Training Notes

FloBoss S600
Training Notes
Page 2
 Contents

CONTENTS 3

OVERVIEW 5

FLOBOSS S600 FLOW COMPUTER 6

CONFIG 600 8

OPERATION 9

KEYPAD 9
KEYPAD 10
F KEYS 10
VECTOR & MENU KEYS 10
ALARM LIGHT & KEYS 11
NUMERIC KEYS 11
OPERATION KEYS 12
DISPLAY 13
MENUS 13
DATA PAGES 13
STATUS/ID LINE 14
DISPLAY MATRIX 14
USING THE S600 15
INITIALISATION 15
NAVIGATING THE DISPLAY 17
ENTERING DATA 19
CHANGING A VALUE 19
CHANGING MODE 21
EXPONENTIAL FORMAT 22
SECURITY CODE 23
ALARMS 24
ALARM LIGHT 24
VIEW ALARM 24
ALARM ACCEPT 24
PRINTING 25
SPECIAL PAGES 27
QUICK SUMMARY OF OPERATION 28
DISPLAY MATRIX 28
VIEW PARAMETER 28
RETURN TO MAIN MENU 28
CHANGE VALUE 28
CHANGE MODE 28
CLEAR 28

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SCIENTIFIC NOTATION 28
ALARM 28
PRINT 29
DEFAULT DISPLAY 29
PROGRAM FUNCTION KEYS 29

CONFIG 600 30

INTRODUCTION TO CONFIG 600 30

SYSTEM REQUIREMENTS 30
SOFTWARE INSTALLATION PROCEDURE 31
CONNECTING TO THE S600 32
FILE LOCATIONS 32
START UP 33

MAINTENANCE 34

COLD START PROCEDURE 34

REFLASH FRMWARE 35
DOWNLOAD & REFLASHING A NEW BINARY FILE 36
DOWNLOAD & REFLASHING A CONFIGURATION FILE 37
COLD START 38
NETWORK SETUP 39
FACTORY SETUP 40
CLEAR SRAM 40
FORMAT FLASH 41

SETUP & WIRING 42

RS232 MODEM PORT 42

RS-422/485 MULTIDROP PORT 43
ETHERNET LAN 43
ON-BOARD BATTERY BACKUP 43
P152 CPU ON-BOARD CONNECTORS 44
P152 CPU BERG LINKS 45
P144 IIO BERG LINKS 47
P154 PROVER BERG LINKS 48

FloBoss S600
Training Notes
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 Overview

The FloBoss S600 (also referred to as the S600) is a compact, microprocessor-based flow computer,
which has been designed and built using proven design techniques and methodologies.

The S600 can function as a stand-alone single/multi-stream flow computer, as a combined meter station
and meter stream computer, or as a slave to an external supervisory computer.

The S600 is supplied with the PCSetup program which allows you to configure the flow computer from
a host PC.

The S600 is illustrated below.

FloBoss S600
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FloBoss S600 Flow Computer
The S600 accepts process input signals and provides process output and control signals to instruments
used for fiscal metering, custody transfer, batch loading and meter proving.

The S600 provides the following hardware features:

§ Powerful, industry standard, 32-bit 80486 DX2 CPU running at 50 MHz with
built-in floating point maths co-processor, and supported by six processors on
each I/O board.

§ The CPU has system capacity, database and processing capabilities for up to
ten mixed metering streams. The CPU can communicate with up to seven plug-
in expansion I/O modules. The panel-mounted case has capacity for one CPU
module and up to three I/O modules.

§ Front panel display and keypad provides the local man-machine interface for
system operation and data entry. It comprises of a backlit LCD display, 29-
button keypad and an alarm status LED.

§ Multiple communication interfaces are provided including two RS232 serial

ports for connection to a printer or RTU, and three RS422/RS485 serial ports,
up to 115 kBaud, for connection to a Modbus SCADA data network.

§ Network connectivity through Ethernet 10baseT using FTP and TCP/IP

protocols.

§ Dedicated configuration port for connection to the Config 600 suite of

programs.

§ Functions include stream and station totalisation, batch totalisation and

correction, 3-term PID control, flow balancing, flow scheduling, automatic
prove sequence, K-factor linearisation, valve monitor/control, and sampler
control.

§ Prover operations can be configured as bi-directional.

§ Modular Intelligent Input Output (IIO). The IIO can be configured to match
most system requirements including multiple streams, multiple products and
primary meters.

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The IIO module can be configured for the following measurement, control and logic service functions:
12 Analogue Inputs
4 Analogue Outputs
1 Raw Pulse Output (Proving)
3 4-Wire RTD
16 Digital Inputs
12 Digital Outputs
3 Frequency Inputs
2 Dual Pulse Inputs or 4 Single Pulse Inputs
5 Programmable Pulse Outputs
The S600 incorporates the following software features:

§ Batches can be programmed using a quantity method, and individual batch-

end warning and end-reached alarms can be configured.

§ Flow and volume weighted averages are configurable for all input variables.
These averages can be used to generate correction factors based on daily totals
and running batch totals.

§ Supports up to 16 different alarm groups; typically, the three most commonly

used are Computer, System and Process Groups. The current alarm status is
displayed via a single tri-colour LED on the front panel of the S600. The alarms
in the system can also be viewed and accepted from the front panel.

§ Up to 19 user defined period reports can be configured. Maintenance, batch

and snapshot (that is, current) reports are also available. Separate report
formats are used for gas, liquid and proving.

§ Each user can be allocated a password-enabled security level from a total of 10

security levels.

§ Current limiting is provided on start-up in order to prevent large in-rush

current spikes.

§ The panel case is fabricated from rugged, spot welded zinc coated mild steel
with the power supply backplane mounted inside the case.

§ PID flow control logic which can be configured for each meter run as either
flow or pressure control.

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Config 600

The Config 600 suite of programs can be purchased to enhance the S600 and allows you to configure
and operate the S600 from a portable or desktop PC running Windows 95, 98, 2000, NT or XP.

Config 600 is used to configure a new S600 during the installation stage; the S600 will not operate
until a configuration file has been downloaded from the host PC.

Config 600 allows you to perform the following functions:

§ Create a new application from base templates for a gas orifice, gas turbine, gas
ultrasonic, liquid turbine or bi-directional prover system.

§ Save a customised stream template containing the preferred values.

§ Edit process configuration data including orifice size, analog input scaling,
alarm limits, and keypad values.

§ Upload data including the process configuration data, archived alarm log and
the archived reports.

§ Build and customise Modbus slave maps, Modbus master polling sequences,
front panel displays, and period report formats.

§ Specify the engineering units and totalisation rollover value to be used.

§ Customise the alarm system including alarm groups, suppression, text and
inhibits.

§ Configure system security by setting user names and passwords, and assign
access levels for each data object.

§ Reflash the CPU module firmware with software upgrades.

For more details on using PCSetup, refer to the online help file provided with the program.

Config 600 has differnet levels, please see below for the differnet editions available;
Professional
Config 600

Config 600

Config 600
Extensions
IPL600

Lite

Transfer Program v v v
PCSetup v v
Report Editor v v
Modbus Editor v v
Display Editor v v
Logitest Debugger v
System Editor v
Configuration Generator v
Remote Front Panel Viewer v
Remote Archive Uploader v

FloBoss S600
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 Operation

This section shows how to use the FloBoss S600 including keypad functions, screen displays, system
initialisation, data entry and printing reports. It also shows how to navigate the display matrix.

The operation of the S600 is through an operator interface comprising a LCD display and keypad. The
layout of the S600 is shown below.

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Keypad

The layout of the keypad has been designed to make it easy to use and to reduce the possibility of error.
The keys on the keypad are colour-coded by function, and comprise the following types:

§ Function (yellow)
§ Alarm (dark green)
§ Vector/Menu (dark green)
§ Numeric (light green)
§ Operation (dark green).

F Keys
At the top of the keypad are arranged four Function keys numbered F1 to F4. Each F key can be
programmed as a shortcut to a frequently used or favourite display page. To program an F key, proceed
as follows:
1 Go to the required display page.

2 Press the Decimal Point key.

3 Press the required F key to which the display page is to be assigned.

Once programmed, an F key cannot be unassigned unless the SRAM is cleared. However, you can
reassign an F key to a different display page.

Vector & Menu Keys

The 4-way directional Vector key is located just below the Menu key. It allows you to navigate the
display matrix and select parameters or data items to view or change.

On a data page, use the <left> or <right> keys to view the previous or next display, respectively. The
number of the current display is indicated after the decimal point on the Status/ID line.

When the display moves vertically to view another row, the data item shown is always the first display
cell of that row, that is, the display wraps round from the last data item of the row to the first.

The <left> key is also used as the delete/backspace key when entering or changing data.

Press the Menu key to return up one level of the display hierarchy; on a data page, this key returns you
to the parent menu. By pressing the Menu key followed by the <up> key

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Alarm Light & Keys

Between the F keys and the Vector keys is the Alarm Light and two Alarm keys, namely View and
Accept.

During normal operation with no alarm activated, the Alarm Light is green.

When an alarm is activated, the Alarm Light flashes red until the cause for the alarm has been viewed
and acknowledged using the View and Accept keys, respectively.

Unacknowledged alarms are initially displayed in reverse video. Once acknowledged, the alarms are
displayed in normal video. Multiple alarms are displayed in chronological order.

The Alarm Light shows a solid red until the alarm has been cleared. A yellow Alarm Light indicates
either a fault with the display or keypad, or alternatively, a communications failure between the front
panel and the CPU module.

Numeric Keys
The lower part of the keypad houses the Numeric keys. The Numeric keys offer the full number set (0-
9), decimal point (.) and a minus (-) key.

§ Numeric 0 to 9
Used to enter or change data and to navigate the display matrix.

§ Minus
Used to define the default display on the S600. To define the default display:
4 Go to the required data display page.
5 Press the Minus key.
6 Press the Minus key again to confirm.
You cannot assign a default display for a data entry or menu page.
You can also use the minus key to enter negative quantities.

§ Decimal Point
Used as a decimal point when entering fractional quantities. It is also used to
define shortcuts to access frequently used displays (see F Keys above).

FloBoss S600
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Operation Keys

The Operation keys are used in conjunction with the Numeric keys to perform a variety of tasks,
including:

§ Exponent
The Expt key is used to enter quantities in scientific notation. Where the value
to be entered exceeds the space available on the display (20 characters), it is
necessary to express the data in exponential terms.

§ Clear
The Clear key is used to cancel or exit from the current operation and return to
the previous data display. It is also used to activate the default display.

§ Display
The Disp key is used to enter the path of a required display. The path is shown
on the Status/ID line at the bottom of every page.

§ Print
The Print key is used to display the print menu, where commands can be
requested for various pre-configured reports or logs to a printer or computer
terminal.

§ Change
The Chng key is used to edit a displayed database item. Only items with an
asterisk (*) next to them are changeable. To enter the edit sequence:

1 Press the Chng key. If more than one asterisk is shown on a data page,
reverse video will highlight the first object on the page. Use the <left> and
<right> keys to move the highlight to the required point.

7 Press the Chng key again to change the data values. The system automatically
determines whether your assigned security level allows you to change the
selected data. In order to prevent accidental data re-configuration, certain
essential data entry fields require confirmation that the required action is to be
undertaken.

Whilst in Change mode, the <left> key can be used to delete digits or characters
by backspacing over the displayed data. The Clear key can be pressed at any
time to abort the current operation or task.

§ Enter
Used in combination with the Numeric and Chng keys, the ↵ key is used to
confirm the data has been entered correctly and complete an operational
sequence.

FloBoss S600
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Display

The LCD display offers eight lines of information displayed as alphanumeric characters. An example
of a typical display is shown below.

1. OVOL FR
2. CVOL FR
3. MASS FR
4. ENERGY FR

All eight lines of the display are used to show the available menu options, which are arranged in a
hierarchical parent menu and sub-menu order. Each menu and associated sub-menu is allocated a
number between 1 to 8 and can be selected using either the Numeric or Vector keys.

Menus
Where a menu option has more than eight sub-menus, the eighth option is dedicated to Next, where a
continuation menu is shown. On the continuation page, the first option is dedicated to Previous to
provide a link to the predecessor menu.

The following characters are used after the option number on the menu pages to identify the type of
sub-menu or data page available:

* An asterisk signifies a further menu page is located below this option.

. A decimal point signifies a data page is located below this option.

Data Pages

Generally each data page will display a single data item, along with its associated descriptor text, units
and page description. Prompts and messages also appear on the data page when entering or editing data
items. For example, if you press the Chng key, the display prompts you with either Enter New Value:
or displays the available menu options.

Depending on the base configuration, not all data items can be modified. A changeable data item is
indicated at the end of the display line by an asterisk.

FloBoss S600
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 Status/ID Line

On the bottom line of every data page is the Status/ID line:

P1.1 <of 2> M.

On the left-hand side of the Status/ID line is the page reference number, for example, P12.5 followed
by the number of associated data pages which can be navigated (using the ƒ and „ keys).

In addition, the Status/ID line indicates if the named function is in Prove mode or Maintenance mode
by displaying the characters P or M, respectively, on the right-hand side.

Display Matrix

The S600 software system is organised as a structured database of parameters, such as TOTALS,
OPERATOR, PLANT I/O, SYSTEM SETTINGS etc.

The database groups the parameters logically in a matrix of display cells, for example, most TOTALS
parameters are grouped in the same area of the matrix. Within these groups, related data items are
organised into rows, for example, for PRT INPUTS, the parameters for Measured, Keypad and Alarm
Limits are all kept in one horizontal row.

PRT Input 1 PRT Input 1 PRT Input 1 PRT Channel 1

I/OO1 PRT 01 I/OO1 PRT 01 I/OO1 PRT 01 I/OO1 PRT 01
Limits (HH/H/L/LL):
In Use Value: Keypad Value: 100.000 Deg.C* Resistance:
25.000 Deg.C 25.000 Deg.C* 95.000 Deg.C* 4567.000 ohms
Mode Status: Measured Value: 5.000 Deg.C*
KEYPAD-F * 30.124 Deg.C* 0.000 Deg.C*
P55.1 <of 4> P55.2 <of 4> P55.3 <of 4> P55.4 <of 4>

The PRT Input group is shown in the example above. The first cell in the row (page 1) displays the In
Use Value parameter. You can move one cell to the right, using the <right> key, and the associated
Keypad Value and Measured Value parameters are displayed (page 2). Press the <right> key two
further times and the display changes to the Resistance parameter (page 4).

i You can use the Print key to request a display dump of the whole display matrix.

The content of the display matrix is application -specific. Although details may vary between different
applications, the principle described is the same.

FloBoss S600
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 Using the S600
If you are already familiar with 869 or S500 products, you may find it useful to refer to Quick
Summary of Operations located at the end of this section.

Initialisation

The S600 automatically performs an initialisation sequence, including a self-test routine, during start-
up. The start-up screen is shown below.

STARTUP COMPLETED

S/W Version 0.9.0

View Angle Setting 8

LCD Back Light ON

Alarm OFF

Depending on the setting of the cold start bit-link (LK13) located on the P152 plug-in board and the
contents of the SRAM, the S600 will start-up in one of two modes:

§ Warm Start
If the S600 has been previously configured and the cold start bit-link is not
fitted, it will re-start where it left off prior to being powered down. The Main
menu will be displayed following a successful startup.

§ Cold Start
If the S600 is unconfigured, has the cold start bit-link fitted or a Clear SRAM
command has been previously issued, it will be unable to warm start. The Cold
Start menu will be displayed.

When the S600 is restarted in warm- or cold-start mode, the firmware is always copied from FLASH to
RAM and subsequent operation uses RAM.

! The default setting of the cold start bit-link is ‘open’ which results in
a warm start.

FloBoss S600
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 During a warm start, the configuration memory (SRAM) is not affected. The S600 will continue
operation using the data stored in the configuration memory just before the restart occurred. Any
current accumulated values and online changes that have not been saved will be preserved. This is the
normal method for seamlessly resuming operation.

A warm start is also required when certain online data is changed, such as a change in the network
settings which affects an operational parameter; a warm start must be performed in order for that
change to take effect.

During a cold start, the configuration files are copied from FLASH and replace any currently
accumulated totals as well as any online changes made to the configuration files since the last
download from the Transfer program or it was last backed up. Therefore, a cold start is used when a
new configuration has been reflashed or to recover from extreme situations such as a corrupted
database.

!
When setting the cold start bit-link, keep in mind this setting will also
be used when the S600 self-starts for any reason such as a low-
battery shutdown or recovery from a malfunction. Ensure the cold
start bit-link setting is removed when not required, otherwise an
unplanned restart could result in lost data.

The description of the operation of the S600 in warm start mode is assumed for this section. For further
details on the cold start mode of operation, refer to Section 5, Maintenance.

Following a successful warm start, the Main menu is displayed.

1* FLOW RATES
2* TOTALS
3* OPERATOR
4* PLANT I/O
5* SYSTEM SETTINGS
6* TECH/ENGINEER

8* CALCULATIONS

The Main menu is the starting point or root of the display matrix. From the Main menu, you can
navigate the sub-menus to access the required data pages.

FloBoss S600
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Navigating the Display
From the Main menu, select the option you require with the appropriate numerical key.

An asterisk before a menu option indicates that further sub-menus are available. A decimal point
(period) before the menu option shows there is no further sub-menu; selecting this option type will take
you to the first cell in a row of related parameters within the display matrix.

To navigate the PLANT I/O option, for example, proceed as follows:

8 Select the *PLANT I/O option from the Main menu and the available sub-menus
are displayed.

1* ANALOG INPUTS
2* PRT/RTD INPUTS
3* FREQUENCY INPUTS
4* PULSE INPUTS
5* DIGITAL I/OS
6* ANALOG OUTPUTS
7* PULSE OUTPUTS

9 Select the ANALOG INPUTS option by pressing 1, and then select ADC - 03 by
pressing 3.

1. ADC 01 – ADC01
2. ADC 02 – ADC02
3. ADC 03 – ADC03

The data item In Use Value for I/O01 ADC 03 is displayed, which is the first cell in the row of
related analogue input parameters.

FloBoss S600
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As the configuration of your S600 may differ from this example, try selecting options from the menus
offered in order to reach the parameter that your require.

The Status/ID line on the bottom of the display changes as you move left or right across the row of
related display pages.

An alternative method of selecting the required data page is to enter the unique page address using the
Disp key. If you know the location number of the parameter you wish to view, proceed as follows:
10 Press Disp followed by the location number in the format column.row, eg. 1.3

11 Press Enter.
If you only enter a single number, that is the column value, the first cell of the row is displayed.

To return to the parent menu, press the Menu key located above the Vector key; repeated pressing of
this key will move you up the display matrix to the Main menu.

If you are on a menu or data page, you can return directly to the Main menu at
i any time (except during a change sequence) by pressing the Menu key followed
by the <up> key.

If you have pressed the Chng key, the Menu key will not respond until either Clear (to abort the
change) or Enter (to complete the change) has been pressed.

FloBoss S600
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Entering Data
Changing the value or mode of any displayed parameter is straightforward with the S600. You can
modify both numeric values and calculation modes using the Chng key.

Locate the parameter to be changed using one of the methods described under Navigating the Display.

If the value is changeable, an asterisk is shown on the right- hand side of the same line as the value on
the display; if there is no asterisk, the data cannot be modified.

Changing a Value
To change the value of a parameter, proceed as follows:
1 Select the required parameter using the <left> or <right> keys.

2 Press Chng and the prompt ENTER CODE: is displayed.

3 Key in your Security Code and press Enter (the security code number is not
displayed, but each digit is indicated by a dot as you key it in).

4 At the prompt ENTER NEW VALUE: key in the new value in integer, numeric or
scientific notation as appropriate (the current value and any entry limits
associated with this parameter are also shown).

5 Press Enter to confirm.

If necessary, you can edit the new data as you key it in. Enter Change mode and use the ƒ key to delete
single figures or characters. If you wish to abort the change, press Clear.

Deleting or cancelling the change to the parameter should be done before pressing Enter. The Enter
command confirms that you wish the revision to proceed.

Example
The following example shows how to change the alarm limits for the ADC analog input.

§ Locate the page displaying the alarm limits (HH/H/L/LL) for the ADC
Channel 1 I/O01 parameter. The display shows the location number and the
asterisk indicates that the values are changeable.

ADC Channel 1
I/O01 ADC 01
Limits (HH/H/L/LL)
100.000 barg*
95.000 barg*
5.000 barg*
0.000 barg*

P52.3 <of 5>

§ Press Chng and highlight the HH value. Press Chng again and the display
responds with the prompt ENTER CODE:. Key in your Security Code and press

FloBoss S600
Training Notes
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 Enter. At the prompt ENTER NEW VALUE: key in the new value 90 and verify this
on the display.

CURRENT VALUE:
100.000 barg
NO ENTRY LIMITS:

ENTER NEW VALUE: 90

§ Once you have verified the data, press Enter to confirm. The value in the
display changes to the new data and recalculates any linked parameters.

§ Repeat the above process for the H, L and LL limits.

FloBoss S600
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Changing Mode
To select a new calculation mode, the key sequence is similar to changing a value.

Locate the parameter to be changed using one of the methods described under Navigating the Display.

If the mode is changeable, an asterisk is shown on the right- hand side of the same line as the mode
status on the display; if there is no asterisk, the data cannot be modified.
1 Select the required parameter using the • or ‚ keys.

2 Press Chng and the prompt ENTER CODE: is displayed.

3 Key in your Security Code and press Enter (the security code number is not
displayed but each digit is indicated by a dot as you key it in).

4 At the prompt, select the required mode by using the appropriate numerical
key (1 to 8).

5 A second mode change window is displayed asking for confirmation. Press 1 to

accept or 2 to reject the mode change.
The Clear key enables you to cancel the mode change to the parameter, if necessary.

Example
The following example shows how to change the standard density parameter to a calculated value from
a keypad-entered value.

§ Locate the page displaying the STR01 STANDARD DENSITY mode status.

STR01 STANDARD DENS

In Use Value:
10.000000 kg/m3

Mode Status:
KEYPAD
P32.10 <of 21>

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§ Press Chng, key in your Security Code and press Enter.

1. CALCULATED
2. KEYPAD

§ Press 1 to select CALCULATED and then press Enter.

CONFIRM

SET TO:
CALCULATED

1. YES
2. NO

§ Press 1 to confirm. The display indicates the revised operational mode.

Exponential Format

The Expt key allows you to enter parameters in scientific notation. Where a value is smaller than
0.00000001 or greater than 10000000 (that is 8 significant figures), you must use the Expt key to
express the value in exponential terms.

You can also use the exponential notation for smaller number entry, but the displayed value will be
shown as a normal number.

To enter an exponential value:

1 Key in the value.

2 Press the Expt key (an E will appear on the display) and then enter the required
power.

3 Press the Enter key.

For example, to enter the figure -0.00000009 as an exponential value, first key in the figure -9.0, press
Expt, enter –9 to represent the power and press Enter to confirm.

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Security Code
The security system allows up to 50 unique users. Each user is allocated two individual passwords; one
is numeric for access to the S600 and the other is alphanumeric for access to the Config 600 suite of
programs or the Web Server. In addition, each user is allocated a security level between 0 (highest) and
9 (lowest).

The configuration parameters are assigned in predefined groups with an associated common minimum-
security level; the security level can be modified on for each user application from within the PCSetup
Editor.

Please refer to your System Administrator for further information on your password settings and
security levels.

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Alarms
The default alarm system installed in the S600 is a latching, manual, common-accept system.

Alarms are triggered when measurements exceed the pre-set limits for a parameter or if there is a
malfunction. The alarm may be relayed to a terminal or klaxon in the Control Room. On the panel of
the S600, a light indicates an alarm and the source of the alarm is shown on the display.

Alarm Light
During normal operation, with no alarms present, the Alarm light is a constant green. When an alarm is
activated, the light flashes red until the cause for the alarm has been viewed and the Accept key has
been pressed (see below).

Once acknowledged, the light shows a constant red until the alarm condition has been cleared.

View Alarm

Press the View key to display the parameters that have triggered the alarm.

The first line of the alarm display indicates the date and time of the alarm. While the alarm remains
unaccepted, the date is shown in inverse video. The second and third lines are used to describe where
the alarm has been activated and its nature. The total number of alarms, accepted and unaccepted, is
shown on the bottom line.

09/11/1999 13:05:00
STR01 CHROM MODE
TELEM

Alarm 1 of 9

When there is more than one alarm to be viewed, the display can be cycled around all the alarms using
the <up> or <down> keys.

Alarm Accept

Press the Accept key to notify the S600 that you have viewed all the alarms and are prepared to
acknowledge them all together. The inverse date on all the alarms then returns to normal video.

Once an alarm condition is cleared, its alarm prompt is automatically cleared from the display. When
all the alarms in the system have cleared, the Alarm light resets to a constant green.

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Printing
The S600 is configured on installation to output reports to a serial printer or terminal. The Print key is
used to generate either a constants’ log or pre-configured reports.

The Print menu is shown below.

PRINT OPTIONS
1. HELP
2* CONFIGURATION
3* REPORTS
4* COMMUNICATIONS
5. CURRENT ALARMS
6. EVENT LOG
7. ABORT PRINTING

The following reports can be requested:

§ Help
Prints a reference list of how to navigate the displays and change values and
modes.

§ Constant Log
Lists all the constants’ parameters and the in-use values that are available for
change from the display. An option is provided for this to be in either ‘text’ or
‘csv’ formats.

§ Display Dump
Lists the whole display matrix.

§ Security Dump
Lists the whole display matrix with the current security levels assigned to each
line.

§ All Alarms
Lists all possible alarms that can be generated by the alarm system.

§ Current Report
Prints a report showing the current totals and flowrates for the streams and
stations installed in the S600.

§ Config Report
Lists a custom report with the configuration constants on it.

§ Archived Reports
Allows you to reprint any report held in the local archive on the S600.

§ Modbus Maps
Lists all modbus maps configured in this current S600 configuration along with
port and data settings.

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§ Current Alarms
Lists all the acknowledged and un-acknowledged alarms currently set in the
flow computer in separate chronological lists.

FloBoss S600
Training Notes
Page 26
Special Pages

The S600 includes display pages to perform specific functions, which are located under the TECH-
ENGINEER/DISPLAY SETUP menu.

1. DISPLAY SETUP
2. CONTRAST
3. DATE & TIME
4. DISPLAY TEST
5. SECURITY
6. COMMUNICATIONS

§ Display Setup
Includes the parameters associated with the display setup.
1. Display T/O
The display timeout is the period of non-use before the default display is
displayed (default 300s).
2. Logout T/O
The logout timeout is the period of non-use in change mode before the current
user is automatically logged out (default 20s).
3. Ident T/O
This is the timeout period of non-use in change mode before display mode is
activated (default 120s).

§ Contrast
Used to set the LCD viewing angle.
Note: Some models have automatic temperature correction of viewing angle
with no manual adjustment provided.

§ Date & Time

Used to set the current date and time.

§ Display Test
Used to turn all the pixels on and off.

§ Security
Used to enable/disable keypad access and file transfer between the S600 and
host PC.

§ Communications
Used to display the available COM ports and link status, and define the serial
port settings.

FloBoss S600
Training Notes
Page 27
Quick Summary of Operation
The following is a summary of the operational features available on the S600.

Display Matrix
Data items are arranged logically in groups and are placed in cells and rows within a display matrix.
See your Application Manual for details of parameters installed on your S600.

View Parameter
First, select the relevant menu and sub-menu option using the numerical keys, and then use the ƒ and
„ keys to display the required parameter in the matrix row. Alternatively, press the Disp, key in the
location number (row.column), and press Enter.

Return to Main
Menu
Press the Menu key to view the parent menu; repeated pressing of this key will move you to the Main
menu. Alternatively, press the Menu key followed by the <up> key on a menu or data page (but not
during a change sequence) to return directly to the Main menu.

Change Value
Select display cell of parameter to be changed; an asterisk indicates that the value is changeable. Press
Chng, enter Security Code, press Enter, enter new value and press Enter to confirm.

Change Mode
Select display cell of parameter to be changed; an asterisk indicates that the value is changeable. Press
Chng, enter Security Code, press Enter, select required mode from option list, press 1 to confirm.

Clear
Press Clear to abort the change sequence.

Scientific Notation

Use the Exponent key when a value exceeds 8 significant figures. Key in new value, press Expt, enter
required power and then press Enter to convert value to exponential format.

Alarm
Alarms are indicated by a flashing red light. Display alarm details by pressing the View key. Accept
each alarm as it is displayed by pressing the Accept key. Once the fault conditions are removed, the
Alarm Light shows a constant green.

FloBoss S600
Training Notes
Page 28
Print
Press the Print key to output a constants’ log or generate a report.

Default Display
Select data display page to be used as default, press the Minus key, and press the Minus key again to
confirm. Note you cannot assign a default display for a data entry or menu page.

To unassign the default page repeat the process above on a menu page, this changes the default page
back to ‘None’.

Program Function Keys

Go to the required display page, press the Decimal Point key, and press the required F key to which
the display page is to be assigned.

Note once these are assigned they can not be unassigned but can be over-written.

FloBoss S600
Training Notes
Page 29
 Config 600

Introduction to Config 600

This section introduces the Config 600 user interface, and lists the system requirements, software
installation instructions and file locations on the host PC.

Information on using the PCSetup program is only provided in the form of online help files.

The Config 600 suite of programs is used to configure the FloBoss S600 Flow Computer and is
supplied on CD-ROM. It is a Windows-based program, which enables you to configure, control and
interact with the S600.

Various parts of Config 600 are used to create and then compile the configuration files, which can be
understood by the firmware installed on the S600. These files are downloaded to the S600 through a
communications port and saved into the Flash memory on the CPU module.

Once the S600 has been programmed with the configuration data, PCSetup can be used to modify the
current configuration settings used by the S600.

The Config 600 suite of programs also allows you to generate reports containing alarm and event
details.

System Requirements
To install and operate PCSetup, you will need either a portable or desktop PC that meets the following
minimum requirements:

Component Required Minimum Suggested

CPU Pentium 133 MHz Pentium 233 MHz
Memory Windows 95: 16MB
32 MB of RAM
Windows NT: 32 MB
Free Disk Space 50MB 100MB
Operating System Windows 95 Windows 95 with
Internet Explorer 4
CD-ROM 2x speed 16x speed
Serial Port 1 No. (38400 Baud) 1 No. (38400 Baud)
Display & Super VGA: Super VGA:
Resolution 800x600 with 256 1024 x 968 with 256
colours colours or greater
Selection Device Pointing device Mouse recommended
compatible with
Windows operating
systems

FloBoss S600
Training Notes
Page 30
Software Installation Procedure

If you are installing the software from a remote CD-ROM drive, ensure you map a network drive letter
to the path of the CD-ROM drive before you begin installation.

To install on a Windows 95/98 or NT 4.0 operating system:

1 Insert the Config 600 compact disc into your CD-ROM drive.

2 Click the Start button on the Taskbar.

3 Click the Run button and the Run Window is displayed.

4 Type x:\setup (where x is your designated CD-ROM drive) in the Open data
box and then click OK.

5 Windows opens the setup file and the Installation Wizard begins. Follow the
instructions provided on each screen.

FloBoss S600
Training Notes
Page 31
 Connecting to the S600

A standard serial cable is required to connect the host PC to the S600 unit. A ready-made link cable is
available from Daniel for use with a PC having a 9-pin serial port.

Alternatively, you may fabricate your own link cable using the wiring details below.

Host PC S600
9w D-Type (F) 15w D-Type (M)

Rx 2 14 Rx

Tx 3 6 Tx

Gnd 5 8 Gnd

CTS 7 15 CTS

RTS 8 7 RTS

Due to the high baud rate used for the communications between the
! host PC and the S600, it is recommended that the maximum cable
length be restricted to 5 meters (15 feet).

File Locations

All files associated with the Config 600 software are located in the directory path Program
Files\Emerson Process Management\Config600

The configuration files containing the settings that appear in the database manager window are located
in the Configs directory. A separate sub-directory is then used for each configuration.

The files which define the report format are located in the Reports directory, and the files specifying
the Modbus settings are located in the Modbus directory.

The following files are downloaded to the S600 during the configuration process:

§ vxworks.bin.xx.yyz
The operating system and task firmware binary file (where xx is the main
release number of the VxWorks file, yy is the sub release and z is the patch
revision).

§ s600conf.cfg
The main configuration file for the metering database and all the initialisation
values.

FloBoss S600
Training Notes
Page 32
 § display.txt
The configuration file for the display menus and data pages.

§ mbxxxxxxxx.txt
The Modbus configuration files including Slave register maps and Master
polling sequences (where xxxxxx indicates the file name is application-specific).

§ Mbpseq.txt
The prover sequence configuration file.

§ Repxx.txt
The report format configuration files (where xx indicates the file name is
application-specific).

Start Up

After PCSetup has been successfully installed, use the Start menu (Start/Programs/menu path) to start
the program.

To start PCSetup directly from the executable file, use the directory path you specified when installing
PCSetup; the default setting is c:\Program Files\Emerson Process Mamangement\Config 600\.

i Refer to the online help for detailed instructions on using PCSetup.

FloBoss S600
Training Notes
Page 33
 Maintenance

Cold Start Procedure

This section describes the procedure for initiating a Cold Start on the FloBoss S600. It also provides
instructions for maintaining and troubleshooting the S600 and includes a spare parts list.

Normally the S600 would be requested to Warm Start. If, however, the S600 has not been previously
configured, has the Cold Start bit-link (LK13) fitted or a Clear SRAM command has been issued, the
S600 will be unable to Warm Start.

!
Only a suitably qualified person should perform reprogramming of
the S600.

The procedure for initiating a Cold Start in a new and unconfigured S600 includes the following steps:

§ Ensure LK13 is fitted.

§ Power up the unit.

FloBoss S600
Training Notes
Page 34
Reflash Frmware
Prior to programming the Flash memory with the S600 operating system firmware, you must set the
run mode to Cold Start, as follows:

1 Go to the SYSTEM SETTINGS menu.

2 Select the SYSTEM STATUS sub-menu.

3 Press Chng and the prompt Enter Code: is displayed.

4 Key in your Security Code.

5 Press 1 to select Cold Start, and press 1 again to confirm.

6 The S600 should automatically reboot however if it doesn’t, power down, wait
a minimum of 5 seconds, and then re-power.

Once the S600 has completed its start-up initialisation sequence, the Cold Start menu is
displayed.

1. WARM START
2. COLD START
3. NETWORK SETUP
4. REFLASH FIRMWARE
5
6.
7.
8. FACTORY SETUP

The Cold Start options include:

§ Warm Start
This is used to restart the metering database on the S600 using the
configuration files stored in SRAM memory. This retains any settings you have
changed and also the current totals (this is the same as power cycling the S600
when LK13 is removed).

§ Cold Start
This is used to build a new metering database on the S600 using the
configuration files stored in Flash memory.

§ Network Setup
This is used to configure the TCP/IP, Gateway and Modbus addresses.

§ Reflash Firmware
This is used to reprogram the S600’s operating system firmware stored in Flash
memory.

§ Factory Setup

FloBoss S600
Training Notes
Page 35
 This should only be used upon instruction from Emerson Process Management
and is used to perform commands such as Clear SRAM and Format Flash.

The Reflash Firmware option allows you to reprogram the Flash memory with new values for the
operating system components and the application firmware. This option requires you to download a
binary file from Config 600 into the volatile RAM disk on the S600 prior to erasing and
reprogramming the Flash memory.

Under no circumstances should you allow the S600 to be de-

! powered whilst it is erasing or reprogramming the Flash memory,
otherwise the S600 will be rendered unusable. In the event of this
occurring, the S600 must be returned to Emerson – Flow Computer
Division for system reprogramming.

Download & Reflashing a New Binary File

To reprogram the Flash memory:

7 Select the REFLASH FIRMWARE command from the Cold Start menu.

8 Press 1 to confirm and the following message is displayed:

PERFORM PCSETUP FLASH COMMAND NOW

9 From PCSetup, enter the Transfer program, select the required vxworks.bin
file and click on Send Now to download it to the S600.

10 The following message is displayed on the S600:

RECEIVING BINARY FILE
Once the file has been successfully downloaded, the S600 displays the message:
RECEIVED OK

! Do not proceed if the message FLASH FAILED is displayed. Remove

the power connector for 5 seconds and the S600 will Cold Start.

The S600 proceeds to erase and reprogram the Flash memory, and displays the
following messages:
ERASING FLASH – PLEASE WAIT
Followed by
REPROGRAMMING FLASH – PLEASE WAIT
And then
RESETTING – PLEASE WAIT
The S600 then restarts; if the S600 is displaying the final message (RESETTING)
and has not restarted after 60 seconds, remove the power connector for 5
seconds and repower to initiate a Cold Start.

FloBoss S600
Training Notes
Page 36
Download & Reflashing a Configuration File
To reprogram a configuration:

1 Ensure the PCSetup Link is enabled in the S600, this is located under
TECH/ENGINEER, SECURITY or put the S600 to the Cold Start Menu

2 From PCSetup, enter the Transfer program, select the required configuration
and click on Send Now to download it to the S600.

3 The following message is displayed on the S600:

SYSTEM IS BEING CONFIGURED EXTERNALLY – PLEASE WAIT
Once the file has been successfully downloaded, the S600 displays the message:
SYSTEM RESTARTING – PLEASE WAIT
The S600 will then restart and return to the Cold Start Menu. (While restarting
the S600 will display COMMUNICATIONS LINK FAILURE, this is normal and
you should not be concerned regarding this).

FloBoss S600
Training Notes
Page 37
Cold Start

Once the configuration file has been downloaded from the host PC, you can select the Cold Start
option to build a new metering database using the configuration data stored in the Flash memory of the
S600.

Prior to any network communications, the necessary network settings should also be set at this stage, as
it is not possible to change them without performing another Cold Start (refer to Network Setup
below).

To initiate a Cold Start of the S600:

Select the COLD START command from the Cold Start menu.

Press 1 to confirm and retain the totals (where possible) or 2 to confirm and zero the
totals, the following message is displayed:

CONFIGURING - PLEASE WAIT

Once completed, the S600 main menu is displayed.

1* FLOW RATES
2* TOTALS
3* OPERATOR
4* PLANT I/O
5* SYSTEM SETTINGS
6* TECH/ENGINEER

8* CALCULATIONS

If the totals can not be retained the following message will be displayed and the S600 will return to the
Cold Start Menu:
TOTALS DO NOT MATCH

FloBoss S600
Training Notes
Page 38
Network Setup
The Network Setup option allows you to define the TCP/IP Ethernet, Gateway and Modbus network
addresses.

When any Modbus slave configuration builder has an address of zero specified, the Modbus port will
be configured with the address entered here. This is typically used when the same configuration file is
loaded into multiple S600 flow computers on the same Modbus network, thus giving each S600 a
unique node address.

These settings are kept in a separate area of the SRAM database and will be retained following a
configuration download.

These parameters can only be viewed or changed on a cold start.

To define the network addresses:

1 Select NETWORK SETUP from the Cold Start menu.

1* NETWORK I/F 1
2* NETWORK I/F 2

4. MODBUS ADDRESS
5. PC SETUP COMMS
6. GO BACK

2 Choosing 1 or 2, allows you to set the TCP/IP ADDRESS, SUBNET MASK and
GATEWAY ADDRESS for either the Master or Secondary Ethernet Port.

3 Enter a valid MODBUS ADDRESS, the valid values for the modbus address is
between 1 and 247.

4 PC SETUP COMMS allows you to set the Modbus protocol from either 8-bit or
16-bit and the serial port settings for the PC SETUP PORT.

5 To invoke these settings reboot the S600 (that is, power down, wait a minimum
of 5 seconds, and then repower).

FloBoss S600
Training Notes
Page 39
Factory Setup
The Factory Setup options include Clear SRAM, Firmware Lock and Format Flash. These options,
with the exception of Clear SRAM, should only be used by Daniel personnel in the event of a problem.

Clear SRAM
The Clear SRAM option is used to clear down the S600 by overwriting the SRAM area. All battery-
backed configuration data will be lost, including system configuration data, process configuration data,
metering totalisers, and network settings.

Following a Clear SRAM command, the S600 will restart to the Cold Start Menu and will not be able
to Warm Start again until it has been Cold Started.

To initiate a clear down of the SRAM:

1 Select FACTORY SETUP from the Cold Start menu.

1. CLEAR SRAM
2. FORMAT FLASH
3* SERIAL PORTS
4* DISPLAY
5. FIRMWARE LOCK
6. GO BACK

2 Select the CLEAR SRAM command.

3 Press 1 to confirm, the S600 will appear to ‘Lock Up’ and the following message
is displayed after approximately 10 seconds:

COMMUNICATIONS LINK FAILURE

4 Reboot the S600 (that is, power down, wait a minimum of 5 seconds, and then
repower). .
Once completed, the Cold Start menu is displayed.

FloBoss S600
Training Notes
Page 40
Format Flash
The Format Flash option is used to reformat the Flash memory; any data stored in Flash will be lost
including the configuration data, report formats, display setting and Modbus Maps. This option is now
automatically performed by the S600 when a new configuration is sent to it from the Transfer program.

To initiate a reformat of the Flash memory:

1 Select FACTORY SETUP from the Cold Start menu.

2 Select the FORMAT FLASH command.

3 Press 1 to confirm.

Once completed, the Cold Start menu is displayed.

FloBoss S600
Training Notes
Page 41
 Setup & Wiring

RS232 Modem Port

Two RS232D communications ports are provided on the S600 and are located on the on the backplate
of the CPU board. The ports use FCC-68 RJ45 connectors and are labelled COM3 and COM4.
Converters are commercially available to either 9-way D type or 25-way D type.

The COM3 and COM4 pin connection schedule is shown below.

Pin Function
1 GND
2 DTR
3 RTS
4 TX
5 RX
6 CTS
7 DSR
8 DCD

Maximum cable length is a function of the baud rate and quality of cable used. For example, a
maximum length of 15m (50 feet) should be used at 19.2 kBaud using unscreened cable.

The ports should be connected to the peripheral devices using multi-core screen cable. It is
recommended that the cable screen is connected to protective earth, keeping signal ground separate,
particularly in noisy environments.

FloBoss S600
Training Notes
Page 42
RS-422/485 Multidrop Port
Three RS422/RS485 ports are located on the backplate of the CPU board and provide high speed/long
distance links of up to 57.6 kBaud and 1200 meters (4000 feet). The ports use the connector labelled
TB-2.

The TB-2 pin connection schedule is shown below.

Pin Port Function

1 COM5 RX-
2 COM5 RX+
3 COM5 TX-
4 COM5 TX+

5 COM6 RX-
6 COM6 RX+
7 COM6 TX-
8 COM6 TX+

9 COM7 RX-
10 COM7 RX+
11 COM7 TX-
12 COM7 TX+

13 COM7 GND

Ethernet LAN
This port is for high-speed communications using Ethernet local area network architectures. The speed
of data transfer is 10Mbits/sec using a 10 baseT, twisted pair.

The port uses a FCC-68 RJ45 connector labelled Network on the backplate of the CPU.

On-board Battery Backup

Two battery options are available as deliverable options. A simple check should be made to ensure
which type has been supplied from the following:

§ Rechargeable, board mounted, nickel metal hydride cell.

§ Non-rechargeable, intrinsically safe cell.

The status of either type of battery is monitored by a voltage sensing circuit. An
alarm is raised if the battery voltage drops below the predefined limit.
These are factory fitted options. Only one of the above can be in-use at any one time. Once the IS or
the 1/2AA cell is installed, without line power to the S600 unit, the battery life will become exhausted.

FloBoss S600
Training Notes
Page 43
P152 CPU On-board Connectors
The miscellaneous device connectors provided on the P152 CPU module are shown below. This
information is for identification purposes only.

Socket Description
J2 CPU cooling fan molex (12 VDC)
J3 PC/104 expansion bus (16-bit)
J4 Additional plug-in battery molex 3.6 VDC
J5 IDE Hard disk pin header
J6 Altera serial programming pin header (factory
use only)
J7 Keyboard and mouse pin header
J8 Security bit link
J9 Optional communications LED backplate
pin header

FloBoss S600
Training Notes
Page 44
P152 CPU Berg Links
The entries shown in boldface are the default configuration settings; however, these may not apply to
your specific configuration.

Link Position Description

SRAM Chipset
LK1 ON 628512 = 1.25MByte
OFF 628128 = 512KByte
LK2 1-2 628512
2-3 628128
CPU & RADISYS
LK3 ON 3 volt operation
OFF
LK4 ON Internal RTC enabled
OFF
LK5 ON Internal keyboard & mouse enabled
OFF Enabled
LK6 ON 8 bit BIOS
OFF
LK7 ON 7 DMA channel operation
OFF
LK8 ON All interrupts available via MUX
OFF
LK9 ON EIDE supported
OFF
LK10 ON* CS_USR1# supported
OFF
LK11 ON COM1, COM2 supported: data & RTS/CTS
only
OFF
LK12 ON COMCLK enabled
OFF
LK13 ON Cold Start forced on power-up
OFF
LK14 ON BIOS monitor start enabled
OFF
Flash
LK15 1-2 Write Prohibited – Block 0 – 1M
2-3 Write Enabled
LK16 1-2 Write Prohibited – Block 1 – 2M
2-3 Write Enabled
LK17 1-2 Write Prohibited – Block 2 – 3M
2-3 Write Enabled
LK18 1-2 Write Prohibited – Block 3 – 4M
2-3 Write Enabled
Clock Multiply
LK19 ON DX2: Off
OFF DX4: On = Clk x3, Off = Clk x2
586: On = Clk x4, Off = Clk x3

FloBoss S600
Training Notes
Page 45
P152 CPU Berg Links, continued

Link Position Description

BIOS ROM Size

LK20 1-2 1M EPROM
2-3 4M EPROM
SQFP 486 CPU
LK21 ON Link to upgrade SQFP 486 CPU
OFF
Clock Speed (see table below)
LK22 ON 50MHz
OFF
LK23 ON 50MHz
OFF
Ethernet
LK24 ON ENEEP
OFF
LK25 ON IOS 2
OFF
LK26 ON IOS 1
OFF
LK27 ON IOS 0
OFF
Cache Select
LK28 ON Non-Enhanced = Off
OFF Enhanced:
On = Writethrough
Off = Writeback
LK29 ON Link when write-back processor fitted
OFF

Clock Speed Selection

Clock Speed Link 22 Link 23
33 MHz OFF OFF
40 MHz ON OFF
50 MHz ON ON
66 MHz OFF ON

FloBoss S600
Training Notes
Page 46
P144 IIO Berg Links

The entries shown in boldface are the default configuration settings; these may not apply to your
specific configuration.

Link Position Description

Flash
LK1 ON Write Enable
OFF Write Protected
Node Addressing (see table below)
LK2 ON
OFF Multiplexed mode (MUX)
LK11 ON
OFF Multiplexed mode (MUX)
MUX Address: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LK3 l l
LK4 l l
LK5 l l
LK6 l l
LK7 l l
LK8 l l
LK9 l l
LK10 1-2 l l l l l l l
2-3 l l l l l l l
LK12 Earth point
LK13-15 Not used
ADC Shunts
LK16 ON Current Mode ADC-CH1
OFF Voltage Mode
LK17 ON Current Mode ADC-CH2
OFF Voltage Mode
LK18 ON Current Mode ADC-CH3
OFF Voltage Mode
LK19 ON Current Mode ADC-CH4
OFF Voltage Mode
LK20 ON Current Mode ADC-CH5
OFF Voltage Mode
LK16-20 should be fitted as a set
LK21 ON Current Mode ADC-CH6
OFF Voltage Mode
LK22 ON Current Mode ADC-CH7
OFF Voltage Mode
LK23 ON Current Mode ADC-CH8
OFF Voltage Mode
LK24 ON Current Mode ADC-CH9
OFF Voltage Mode
LK25 ON Current Mode ADC-CH10
OFF Voltage Mode
LK21-25 should be fitted as a set

Node Addressing: Communications Mode Selection

Mode Link 2 Link 11 Link 3-10
Point-to-point ON OFF IGNORED
Multi-dropped ON ON IGNORED
Multiplexed (MUX) OFF OFF ADDRESS

FloBoss S600
Training Notes
Page 47
P154 Prover Berg Links
The entries shown in boldface are the default configuration settings; these may not apply to your
specific configuration.

Link Position Description

Flash
LK1 ON Write Enable
OFF Write Protected
Node Addressing (see table below)
LK2 ON
OFF Multiplexed mode (MUX)
LK11 ON
OFF Multiplexed mode (MUX)
MUX Address: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LK3 l l
LK4 l l
LK5 l l
LK6 l l
LK7 l l
LK8 l l
LK9 l l
LK10 1-2 l l l l l l l
2-3 l l l l l l l
Altera Voltage
LK12 1-2 3.465V
2-3 5V – Vcc
Raw Pulse Output Mode
LK13/14 1-2 RS422 differential driver
2-3 Open collector
Raw Pulse Input #3 – Line Determination
LK15/16 ON Line determination resistors connected: +ve pulled up to
Vcc and -ve down to 0 V
OFF Lines undetermined

Node Addressing: Communications Mode Selection

Mode Link 2 Link 11 Link 3-10
Point-to-point ON OFF IGNORED
Multi-dropped ON ON IGNORED
Multiplexed (MUX) OFF OFF ADDRESS

FloBoss S600
Training Notes
Page 48