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ABB XSeriesG4 - User Manual

ABB XSeriesG4
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An engineering milestone in
development of remote, low
power, measurement and
control devices
User’s manual/2103335 Rev. AB
XSeriesG4 products
Flow computer
XFC
G4

Table of Contents

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Summary

Typographical conventions

Additional publications

1 Health and safety

1.1 General information and notes for the reader

General instructions for safe installation and operation of the flow computer.

1.2 Safety; warning symbols, note symbols

Explains the meaning of various safety symbols used in the manual.

1.3 Potential safety hazards

Outlines potential hazards related to pressurized gas and electrical equipment.

3 System Description

3.1 Overview

Introduces the XSeriesG4 flow computers and their applications in oil and gas systems.

3.1.1 Hardware

Describes the hardware components and enclosures of the XFCG4 models.

3.1.2 Functionality

Details the system's data collection, trending, and measurement capabilities.

3.2 XSeriesG4 Flow Computer Hardware

3.2.1 XFCG4 Board

Details the XFCG4 board's input/output points and interfaces.

3.2.2 CPU Engine Card

Describes the CPU engine card, its processor, memory, and lithium backup battery.

3.2.3 Communication Compartment

Explains the compartment for mounting communication devices like radios and modems.

3.2.5 Solar Panel

3.2.6 Resistive Temperature Detector (RTD)

Explains the optional RTD for measuring flowing gas temperature.

3.2.7 Additional Features

Lists features like security, clock, charging sources, and LCD programmability.

3.3 Standard Enclosures

3.4 XFCG4 Board Specifications

3.5 External Integral Multi-Variable (XIMV)

3.6 XSeries On-board Input;Output

3.6.1 Communication Ports

Describes the two onboard communication ports for local and remote communication.

3.6.2 Digital Input

Details the two digital/pulse inputs for monitoring external equipment.

3.6.3 Digital Output

Explains the two digital (12 Vdc) outputs used to control external equipment.

3.7 Functions of the XFCG4

3.7.1 Records

Lists the types of flow and operational records the computer logs.

3.7.2 XFCG4 Capabilities

Details calculations and data recording capabilities like AGA-3 and AGA-8.

3.7.3 Additional Features

Lists features like no-flow cutoff, security, RTD calibration, and power sources.

3.8 Display Function

3.9 Display Annunciators

3.10 XFCG4 Application Licensing

3.10.1 Credit Key (USB)

Details how credits are managed on a USB credit key and transferred.

3.11 Laptop Computer Running PCCU32

Describes the use of PCCU32 software for programming the flow computer.

3.12 Local PCCU Connections

Explains methods for establishing local communication (RS-232, USB).

3.13 Network Connectivity (Dynamic IP w;Router)

3.14 Optional Key Pad

3.15 Optional Totalflow Input;Output Modules

3.15.1 TFIO Module Specifications

Details the specifications and loading capacities of TFIO modules.

3.15.2 TFIO Module Hardware

Describes the I/O module hardware packaging and features.

4 Installation

4.1 Unpacking and Inspection

Instructions for unpacking and inspecting the flow computer and its components.

4.2 Installation Overview

Overview of installation procedures applicable to all XSeries flow computers.

4.3 Pipe Mount Installation

Step-by-step instructions for mounting the flow computer onto a pipe.

4.4 Wall Mount Installation

4.4.1 Optionally Supplied Materials

Lists optionally supplied materials for wall mounting.

4.4.2 Materials Not Supplied

Lists materials not supplied for wall mounting.

4.4.3 Step-by-Step Instructions

Provides step-by-step instructions for performing a wall mount installation.

4.6 Manifold Input Lines

4.6.1 Step-by-Step Instructions

Instructions for installing manifold input lines connecting to the flow computer.

4.7 Direct Mount Installation for Pulse Meter

4.7.1 Step-by-Step Instructions

Provides step-by-step instructions for direct mounting to a pulse meter.

4.8 Static Pressure Input Line

4.8.1 Description

Describes the static pressure input line connection to the flow computer.

4.8.2 Step-by-Step Instructions

Provides steps to install the static pressure input line.

4.9 Battery Pack Installation

4.9.1 Step-by-Step Instructions

Step-by-step instructions for installing the flow computer's battery pack.

4.10 Solar Panel Installation

4.10.1 Step-by-Step Instructions

Step-by-step instructions for installing the solar panel.

4.11 RTD Probe Installation

4.11.1 Step-by-Step Instructions

Provides steps for installing the RTD probe into the meter run.

4.12 AC Charging Unit Installation

4.12.1 Step-by-Step Instructions

Step-by-step instructions for installing the AC charging unit.

4.13 XFCG4 Communication, Jumper Settings and Field Wiring

4.13.1 Communication Wiring

Details communication wiring for onboard ports and modules.

4.13.2 Communication Modules

Explains the 21-pin communication modules for RS-232, RS-422, or RS-485.

4.13.3 Board Configuration

Briefly describes configurable points on the main electronic board.

5 XFCG4 Startup

5.1 Overview

Outlines the chapter's focus on getting the flow computer up and running.

5.2 PCCU32 Installation and Setup

Instructions for installing and setting up the PCCU32 software.

5.3 Establishing Initial Local Communication

Describes methods for establishing local communication (RS-232, USB).

5.4 Setup of the XFC for Ethernet communication

5.4.1 Enable Ethernet for local point-to-point connection with a host

Procedure to enable Ethernet for temporary local connection.

5.4.3 Enable and configure Ethernet for network connection with hosts

Configuring Ethernet for network connection using static or dynamic IP addressing.

5.4.4 Establish network connection over Ethernet (using default TCP port)

Procedure to establish a network connection using the default TCP port.

5.5 Setting up the XFCG4

5.5.1 Station ID

How to set a unique station identifier code for the flow computer.

5.5.2 Device ID;Application ID

How to set a unique identifier for each tube/application on the device.

5.5.5 Bi-Level Security System

Describes data and configuration security across flow meter, PCCU32, and WinCCU32.

5.6 Application Licensing Credit Key

5.6.1 Credit key driver Installation

Instructions for installing the USB credit key driver.

5.6.2 Access and view the credit key with PCCU32 7.0 (or later)

How to access and view credit key information using PCCU32.

5.6.4 Transferring Credits to the G4 Controller from Credit Key

How to transfer application credits from the credit key to the G4 controller.

5.6.5 Transferring Credits to the Credit Key from G4 Device

5.7 XFCG4 Configuration

5.7.1 Contract Hour

How to program the flow computer to begin the contract day.

5.7.2 Log Period

Setting the specified length of time for writing accumulated volume records.

5.7.3 Volume Calculation Period

Setting the time between volume calculations, must divide Log Period.

5.7.4 Calculated Method

Setting the calculation method (e.g., AGA-3, AGA-7) and toggling factors.

5.7.6 Constants

5.7.7 Alarm Limits

Setting alarm limits for parameters to control output or send signals.

5.7.8 Reset Volume

Procedures for resetting the volume accumulator and its effects.

5.8 Startup the flow computer

5.8.1 Put the flow computer on-line

Instructions for putting the flow computer online, including valve operations.

5.8.2 Setting flow computer temperature calculation

Options for setting temperature calculations (Fixed, RTD, or both).

5.8.3 Volume reset

How volume calculations are affected by changes and the use of Reset Volume.

5.9 XFCG4 Standard Displays

5.9.1 Program Display

Default displays and how to change display items, units, and formats.

5.10 Key Pad

6 Service and maintenance

6.2 Data preservation

Importance of preserving data (measurement, logs, config, calibration) before maintenance.

6.2.1 Data collection

Steps to collect measurement data, alarms, and event codes using PCCU.

6.2.2 Back up configuration files (save)

Procedure for backing up configuration and calibration data to a laptop.

6.2.3 Restoring configuration files (Restore)

6.3 Performing a Warm Boot

6.3.1 Hardware Warm Boot

Steps for performing a hardware warm boot using the reset button or power cycling.

6.3.2 Software Warm Boot

Steps for performing a software warm boot using the 32-Bit Loader.

6.4 Performing a Cold Boot

6.4.1 Hardware Cold Boot

Steps for performing a hardware cold boot by disabling memory backup.

6.4.2 Software Cold Boot

Steps for performing a software cold boot using the loader or terminal.

6.5 Changing XFCG4 Clock

6.5.1 Clock change not crossing an hour boundary

How clock changes not crossing an hour boundary affect records.

6.5.2 Forward clock change crossing an hourly boundary

How forward clock changes crossing an hour boundary affect records.

6.5.3 Backward clock change crossing an hourly boundary

How backward clock changes crossing an hour boundary affect records.

6.6 Replacing the lithium battery

6.7 Replacing XFCG4 Battery Pack

6.8 Replacing the Main Electronic Board

6.9 Replacing the CPU Engine Card

6.10 Replacing Liquid Crystal Display (LCD) Board

6.11 Replacing XIMV

6.12 Replacing Static Pressure Transducer

6.13 Calibration

6.13.1 Required Test Equipment

Lists the test equipment needed to calibrate the XFCG4 XIMV.

6.13.2 Hold Mode

Explains the Hold mode used during calibration to ignore live values.

6.13.3 Static Pressure (SP) Calibration Checks

How to check static pressure calibration and log pressure marker points.

6.13.4 Differential Pressure (DP) Calibration Checks

6.13.5 Calibrating Static Pressure (SP)

6.13.6 Calibrating Differential Pressure (DP)

6.14 On-Board I;O Calibration Overview

6.14.1 Hold Mode

Explains the Hold mode for I/O calibration, ignoring live values.

6.14.2 Calibrating On-Board Analog Input

Steps for calibrating the onboard analog inputs.

6.14.3 Calibrating On-Board Pulse and Digital Inputs

Procedure for calibrating pulse inputs and setting the K-Factor.

6.15 Calibrating TFIO Module Analog Outputs

6.16 How to Change Orifice Plate

6.16.1 Taking Meter Run Out-of-Service Procedure (Simplex Fitting)

Procedure for changing orifice plate when meter run is out of service.

6.16.2 Leaving Meter Run In-Service Procedure (Senior Fitting)

Procedure for changing orifice plate while meter run is in service.

6.17 Zero Transducer

6.17.1 Static Pressure

Steps to zero the static pressure (SP) transducer.

6.17.2 Differential Pressure

Steps to zero the differential pressure (DP) transducer.

7 Troubleshooting

7.1.1 Troubleshooting Support

Information on contacting Totalflow Service Department for assistance.

7.1.4 Visual Alarm Codes

Explains how LCD annunciators indicate status, errors, and alarm conditions.

7.2 Troubleshooting Visual Alarm Codes

Assists in determining the cause of visual indicators (alarms/codes).

7.2.1 Troubleshooting a Blank LCD Screen

7.2.2 Troubleshooting a Low Lithium Alarm (LL)

Guidance for addressing the Low Lithium alarm, suggesting battery replacement.

7.2.3 Troubleshooting a Low Charger Alarm (LC)

Steps to troubleshoot the Low Charger alarm, related to battery charging voltage.

7.2.4 Troubleshooting a Analog to Digital Failure Alarm (AD)

Troubleshooting steps for Analog to Digital converter failure alarms.

7.3 Power Troubleshooting

7.3.1 Overview

Focuses on determining the cause of power loss, often related to the power supply.

7.3.2 Power Supply Test

Steps to perform a power supply test, checking voltage, current, and connections.

7.3.3 Solar Panel Charging System Test

How to test the solar panel charging system for proper voltage output.

7.3.4 AC Charging System Test

7.3.5 Auxiliary Equipment Isolation Test

Isolating auxiliary equipment to find power drain issues.

7.3.6 TFIO Module Isolation Test

Isolating TFIO modules to check battery pack output voltage consistency.

7.3.7 SLEEP Mode

Explains the SLEEP mode and how to wake the unit.

7.3.8 Reset Procedures

7.3.8.1 Cold Start

Clearing RAM and resetting variables to factory defaults.

7.3.8.2 Cold Start Procedures (Hardware)

Hardware steps for performing a cold start.

7.3.8.3 Cold Start Procedure (Software)

Software steps for performing a cold start via PCCU.

7.3.8.4 Warm Start

7.3.8.5 Warm Start Procedures (Hardware)

Hardware steps for performing a warm start.

7.3.9 SLEEP Mode

Explains SLEEP mode, voltage triggers, and wake-up functions.

7.4 Troubleshooting Communications

7.4.1 Communications Overview

Overview of troubleshooting procedures for RS-232, RS-485, and RS-422 communications.

7.4.1.1 Setting up communication

Notes for setting up communication equipment and verifying wiring.

7.4.2 Transceiver Supply Voltage Test

Verifying the transceiver receives the manufacturer's suggested voltage.

7.4.3 12 V Communication Supply Voltage Test

How to perform a 12V communication supply voltage test.

7.4.5 RS-232 Communication Test

7.4.6 RS-485 Communication Test

7.4.7 RS-485 Communication Test

Steps for performing an RS-485 communication test.

Customer support

Client warranty

Information on warranty requirements for equipment under warranty.

ABB XSeriesG4 Specifications

General IconGeneral
DisplayLCD
Power supply100 to 240 V AC, 24 V DC
Enclosure protectionIP66
Measurement principleElectrochemical
CommunicationHART, Modbus
Operating temperature-20°C to +50°C
Measurement RangeDepends on sensor type
WeightDepends on configuration
Input ImpedanceNot applicable

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