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TotalFlow XSeries User Manual

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

Table of Contents

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TotalFlow XSeries Specifications

General IconGeneral
BrandTotalFlow
ModelXSeries
CategoryRemote Control
LanguageEnglish

Summary

Introduction

System Description

Provides a description of the Totalflow, XSeries system components and specifications.

Installation

Includes unpacking and detailed procedures for setup and installation.

XRC Startup

Provides a tutorial on how to get a newly installed XRC system up and running.

Maintenance

Provides instructions on how to remove and replace major modules.

Troubleshooting

Describes XRC front panel error messages and provides a troubleshooting chart.

Appendix A: Register Documents

Lists and describes various register documents for system configuration.

Appendix B: Definitions & Acronyms

Provides quick access to terms and abbreviations used in the manual.

Getting Help

Key Symbols

Explains symbols used in the manual for important information.

Safety Practices and Precautions

Safety Guidelines

DO NOT open equipment, use trained technicians, exercise care with live parts.

Safety First

Highlights conditions leading to damage, injury, or loss of life.

Safety Practices and Precautions, Cont.

Explains DANGER/CAUTION, equipment markings, grounding, and fuse replacement.

Chapter 1 System Description

Overview

Introduces Totalflow XSeries Remote Controllers (XRC) and their applications.

XSeries Remote Controller Hardware

Details the components of the XRC, including enclosure, boards, and modules.

Standard Enclosure

Describes the hinged-door box enclosure for XRC6490, 6790, 6890.

Rack Mount Enclosure

Describes the XRC6990 enclosure for 19” Rack Mount.

XRC General Specifications

Provides dimensions, weight, I/O module capacity, and environmental specs.

XRC-195 Electronic Board Specifications

Details the specifications of the XRC-195 Electronic Board.

XSeries On-board Input/Output

Lists the base I/O capabilities of the XRC.

Digital Input

Describes the 4 digital inputs, usable as high-speed pulse inputs.

Digital Output

Describes the 4 digital (12Vdc) outputs for controlling external equipment.

Analog Inputs

Details the 5 analog inputs supporting 0-10VDC or 0-20mA loops.

Display Function

Explains the front panel LCD scrolling through operating parameters.

Functions of the XRC

Outlines the practical and efficient capabilities of the XRC.

Display Annunciators

Describes how the XRC indicates unusual or alarm conditions.

Laptop Computer running PCCU32

Discusses the PCCU32 software for programming the XRC.

FS/2 Handheld PCCU

Describes the DOS-based FS/2 unit for basic operations.

Optional Equipment

Lists optional hardware like Key Pad and I/O Modules.

Key Pad

Details the optional keypad for monitoring display items without extra equipment.

Totalflow Input/Output Modules

Explains extending XSeries functionality with modular I/O.

Chapter 2 Installation

Overview

Provides information for installing and setting up the XRC system.

Unpacking & Inspection

Details the process of unpacking and inspecting the XRC and its components.

Pipe Saddle Mount Installation

Provides procedures for installing the unit directly to a meter run using a pipe saddle.

Wall Mount Installation

Outlines procedures for mounting the XRC to a wall.

Battery Pack Installation

Details the procedure for installing the battery pack for operating power.

Solar Panel Installation

Explains the process of mounting and connecting the solar panel.

AC Charging Unit Installation

Describes the installation of the AC power charging unit.

XRC6990 Rack Mount Installation

Provides instructions for rack mounting the XRC6990.

XRC Communication, Jumper Settings and Field Wiring

Covers setup, wiring, and jumper configurations for XRC communication.

Chapter 3 XRC Startup

Overview

Describes steps to get a newly installed XRC system operational.

PCCU32 Installation and Setup

Details the installation of the PCCU32 software required for XSeries equipment.

Connecting To Local Port

Explains connecting the laptop computer to the XRC via a serial MMI cable.

Setting up the XRC

Guides through initial setup steps like Station ID and Device ID.

On Board I/O Calibration

Covers calibration procedures for Analog, Pulse, and Digital Inputs.

Options

Discusses the two programming equipment options: PCCU32 software or DOS-based FS/2 device.

Chapter 4 Maintenance

Overview

Provides standard maintenance information and component removal/installation instructions.

Backing up Configuration Files

Instructions on backing up XRC configuration files to a laptop or floppy disk.

Changing XRC Clock

Details how clock changes affect log period entries and XRC handling.

Downloading a New Flash

Procedures for downloading new software to the XRC Flash Memory.

Components and Spare Parts

Information on identifying and replacing components and spare parts.

Replacing XRC Battery Pack

Step-by-step instructions for removing and installing the XRC battery pack.

Replacing Liquid Crystal Display (LCD) Board

Procedures for accessing and removing/reinstalling the LCD board.

Chapter 5 Troubleshooting

Overview

Provides troubleshooting guidelines for various subsystems and a flowchart.

Troubleshooting Visual Alarm Codes

Assists in determining causes and corrective steps for visual indicators/alarms.

Power Troubleshooting

Focuses on determining causes of power loss.

Troubleshooting Communications

Guides through troubleshooting communication problems with installed radios.

Troubleshooting a Blank LCD Screen

Provides steps to diagnose why the Liquid Crystal Display is blank.

Troubleshooting a Low Charger Alarm (LC)

Addresses the Low Charger alarm, typically indicating low charging voltage.

Troubleshooting a Analog to Digital Failure Alarm (AD)

Deals with the A to D Failure alarm code or SLEEP mode issues.

Resistive Temperature Detector (RTD) Continuity Test

Provides instructions to test the RTD Probe for continuity.

RTD Current Source (Resistive) Test

Tests the current source on the Termination Board to verify power reception.

RTD Impedance Test

Tests the current source on the Termination Board to verify power reception.

Power Supply Test

Details various tests for power supply configurations.

Solar Panel Charging System Test

Steps to test the solar panel if it's not supplying required voltage.

AC Charging System Test

Instructions to test the AC charger if it's not supplying required voltage.

Auxiliary Equipment Isolation Test

Tests battery pack output voltage consistency and checks for power drains.

TFIO Module Isolation Test

Tests battery pack output voltage consistency with TFIO Modules installed.

SLEEP Mode

Explains the SLEEP mode as a safety feature and provides wake-up steps.

Reset Procedures

Covers cold start and software restart procedures.

Cold Start

Clears RAM data, resets variables to factory defaults, and is used for new installations.

Software Procedures

Describes performing a software restart by typing a command in PCCU.

Transceiver Check

Verifies transceiver output power, frequency, and antenna orientation.

RS-232 Communication Test

Tests RS-232 serial communication by checking voltage on Receive Data and Request to Send pins.

RS-485 Communication Test

Tests RS-485 serial communication, including wiring and termination settings.

RS-485 Field Wiring on XRC-195 Board

Details the field wiring for RS-485 communication on the XRC-195 Board.

RS-485 Terminations

Describes the jumper settings for RS-485 bus termination.

Appendix A Register Documents

Standard Registers

Lists standard registers including Alarm System Application Registers.

Alarm System Application Registers (Rev AB)

Details registers for alarm system application, including records and constants.

Display Application Registers (Rev AA)

Lists registers for controlling display options, file names, and units.

Holding Register Application (Rev AA)

Details registers for holding arrays, including descriptions, types, and access levels.

Operations Application Registers (Rev AB)

Lists registers for periodic operations, math, bit, compare, and array operations.

Communication Registers

Lists registers related to communication settings like port flags, baud rate, and protocols.

Communication Application Registers (Rev AA)

Lists registers related to communication settings like port flags, baud rate, and protocols.

FS2 Application Registers (Rev AA)

Lists registers for FS2 application, including byte, 32-bit integer, and floating point types.

XMV Interface Application Registers (Rev AC)

Details registers for XMV interface, categorized by arrays for communication, calibration, and scroll text.

Therms Master Application Registers (Rev AB)

Lists byte registers for Therms Master, including components and triggers.

Therms Master Btu Byte Registers

Lists byte registers for Therms Master, including components and triggers.

Therms Master Btu Integer Registers

Lists integer registers for Therms Master, including component tables.

I/O Subsystem

Lists data array registers for I/O subsystem, including 32-bit, 16-bit, and 8-bit integer arrays.

I/O Subsystem Data Array Registers

Lists data array registers for I/O subsystem, including 32-bit, 16-bit, and 8-bit integer arrays.

Tube Applications

Lists byte registers for AGA3 Tube Application, including configuration flags and component settings.

AGA3 Tube Application Registers (Rev AM)

Lists byte registers for AGA3 Tube Application, including configuration flags and component settings.

AGA7 Tube Application Registers (Rev AH)

Lists byte registers for AGA7 Tube Application, including configuration flags and component settings.

Enron Tube Registers (Rev AA)

Lists byte registers for Enron Tube, covering status, logging, and event data.

Enron Byte Registers

Lists byte registers for Enron Tube, covering status, logging, and event data.

Enron Integer Registers

Lists integer registers for Enron Tube, covering log events and parameters.

Enron Float Registers

Lists float registers for Enron Tube, covering model, revision, and time settings.

Enron Bool Registers

Lists boolean registers for Enron Tube, covering low battery and other flags.

Enron Var Bytes Registers

Lists variable byte registers for Enron Tube, including user byte and offset index.

Enron Var Integer Registers

Lists variable integer registers for Enron Tube, covering modbus events and user integers.

Selectable Units

Lists byte registers for AGA3 Selectable Units, including configuration flags and component settings.

AGA3 Selectable Units Tube Registers (Rev AE)

Lists byte registers for AGA3 Selectable Units, including configuration flags and component settings.

Tube PI Calibration Byte Registers

Describes byte registers for PI calibration, including meter factor and calibration control.

Tube PI Calibration Frequency Registers

Details registers for frequency points used in PI calibration.

Tube PI Calibration Meter Factor Registers

Lists meter factor registers for PI calibration points.

Modbus Register Map: Register Groups

Shows proposed indexing for different register types across tubes.

Proposed map indexing

Shows proposed indexing for different register types across tubes.

Modbus Register Mapping for Tube 1: Boolean Registers

Maps Modbus registers to App Type, Array, Reg, Event Code, and Variable for Tube 1.

Appendix B Definitions & Acronyms

Glossary of technical terms and acronyms used in the manual.

TERM DEFINITION

Glossary of technical terms and acronyms used in the manual.