0 (2011)

IEC 60079-1 (2007)

IEC 60079-15 (2010)

IEC 60529

Certified by CSA as Model W40149.

IEC Cert IECEx LCI 08.0039 (Flameproof)

IEC Cert IECEx LCI 08.0015 (Type n)

Product Markings for Hazardous Locations:

Ex d IIB T5 Gb (-40°C ≤ Tamb ≤ +75°C), IP66

Ex nA IIC T3 Gc (-40°C ≤ Tamb ≤ +75°C), IP66.

IECEx Version (Type n Only)

Evaluated per Approval standards:

IEC 60079-0 (2011)

IEC 60079-15 (2010)

IEC 60529

Certified by CSA as Model W40150.

IEC Cert IECEx LCI 08.0015 (Type n)

Product Markings for Hazardous Locations:

Ex nA IIC T3 Gc ((-40°C ≤ Tamb ≤ +75°C ), IP66.

The following tools are required for installation,

maintenance, and troubleshooting:

▪Personal computer running Microsoft®Windows® 7,

Windows 8.1, or Windows 10 and Emerson Field Tools

configuration software (providing ROCLINK™800

configuration software).

▪Phillips (cross-head) screwdriver.

▪Flat-head screwdriver.

▪Hex socket wrench (M4).

1. You receive the FloBoss 104 in a box. Remove it from

the box.

2. Find a suitable location for the FloBoss 104. When

choosing an installation site, be sure to check all

clearances. Provide adequate clearance for wiring and

service. The optional LCD should be visible and accessible

for the on-site operator. See Figure 8.

3. Mounting of the FloBoss 104 can be accomplished

using one of the following methods:

▪Pipestand mounted to a 2-inch pipestand. Use the

standard Rosemount 2" (50mm) pipe mounting kit (with

impulse tubing connecting the FloBoss 104 to the meter

run). Ensure that the pipestand meets all weight

requirements and installation conforms to local building

codes. See Figure 9.

Safe Use Instructions –Emerson FloBoss 104

Part D301733X012

February 2018

www.Emerson.com/RemoteAutomation 3

Note: The Rosemount pipe mounting kit is not suitable for

the stainless steel housing. Customers must provide

an appropriate mounting.

▪Direct mounting on a meter housing.

4. The FloBoss must be properly grounded. The FloBoss

104 has one grounding screw outside the enclosure and

two grounding screws inside the enclosure. See Figure 2.

Internal Grounding Screws

External Grounding Screw

Figure 2. Back End of FloBoss 104

(with Termination Board)

Proper grounding of the FloBoss 104 helps to reduce the

effects of electrical noise on the unit’s operation and

protects against lightning. The FloBoss provides lightning

protection for built-in field wiring inputs and outputs.

Install a surge protection device at the service disconnect on

DC voltage source systems to protect against lightning and

power surges for the installed equipment. You may also

consider a telephone surge protector for the optional dial-up

modem communications card.

All earth grounds must have an earth to ground rod or grid

impedance of 25 ohms or less, as measured with a ground

system tester. The grounding conductor should have a

resistance of 1 ohm or less between the FloBoss enclosure

ground and the earth ground rod or grid.

If the pipeline to earth impedance is greater than 2 ohms,

the FloBoss installation should be electrically isolated and

a ground rod or grid grounding system installed.

The recommended cable for I/O signal wiring is an

insulated, shielded, twisted-pair. The twisted pair and the

shielding minimize signal errors caused by EMI

(electromagnetic interference), RFI (radio frequency

interference), and transients.

5. The FloBoss must be connected to power, I/O

devices, and communication devices. The external

connections, or field terminals, are all located on the

termination board. The terminal block accepts wires

up to 1.29 mm (16 AWG) in size.

The FloBoss Termination Board connectors use

compression terminals. The input power termination

(CHG+ / CHG-) uses a removable connector and

accommodates wiring up to 1.29 mm (16 AWG) in

size. In all cases, make connections by baring the end

(6 mm maximum) of the wire, inserting the bared end

into the clamp beneath the termination screw, and

then tightening the screw to 0.25 N-m.

Access to wiring connections is via field wiring entries.

The metal pipe plugs provided must remain in place

on unused entries to maintain flame-proof integrity of

enclosure. If these plugs are replaced for any reason,

only install certified plugs or thread adapters that

meet or exceed the product ratings.

DANGER

Do not over torque the connector screws.

Note: Check the input power polarity before turning

on the power.

The inserted wires should have a minimum of bare

wire exposed to prevent short circuits. Allow some

slack when making connections to prevent strain.

The FloBoss 104 accepts input voltages from 8.0 volts

to 28 volts at the charge terminals (CHG+ / CHG-) with

no external current limiting (internal current limit is

200 mA).

The terminals are labeled CHG+ for positive power

connection and CHG- for negative power connection

on a label on the termination board. See Figure 3.

Safe Use Instructions –Emerson FloBoss 104 Flow Manager

Part D301733X012

February 2018

4www.Emerson.com/RemoteAutomation

Figure 3. Termination Board

6. The FloBoss 104 ships with the NORM/RESET jumper

in the NORM position, and the ON/OFF jumper in the OFF

position.

To apply power to the FloBoss 104:

▪Unscrew the cover clamp at the base of the front end

cap (LCD end). See Figure 4.

Figure 4. Cover Clamp Assembly

▪Unscrew the front end cap cover.

▪Place the power jumper (located on the LCD if

installed or located at J1 on the Battery Charger Board)

in the ON position. See Figure 5 and Figure 6.

NORM/RESET Jumper

ON/OFF Jumper

Figure 5. Front End of FloBoss 103 (with LCD)

▪Replace the front end cap cover (LCD end) and cover

clamp.

After the FloBoss 104 completes start-up diagnostics

(RAM and other internal checks), the optional LCD displays

the date and time to indicate that the FloBoss has

completed a valid reset sequence. If the LCD does not

come on, perform trouble-shooting for possible causes

(see Step 9).

ON/OFF Jumper

Figure 6. Front End of FloBoss 104 (without LCD)

7. The FloBoss 104 must be configured before it is

calibrated and placed into operation. Configuration must

be performed using ROCLINK 800 software, which runs on

a PC. The PC is normally connected to the LOI port of the

flow computer to transfer configuration data into the

FloBoss 104, although much of the configuration can be

done off-line and later loaded into the FloBoss.

Safe Use Instructions –Emerson FloBoss 104

Part D301733X012

February 2018

www.Emerson.com/RemoteAutomation 5

Default values for all parameters exist in the firmware of

the FloBoss. If the default is acceptable for your

application, it can be left as it is. Perform adjustments to

the FloBoss through the configuration software. Refer to

the ROCLINK 800 Configuration Software User Manual (Part

D301159X012).

8. The calibration routines support 5-point calibration,

with the three mid-points calibrated in any order. The low-

end or zero reading is calibrated first, followed by the

high-end or full-scale reading. The three mid-points can

be calibrated next, if desired. The diagnostic analog

inputs—logic voltage (E1), battery voltage (E2), and

board/battery temperature (E5)—are not designed to be

calibrated.

With the optional I/O termination points installed, the

Analog Input can be calibrated using ROCLINK 800

software.

The built-in inputs that are supported with the 5-point

calibration are:

▪Differential pressure located at AI Point A1.

▪Static pressure located at AI Point A2.

▪RTD temperature located at AI Point A3.

These inputs are assigned to the first three Analog Input

points. The calibration procedure for these inputs is

described in the ROCLINK 800 Configuration Software User

Manual (Part D301159X012).

9. To troubleshoot problems with the FloBoss 104,

identify whether the problem is with the configuration or

the hardware. Check the configuration in ROCLINK 800

software to identify any incorrect settings. Inspect the

hardware for damage. Inspect the termination boards for

connection location errors.

If you are experiencing problems with the FloBoss 104 that

appear to be software related, try resetting the FloBoss

with a warm start, a cold start, or a jumper reset.

If you are experiencing problems that appear to be

hardware-related, verify the wiring. If you still experience

problems, contact your local sales office for return

authorization.

During operation, the FloBoss 104 can be monitored (to

view or retrieve current and historical data) either locally

or remotely. Local monitoring is accomplished either by

viewing the LCD panel detailed in Section 2, or by using

ROCLINK 800 software on a PC connected through the LOI

port. Remote monitoring is performed through Comm 1

or Comm 2 of the FloBoss using ROCLINK 800 software, or

host system. Refer to Figure 8 for the communication

terminations.

10. To remove the FloBoss 104 from operation.

disconnect power from the unit and then remove all

external wiring connections. Remove the gas lines. Finally

remove the FloBoss housing from the pipestand or orifice

plate. The FloBoss may be placed in a box for

transportation.

DANGER

Take care when removing gas lines from the FB104.

Use one wrench to prevent the sensor connector from

moving, and use a second wrench to disconnect the

gas line. Allowing the sensor to rotate will damage the

internal wiring.

Figure 7. FB104 Pulse Interface Housing

When connecting gas pressure lines to the optional

Pulse Interface module, note the maximum working

pressure limits to the individual P1 and P2 sensors

based on the model number of the module. For

example, Figure 7 shows a model PM24 module with

its P1 (300 PSIG/2068 kPa) and P2 (1000 PSIG/6894

kPa) sensor ranges.

Safe Use Instructions –Emerson FloBoss 104 Flow Manager

Part D301733X012

February 2018

6www.Emerson.com/RemoteAutomation

FloBoss 104 nameplate

DVS Sensor label

Figure 8. FloBoss 104 Dimensions

¾ - 14 NPT Field Wiring entries

Figure 9. FloBoss 104 Mounting Styles

Safe Use Instructions –Emerson FloBoss 104

Part D301733X012

February 2018

For customer service and technical support,

visit www.Emerson.com/SupportNet.

Global Headquarters,

North America, and Latin America:

Emerson Automation Soltuions

Remote Automation Solutions

6005 Rogerdale Road

Houston, TX 77072 U.S.A.

T +1 281 879 2699 | F +1 281 988 4445

www.Emerson.com/RemoteAutomation

This publication is for informational purposes only. While every effort has been made to ensure

accuracy, this publication shall not be read to include any warranty or guarantee, express or

implied, including as regards the products or services described or their use or applicability.

Remote Automation Solutions (RAS) reserves the right to modify or improve the designs or

specifications of its products at any time without notice. All sales are governed by RAS terms

and conditions which are available upon request. RAS accepts no responsibility for proper

selection, use or maintenance of any product, which remains solely with the purchaser and/or

end-user.

Europe:

Emerson Automation Solutions

Remote Automation Solutions

Unit 8, Waterfront Business Park

Dudley Road, Brierley Hill

Dudley UK DY5 1LX

T +44 1384 487200 | F +44 1384 487258

Middle East/Africa:

Emerson Automation Solutions

Remote Automation Solutions

Emerson FZE

P.O. Box 17033

Jebel Ali Free Zone –South 2

Dubai U.A.E.

T +971 4 8118100 | F +971 4 8865465

Asia-Pacific:

Emerson Automation Solutions

Remote Automation Solutions

1 Pandan Crescent

Singapore 128461

T +65 6777 8211| F +65 6777 0947

Remote Automation Solutions

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