ABB XSeriesG4 User Manual
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ABB XSeriesG4 User Manual

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User's manual 2103334MNAB
XSeriesG4
Remote Controller
An engineering milestone in
the development of remote,
low power, powerful control
and measurement devices
G4
XRC

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Summary of Contents for ABB XSeriesG4

  • Page 1 User's manual 2103334MNAB XSeriesG4 Remote Controller An engineering milestone in the development of remote, low power, powerful control and measurement devices...

  • Page 2: Table Of Contents

    Contents Contents ..................................i List of figures ................................v List of tables ................................vii Health and safety ..............................viii General information and notes ............................. viii Safety, warning, and note symbols ............................viii Storage ....................................ix Compliance ....................................ix Additional publications .............................. x Typographical conventions ............................
  • Page 3 Pipe saddle mount installation ............................26 Wall mount installation ..............................29 Battery pack installation ............................... 31 Solar panel installation ..............................32 AC charging unit installation ............................34 6990 rack mount installation ..........................36 communication field-wiring ..........................38 startup ..............................44 Overview ..................................
  • Page 4 On-board I/O calibration ............................... 65 Keypad ..................................67 Maintenance ..............................69 Overview ..................................69 Backing up configuration files ............................69 Changing the XRC clock ............................70 Components and spare parts ............................71 Replacing the lithium battery ............................74 Replacing the XRC battery pack ..........................
  • Page 5 Troubleshooting communications ..........................94 Getting technical support help ............................99 Returning devices............................... 100...

  • Page 6: List Of Figures

    List of figures Figure 1: XRC 6490 ..............................4 Figure 2: XRC 6790 ..............................4 Figure 3: XRC 6890 ..............................5 Figure 4: XRC 6990 rack mount ..........................6 Figure 5: XRC board ..............................8 Figure 6: Typical DI point schematic .......................... 10 Figure 7: DI connection examples ..........................
  • Page 7 Figure 47: Communication setup for Totalflow /TCP protocol (default TCP port) ............48 Figure 48: Set up TP/IP communication over Ethernet ....................49 Figure 50: Network tab: Configure static IP addresses ....................51 Figure 53: Meter setup and security screen ........................ 57 Figure 54: PCCU32 Security Code setup ........................
  • Page 8 List of tables Table-1: Typographical conventions ..........................xi Table 2: General specifications ............................ 1 Table 5: 2103329-xxx board specifications ........................6 Table 6:XRC board identification ..........................9 Table 7: Typical XRC display options ........................13 Table 8: Status and alarm description ........................17 Table 9: TFIO module loading ............................

  • Page 9: Health And Safety

    The content of these instructions is neither part of nor provided for changing a previous or existing agreement, promise, or legal relationship. All obligations to ABB result from the respective sales contract, which also contains the full and solely valid warranty clauses. These are neither limited to, nor extended by, the content of these instructions.

  • Page 10: Storage

    EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE) ABB Industrial Automation, Measurement and Analytics, is committed to actively protecting the environment. Do not dispose of WEEE as unsorted municipal waste. Collect WEEE separately. Participation in the management of WEEE is critical to the success of WEEE collection.

  • Page 11: Additional Publications

    XRCG4 (2103329 BD) AI to ABB 266 Pressure Transmitter 2104925 XRCG4 (2103329 BD) to ABB Vortex and Swirl 2104951 XRCG4 (2103329 BD) AI to ABB TTH300 Temperature Transmitter using 12 V Aux Power 2104954 XRCG4 (2103329 BD) COMM2 to K-TEK for Modbus/RS485 2104955...

  • Page 12: Typographical Conventions

    Typographical conventions Table-1: Typographical conventions Element Convention Example Cross-reference a figure or table Hyperlink to figure or table See Figure 2 or See Table 3. Cross-reference to a section Hyperlink with name in Italic Go to section 2.1, Device setup. Use the key pad to locate and select Indicates that the following item is an Greater than character (>)

  • Page 13: System Overview

    10.21” (259.33 mm) 6990 Installed Depth Pipe Mounted Direct Mounted 12.75” (323.85 mm) 11.00” (279.40 mm) 6490 15.75” (400.05 mm) 14.00” (355.60 mm) 6790 18.01” (457.45 mm) 16.26” (413.00 mm) 6890 6895 XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 1...

  • Page 14: Xseries Remote Controller Hardware

    Description Model Width Height Depth 19” (482.6 mm) 10.47” (265.93 mm) 14.72” (373.89 mm) 6990 Enclosure Specs Weight (w/o battery) Max I/O Modules Max Battery Capacity 6490 8.86 lbs. (3.31 k) 26 Ah 6790 29.0 lbs. (13.17 k) 42 Ah 6890 45.5 lbs.
  • Page 15 An optional ability allows rapid data collection over several communication links. – Additional I/O for valve control, pressure, level monitoring, remote communication, etc. are available. – An optional keypad is available. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 3...

  • Page 16: Standard Enclosure

    Standard enclosure The standard enclosure consists of a hinged-door box in varying sizes for the XRC 6490, 6790 and 6890 (Figure 1, Figure 2 and Figure 3). The door provides a watertight, corrosion resistant seal between the outside elements and the XRC components.

  • Page 17: Figure 3: Xrc 6890

    (.65") 15.52" 18.70" (1.651 cm) 47.498 cm 39.42 cm 28.81" 73.177 cm 28.00" 71.12 cm (2) Holes for .50 NPT Cord Connector (.875" / 2.22 cm) Figure 3: XRC 6890 XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 5...

  • Page 18: Rack Mount Enclosure

    Rack mount enclosure 6990 enclosure is designed for 19” rack mount (see Figure 4). This enclosure may be configured to house up to two The XRC boards, up to two LCD displays and up to two optional key pads. This unit is not designed for exposure to the elements. With the exception of the local PCCU connector, all terminals are located on the back panel of the enclosure.
  • Page 19 2 of the above listed 4 DIs can be used as pulse inputs (DI1 and DI2) Pulse inputs (up to 20 KHz) Digital outputs 4 outputs, open channel FET transistor switches XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 7...

  • Page 20: Figure 5: Xrc Board

    BATT I/O EXP to TFIO Modules XRC Controller Board 2103022 CHARGER INPUT USB A/B ETHERNET SD CARD RESET CPU ENGINE COMM1 KEYPAD COMM2 DIGITAL I/O SECURITY XBT1 Jumpers J21, 22, 24, 25 & 26 configure AIs #1-5 for 0-10VDC or 0-20ma operation.

  • Page 21: Xseries On-Board Input/Output

    XRC (See Figure 5: XRC board, items 19 and 20). XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 9...

  • Page 22: Figure 6: Typical Di Point Schematic

    DANGER – Serious damage to health / risk to life. When connecting or disconnecting any wires to the board, remove all power sources and make sure to be grounded properly. The digital input reads an external contact. Figure 6 is a typical point schematic for the digital input. Figure 7 shows an example of point connections for the DI and the typical input voltage.

  • Page 23: Figure 8: Typical Do Point Schematic

    Figure 8 is a typical point schematic for the digital output. Figure 9 shows an example of point connections for the DO. 2.5A OUTPUT CONTROL Figure 8: Typical DO point schematic XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 11...

  • Page 24: Figure 9: Do Connection Example

    TYPICAL SINK OUTPUT FIELD WIRING BATTERY (+) OR POWER LOAD POSITIVE TERMINAL (24 VDC MAX) 2.5A SOURCE OUTPUT CONTROL BATTERY (-) OR POWER COMMON OR GND SOURCE TERMINAL Figure 9: DO connection example Electrical specification (each point): – Open circuit voltage, 0 Vdc –...

  • Page 25: Display Function

    Go to section 3.5.5, Program display (and PCCU32 help files) for more details. Table 7: Typical XRC display options Display Description DATE/TIME Current Date and Time MM/DD/YY 24 hour clock HH:MM:SS XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 13...

  • Page 26: Functions Of The Xrc

    Display Description Yesterday’s Percent DP Low Limit YEST DP LO NN PERCENT Percent time below DP Low Set Point Yesterday’s Percent DP High Limit YEST DP HI NN PERCENT Percent time below DP High Set Point FLOWRATE Current Flow Rate NNNNNN.N SCF/HR Programmable SCF, MCF, MMCF ACCUM VOL...

  • Page 27: Xrc G4 Application Licensing

    Host interface – Displays General applications typically provide some type of measurement, control, logging or archival function. General applications include: – LMV interface (future) – NGC client – AGA-3 measurement XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 15...

  • Page 28: Display Annunciators

    – AGA-7 measurement – Trend system – Alarm system – Pulse accumulator – Valve control – Safety – Plunger – Oil custody transfer measurement IEC applications are generally custom applications provided by Totalflow at the customer’s request. They might include special control and/or measurement algorithms required by the customer.

  • Page 29: Table 8: Status And Alarm Description

    A to D Failure:. Displayed if A to D Converter Absolute Differential Pressure, Absolute Static Pressure or temperature readings exceed maximum counts or are less than minimum counts. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 17...

  • Page 30: Laptop Computer Running Pccu32

    Laptop computer running PCCU32 PCCU32 software running in a laptop Windows environment offers the most capabilities for programming the XRC . The Windows environment features user-friendly help files and easy to follow menus. Easy to follow menus and icons step the user through many required choices.

  • Page 31: Network Connectivity (Dynamic Ip With Router)

    NOTE: To be able to view various display items, those items must be pre-programmed for keypad entry. All the display items for an application may be programmed, or display items may be individually programmed within the application using PCCU32. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 19...

  • Page 32: Figure 16: Optional Keypad

    Figure 16: Optional keypad SIDE VIEW WITH KEYPAD FRONT VIEW WITH KEYPAD Figure 17: XRC 6990 with dual keypads...

  • Page 33: Figure 18: Xrc 6490 With Optional Keypad

    1 System overview 10.60 Figure 18: XRC 6490 with optional keypad 13.72 Figure 19: XRC 6790 with optional keypad XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 21...

  • Page 34: Optional Totalflow Input/Output Modules

    15.85 Figure 20: XRC 6890 with optional keypad Optional Totalflow input/output modules In addition to Totalflow’s enhanced on-board I/O capabilities, the hardware functionality of the XSeries can be extended in a flexible and friendly way by adding modular I/O as needed (see Figure 21). Totalflow I/O (TFIO) modules are designed to accommodate low power, harsh environments and economical cost requirements.

  • Page 35: Figure 21: Tfio Module Housing

    Type of module (name and color coded) – LED light panel – Reset button switch – Module address selector For additional information, please refer to the TFIO Module User’s Manual (Part No.2101226-001). XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 23...

  • Page 36: Figure 22: Xrc G4 6490 Inside View

    Figure 22: XRC 6490 inside view Figure 23: XRC 6790 inside view...

  • Page 37: Figure 24: Xrc 6890 Inside View

    1 System overview Battery compartment Inside front door Figure 24: XRC 6890 inside view Termination XRC #1 Termination XRC #2 XRC #1 XRC #2 Figure 25: XRC 6990 inside view XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 25...

  • Page 38: Installation

    Installation Overview This section provides the information for installation and setup. For safe and trouble-free installation, follow all instructions and advisories. Due to its unique configuration, the XRC 6990 installation instructions, and its optional equipment, are grouped together near the end of this section. To plan the installation, read through this section before beginning the installation.

  • Page 39: Figure 26: Typical Pipe Saddle Installation

    Figure 27: XRC pipe mounting. See Figure 28 through Figure 30 for final installation dimensions. Flat and lock washers with nut U - Bolt 2 " Mounting Pipe Figure 27: XRC pipe-mounting XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 27...

  • Page 40: Figure 28: Model Xrc 6490, Pipe-Mounted

    11.00" 27.94 cm 2.83" 0.6" 7.188 cm 4 X 0.437" 1.524 cm 17.20" 43.688 cm 16.00" 40.64 cm 0.75" 1.905 cm Figure 28: Model XRC 6490, pipe-mounted 14.56" (2.83") 36.98 cm (7.188 cm) 0.6" 4 X 0.437" 1.524 cm 21.20" 53.85 cm 20.00"...

  • Page 41: Wall Mount Installation

    Step-by-step instructions See Figure 31 through Figure 33 Outline Drawings. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 29...

  • Page 42: Figure 31: Model Xrc 6490, Wall-Mounted

    Install mounting brackets on the back of the XRC , as shown. Drill mounting holes in wall supports. Lift and align XRC wall-mounting brackets with the mounting holes drilled in the wall. Insert 1/4” diameter machine bolts through the XRC mounting brackets into the wall.

  • Page 43: Battery Pack Installation

    Connect the battery pack connector to the digital board battery connection J16 connector (Figure 34), located in upper right corner of the board. Observe the LCD; the display should be on and scrolling through the startup diagnostics sequence. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 31...

  • Page 44: Solar Panel Installation

    J18 I/O EXP BATTERY CHARGER CONNECTION INPUT Figure 34: Battery and charger input connections Solar panel installation The solar panel is designed for outdoor mounting on a 2” extension pipe installed on the upper end of the XRC 40” mounting pipe.

  • Page 45: Figure 35: Typical Solar Panel Installation

    Following connection of the solar panel power cable, secure the cable to the 2’ extension pipe and mounting pipe cable with the plastic tie-wraps provided. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 33...

  • Page 46: Ac Charging Unit Installation

    AC power wiring to a customer-supplied primary AC power source. CAUTION – LOSS OF CERTIFICATION. To maintain system certification, all wiring must comply with NEC 501 code and applicable ABB certification drawings. Remove one of the plugs from the side of the XRC so that the AC charging unit can be mounted without obstruction.

  • Page 47: Figure 37: Dc Wiring Instructions

    Verify that the DC power wires are terminated properly inside the cabinet and verify that the main battery pack is plugged into J16. Apply AC power to the AC charger. Monitor DC charging voltage by observing the XRC display. The LCD should indicate: CHARGER 13.0 - 13.5 VOLTS. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 35...

  • Page 48: Xrc 6990 Rack Mount Installation

    6990 rack mount installation Overview The XRC 6990 is intended for rack-mounting. For purposes of these instructions, we assume that the mounting rack is already in place and that instructions are not required for mounting the unit into the rack (see Figure 39). Figure 39: XRC 6990 rack mount Termination panel...

  • Page 49: Figure 40: Single And Dual Unit Termination Panels

    Figure 40 shows the single and dual unit termination panel. XRC #1 XRC #2 XRC #1 Unit #1 Unit #2 Unit #1 DUAL UNIT PANEL SINGLE UNIT PANEL Figure 40: Single and dual unit termination panels XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 37...

  • Page 50: Xrc G4 Communication Field-Wiring

    communication field-wiring The XRC main electronic board may require some basic setup and wiring. The standard XRC enclosure allows the user access to the main electronic board for configuration of jumpers, communication modules and switches. All user wiring is wired directly to this board. While the XRC panel-mount main electronic board(s) are pre-wired inside of the rack mount enclosure to the termination panel on the rear of the enclosure, it may be necessary to configure some of the jumpers, communication modules and switches that...

  • Page 51: Figure 41: Xrc Standard Communication Wiring

    To prevent this from occurring, the user should wear a grounding strap. Remove power to the unit prior to changing jumper settings or field-wiring to on-board I/O. Figure 41: XRC standard communication wiring XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 39...

  • Page 52: Figure 42: Xrc Panel-Mount Field-Wiring Diagram

    XRC # 1 Unit # 1 Communications Communications P 6 B P 6 A COMM 2 COMM1 232 / 485 232 / 485 VBAT VBAT SW - VBAT SW - VBAT OPER OPER RTS / RRTS RTS / RRTS DCD / BUS - DCD / BUS - RXD / BUS - RXD / BUS -...

  • Page 53: Figure 43: Xrc Main Electronic Board Jumper Configuration

    RS-485 Terminations CPU ENGINE COMM1 COMM2 DIGITAL I/O Pulse input debounce Security Switch Lithium battery backup Analog Input 0-20ma or 0-10VDC AUXPWR OUTPUT Figure 43: XRC main electronic board jumper configuration XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 41...
  • Page 54 Other field wiring For other wiring connections directly on the XRC main electronic board, use Figure 43: XRC main electronic board jumper configuration, and Figure 44: Other field-wiring I/O connections. When wiring to the termination panel on the back of the panel XRC # 1 Unit # 1 Communications...

  • Page 55: Figure 44: Other Field-Wiring I/O Connections

    2 Installation Figure 44: Other field-wiring I/O connections XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 43...

  • Page 56: Xrc G4 Startup

    232 (MMI) cable and connect to a USB port on the PC. The Digi® Edgeport®/1 converter is recommended and can be purchased from ABB (part number 1801382-001). Contact technical support to order or for more details. To connect to the local port using an RS-232 cable: Connect the MMI cable to a serial port on your PC and to the RS-232 local port located on the unit.

  • Page 57: Figure 45: Setup For Local Communication

    If the meter has been given a security code, enter that code in the PCCU32 System Setup screen (see Figure 45). However, if the meter has been COLD-started, the security code will be reset to factory default and historical data will be lost. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 45...

  • Page 58: Set Up The Xrc For Ethernet Communication

    Connect the USB cable to a USB port on your PC and to the USB port on the unit. IMPORTANT NOTE: If connecting directly to the USB port on the board, you need to purchase the Y adapter cable (part number 1803009-001). To order contact ABB. Click on the Windows Start button.

  • Page 59: Figure 46: Network Id Setup

    Click OK to confirm changes. On the navigation tree, select Communications > Totalflow/TCP>Setup tab to view or change additional port parameters (Figure 47). The default protocol enabled on the port is Totalflow/TCP. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 47...

  • Page 60: Figure 47: Communication Setup For Totalflow /Tcp Protocol (Default Tcp Port)

    Figure 47: Communication setup for Totalflow /TCP protocol (default TCP port) Click Send to save changes. Open the door to the flow computer. Press the Reset button on the board. This restarts the XRC with the Ethernet port enabled. The current PCCU connection to the XRC over the serial or USB port may terminate as the XRC resets.

  • Page 61: Figure 48: Set Up Tp/Ip Communication Over Ethernet

    To enable and configure Ethernet: Establish a local connection to the Entry screen as described in section Connect the XRC Ethernet port to the network equipment (switch) with the Ethernet cable. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 49...
  • Page 62 Select Communications> Network tab from the navigation tree. The Network screen displays with options to configure the Ethernet port or Network Adaptor (Figure 49). In the Network ID field, type a name that helps to identify the device uniquely. Set Network Adaptor to Enable. Configure the IP parameters.

  • Page 63: Figure 50: Network Tab: Configure Static Ip Addresses

    If unable to use DHCP, obtain IP addresses and configure the XRC manually. Click Close to terminate the connection over the serial or USB port. Connect to the XRC over the network as described next in section 0, XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 51...
  • Page 64 Establish network connection over Ethernet (using default TCP port).
  • Page 65 Click Close to exit setup and return to the PCCU main screen Click Entry from the toolbar. When the Entry screen displays, the Ethernet connection over the network is successful. Figure 51: Setup of the network connection over Ethernet XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 53...
  • Page 66 Add and configure additional communication instances for Ethernet The default Ethernet port configuration supports connections on TCP port 9999. This port value is read-only. To support connections using another TCP port, add a new communication instance for Ethernet and configure the desired port number. Add communication instance Establish local communication as described in section 3.3, Establishing initial local communication.

  • Page 67: Setting Up The Xrc

    Depending on the programming device used, the following are the minimum required entries. Specific information required to complete each step (depending on the equipment choice) is discussed in the PCCU32 help files. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 55...
  • Page 68 Station ID The station identifier code should uniquely identify one station from that of others. If running a multiple tube station, the station ID is the same for all tubes on that XRC . If left blank on a single tube device, it will be the same as the device ID. Description Format Note...

  • Page 69: Figure 53: Meter Setup And Security Screen

    Have the security switch in the OFF position. Connect locally with PCCU32. Enter a four digit number for level 1 and level 2 security codes (see Figure 54). Figure 53: Meter setup and security screen XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 57...

  • Page 70: Figure 54: Pccu32 Security Code Setup

    Click Send. Turning the security switch (S1) on will activate the security codes. The level 1 code (example above: '1234') will allow data and configuration values to be read, but not altered. The level 2 code (example above: '5678') will allow full access to read and to write.

  • Page 71: Application Licensing Credit Key

    It may be necessary to point the wizard to the PCCU32 directory. In the Files Needed screen, select Browse and locate the driver (usbkey.sys) in the PCCU32 directory. Once located, click OK. Software driver installation will commence. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 59...

  • Page 72: Figure 56: Loading Credit Key Status

    When installation is complete, click Finish. NOTE: If the user inserts the credit key in a different USB port on the computer, it will need to be installed for that new USB port. In other words, the credit key must be installed on each available USB port if not using the same USB port each time.

  • Page 73: Figure 57: Loaded Credit Key Status

    USB port. In other words, the credit key must be installed on each available USB port if not using the same USB port each time. Click OK when connected with an Order Entry clerk. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 61...

  • Page 74: Figure 59: Application Credit Entry Screen

    The clerk will ask for the five (5) encrypted codes that appear directly beneath Do Phone Update. Read them from top to bottom (Figure 59). Figure 59: Application credit entry screen The clerk will give four codes to enter in the fields to the immediate right. After the proper codes have been entered (from top to bottom), click Update.

  • Page 75: Figure 61: Transfer To Device: Type And Amount

    Below that, select the number of credits to transfer. Click Transfer. Transferred credits should now appear on the lower right-hand side (Figure 62). Figure 61: Transfer to Device: type and amount XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 63...

  • Page 76: Figure 62: Transferred To Device Application Credits

    Figure 62: Transferred to Device application credits Transferring credits from device to credit key As has been mentioned before, excess credits (credits beyond what would be required to be fully licensed) can be taken from the G4 device and returned to the credit key to be used on other G4 meters. Credits can be transferred from the device (G4).

  • Page 77: On-Board I/O Calibration

    (This is called the HOLD mode). To exit the hold mode, perform any of the following: – Unplug the DATA cable at the XRC connector – Exit Calibration mode XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 65...

  • Page 78: Figure 65: Xrc Board- Analog Input Calibration Points

    Analog input calibration The Totalflow XRC comes standard with five analog inputs on the XRC board (see Figure 65: XRC board- analog input calibration points). As the user enters calibration, the XRC enters the hold mode and displays the current values. The Current Values section will display the current values continuously by checking the Update box.

  • Page 79: Keypad

    The XSeries models may be configured to include the optional keypad (see Figure 67) located on the front cover of the unit. Keypad entry allows the user to monitor programmed display items without using additional equipment. See Table 13. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 67...

  • Page 80: Figure 67: Optional Keypad (P/N 2100652-Xxx)

    NOTE: To view various display items, those items must be pre-programmed for keypad entry. Either program all the display items for an application or individual display items within the application using PCCU32. Figure 67: Optional Keypad (P/N 2100652-xxx) Table 13: Optional Keypad Commands Command Description Log On...

  • Page 81: Maintenance

    The default path stores the backup files in the StationFiles directory under the PCCU installation directory. The backup file default name is the station ID with the .xfc extension. Click OK. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 69...

  • Page 82: Changing The Xrc Clock

    Wait for the backup to complete. Progress status messages display at the bottom of the screen. When the upload complete message displays, select Yes to restore (copy) the warm configuration to tfCold Wait for the tfCold update to complete. Progress status messages display at the bottom of the screen. Verify that the update is complete by expanding tfCold on the navigation tree.

  • Page 83: Components And Spare Parts

    Figure 68 and Figure 69. Component details and Spare part list are available in Table 14 and Table 15 respectively. Figure 68: XRC 6490 component/cable locations XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 71...

  • Page 84: Figure 69: Xrc G4 6890 Component/Cable Locations

    Figure 69: XRC 6890 component/cable locations Table 14: XRC 6490 and 6890 component identifications Spare Part ID No. Description Number Enclosure PCCU Internal Cable 2000073-xxx Door (6490) 1800308-xxx Door (6790) 1800309-xxx Door w/keypad (6490) 2100548-xxx Door w/keypad (6790) 2100924-xxx Communication Bracket 2015260-xxx External PCCU Connector Cap 1215000-xxx...

  • Page 85: Table 15: Additional Spare Parts

    2017373-004 LCD Window w/Adhesive (Hoffman) 1800553-xxx Battery, 8 Ah 2015113-xxx Battery, 26/30 Ah 2015052-001 Battery, 38/42 Ah 2015052-004 Battery, 16 Ah 2015052-003 Battery, 13 Ah 2015052-002 Battery, 70 Ah 2015052-010 XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 73...

  • Page 86: Replacing The Lithium Battery

    Description Spare Part Number Battery Charger 115 Vac/12 Vdc 2011720-007 Battery Charger 230 Vac/12 Vdc 2011720-008 Power Supply Converter 120 Vac/Vdc 2018200-004 Power Supply Converter 240 Vac/Vdc 2018200-005 Battery Charger 115 Vac/12 Vdc 2100269-001 Battery Charger 230 Vac/12 Vdc 2100269-002 Communication Mounting Bracket 2015260-005 Replacing the lithium battery...

  • Page 87: Figure 70: Memory Backup Enable Jumper

    (see Figure 71) connector J16. Reconnect the battery charger to the XRC board terminals CHGR INPUT +/- terminals J17. After closing the XRC door, check the door-mounted LCD for normal operational readings. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 75...

  • Page 88: Replacing The Main Electronic Board (Xrc )

    Replacing the main electronic board (XRC The XRC board is mounted to the backside of the access door. It is mounted to the door on standoffs. See Figure 68: XRC 6490 component/cable locations or Figure 69: XRC 6890 component/cable locations. NOTICE –...

  • Page 89: Figure 72: Xrc Board Connections

    If the replacement board does not include a new engine card, follow the instructions in section 4.8, Replacing the CPU engine card in this section. RESET Figure 72: XRC board connections XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 77...

  • Page 90: Replacing The Cpu Engine Card

    Replacing the CPU engine card One of the major differences in the XRC is the incorporation of a 32-bit CPU engine card. This engine card holds the main processor, as well as the Flash, RAM and serial E PROM. Should the engine card require replacing, perform the following procedure.

  • Page 91: Replacing The Liquid Crystal Display (Lcd) Board

    To access the LCD board, open the TOTALFLOW unit door. The LCD board is located behind the XRC board. NOTICE – Property damage. Do not remove the board-mounted lithium battery since it provides power to RAM. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 79...
  • Page 92 Disconnect the external charging unit J17 from the XRC board. Disconnect the battery pack connector, J16, from the board mounted connector. Disconnect the LCD board cable connector from the XRC board display interface connector J13. Remove four XRC board mounting screws and lock washers. Do not let the screws and lock washer fall onto the board circuitry.

  • Page 93: Troubleshooting

    This is discussed in more detail in section 5.4.1, Communications overview. Other communication troubleshooting information is shared in the following categories: – RS-232 Communications – RS-485 Communications – RS-422 Communications XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 81...

  • Page 94: Figure 75: Troubleshooting Flowchart

    START Go To Troubleshooting Return to Receive Alarm Codes START Alarm? Go To Power Batteries Troubleshooting Return to Dead? START Go To COMM Troubleshooting COMM Return to Trouble? START Still Call Totalflow Having Technical Return to Trouble? Support START Figure 75: Troubleshooting flowchart...

  • Page 95: Troubleshooting Visual Alarm Codes

    RTU protocol is selected for the port assigned to this annunciator. Local Protocol: Displayed when PCCU port is active and running Totalflow Local Protocol. ¥ ID Recognized: The ID has been recognized but is waiting for Sync. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 83...

  • Page 96: Figure 77: Battery Charger And Battery Pack Connections

    Troubleshooting a blank LCD screen When the LCD is blank, this means that the unit has entered SLEEP mode. This generally indicates the battery voltage has dropped below 10.9 Vdc. Step-by-step instructions Make a local connection with the XRC . This wakes up the unit so that the user may check all alarm conditions and determine the problem.
  • Page 97 Perform continuity test on wires leading to the probe. Set DMM to 200 Ohm or Continuity Audio. Check continuity of the first wire pair (typically red or black) by connecting one lead to each wire. The meter should read zero or close to zero. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 85...

  • Page 98: Figure 78: Rtd Wiring Diagram

    If there is continuity, skip to step 7. If there is no continuity, verify that the wiring at the RTD head is correct. If wiring at the connection head is correct, the RTD is defective. Replace the probe. Otherwise continue to the next step. Check continuity of the second wire pair (typically white) by connecting one lead to each wire.

  • Page 99: Power Troubleshooting

    Notice that the Power troubleshooting flowchart (Figure 80) goes through several tests but also directs the user to Figure 79: Communication troubleshooting flowchart located later in this section. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 87...

  • Page 100: Figure 80: Power Troubleshooting Flowchart

    START Go To Power Supply Test Go To Go To Solar Panel AC Charging Charging System Test AC Charging System Test System ? Perform Isolation Tests Sequentially as Required RETURN Go To Auxiliary Go To Go To Equipment TFIO Module Remote COMM Power Isolation Isolation Test...

  • Page 101: Table 17: Specifications For Solar Panels

    If the solar panel is not above minimum, replace the solar panel. Return to step 1. Disconnect the solar panel from the XRC board. Set the DMM range to read over 20 Vdc. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 89...
  • Page 102 Determine if the Open Circuit voltage is greater than or equal to specification listed in Table 17 by clipping the positive lead of the DMM to the positive wire and clipping the negative lead of the DMM to the negative wire. If the solar panel is not above minimum, continue to the next step.

  • Page 103: Figure 81: Ac-Dc Charger Wiring Instructions

    If the power drain has not been located, return to Figure 80: Power troubleshooting flow chart. BLACK DMM CONNECTOR TO CHARGER REGULATOR RED DMM CONNECTOR TO BATTERY CABLE Figure 82: Current measurement troubleshooting cable XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 91...
  • Page 104 TFIO module isolation test This test will need to be performed if the unit is configured to include TFIO modules, the unit’s battery pack output voltage is not remaining consistent and no errors were found during the previous auxiliary equipment isolation test. Step-by-step instructions Disconnect the solar panel charger or AC charger.

  • Page 105: Figure 83: Lithium Battery Backup Enable/Disable

    When the XRC has been COLD-started, the 24-hour clock will reset to 00:00:00. Enable the memory backup J1 (see Figure 83), by moving the pin jumper to pins 1 and 2. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 93...
  • Page 106 COLD start procedure (software) While the hardware restart requires physically disconnecting and reconnecting jumpers from the main electronic board, performing a software restart involves typing in a command in PCCU. If an error was made while typing, begin the procedure again.

  • Page 107: Figure 84: Communication Troubleshooting Flow Chart

    Test Cable Request? Contact Totalflow Communication Communication Technical RS-232? RS-485? Support RS-232 RS-485 Communication Communication Test Test Does Unit Respond? Transceiver Comm Check Test Passed? Figure 84: Communication troubleshooting flow chart XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 95...
  • Page 108 Verify communication set up Verify the following items were correctly set up during the initial installation. If communications were previously operational, verify that no changes have altered the correct settings: – Verify RS-232 or RS-485 interface modules and jumpers are installed or set correctly. –...

  • Page 109: Figure 85: Xrc Communication Wiring

    If a directional antenna is used, verify the orientation to the antenna to the master site. NOTE: If a communication problem still exists and the unit has passed the transceiver check test, contact Totalflow Technical Support for additional help. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 97...

  • Page 110: Table 18: Rs-232 Field Wiring On Xrc

    RS-232 communication test The following RS-232 Serial Communication Test procedure is directed from Figure 84: Communication troubleshooting flow chart, and will assist the user with what may be the possible cause for an indicated error message. Before performing this test, please verify that the field wiring is correct (see Table 18). Table 18: RS-232 field wiring on XRC electronic board Description...

  • Page 111: Table 19: Rs-485 Field Wiring On Xrc

    Totalflow takes pride in providing on-going support to customers. Purchased products come with documentation which should answer most questions; however, Totalflow Technical Support provides an 800 number as an added source of information. For assistance, call: USA: (800) 442-3097 International: 001-918-338-4880 XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 99...
  • Page 112 Before calling – Know the Totalflow device’s model and serial number. Serial numbers can be found on a plate located on each unit. – Be prepared to give the Technical Support representative a detailed description of the problem. – Note any alarms or messages as they appear. –...
  • Page 113 Batteries in a battery-backed solar installation can drop to 12 Vdc or less. Some transmitters may not be able to drive 20 mA into a 250 Ohm load with only 12 Vdc applied to them. Fully charged batteries, connected to an operational battery charger, may be sitting at about 13.5-14 Vdc. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 101...
  • Page 114 Appendix A 4–20 mA transmitters External to Flowmeter flowmeter 2-wire (line powered) AI + 4-20ma transmitter To A/D Converter User supplies 250Ω resistor and wires it 250Ω across the AI input pins AI - External to Flowmeter flowmeter 2-wire (line powered) AI + To A/D Converter 4-20ma transmitter...
  • Page 115 This places the two resistors in parallel with one another. The parallel combination produces an equivalent resistance that is less than either of the two resistors alone. The value of this equivalent resistance is calculated as shown in the figure. XSeriesG4 Remote Controller User's manual 2103334 Rev. AB | 103...
  • Page 116 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

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