Spirit IT Flow-X Level 1

Transcription

1 ABB MEASUREMENT & AN ALY TICS TR AINING M ANUAL Spirit IT Flow-X Level 1 Authors Eric van Boxtel, Peter van Deurzen Version 1.4 Date November 2017 Copyright 2017 ABB. All rights reserved.

2 2 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Content Introduction... 3 Spirit IT Flow-X products... 4 Introduction... 4 Flow-X/M... 4 Flow-X/S... 5 Flow-X/P... 7 Flow-X/C Flow-X/R Flow-X/K Tamper switch Set up the Spirit IT Flow-X Device setup Network setup - individual Flow-X modules Flow-X/P Communication check Ways of working with Spirit IT Flow- X Spirit IT Flow-Xpress Basic edition Professional edition Reading and writing applications Master applications Standard Spirit IT Flow-X applications Standard Spirit IT Flow-X application properties Gas metric Application functionality Calculations Liquid metric Application functionality Calculations Coriolis Mass I/O Grounding Digital connections Digital status inputs Pulse inputs Digital status outputs Time period inputs Analog signals Analog inputs HART inputs PT100 inputs Analog outputs Serial ports Connecting I/O I/O Calibration Calibration settings Calibration of analog inputs Calibration of PT100 inputs Configure the Spirit IT Flow-X with web GUI...39 Spirit IT Flow-X configuration Overall setup Flow computer type Flow meter configuration Pulse meters Smart & Pulse meters Differential pressure flow devices Temperature & Pressure Transmitters Density configuration (Liquid) Density configuration (Gas) Alarms & Events Application development with Spirit IT Flow-Xpress Parameter editor Debug offline Ports & Devices HART communication Modbus serial Modbus TCP/IP How to check the communication? Debug information Adding a printer Report configuration Security editor Versions Miscellaneous settings Spirit IT Flow-Xtract Document Control... 61

3 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 3 Introduction Welcome to the exciting world of Spirit IT Flow-X! Using one of our Spirit IT Flow-X products, you are able to create your own flow-measurement solution, fully adapted to your specific needs. The Spirit IT Flow-X flow computer is a modular product. It can be used in different enclosures. The advantage is that one module can be used on different ways while the software determines the functionality. Using this training manual the details of the different products will be explained and if it gives a lot of possibilities to train it yourself. Besides the training manuals (level1, level 2 and level 3) there are three reference manuals: Volume I Installation manual, with the installation instructions. Volume II The Operation and Configuration manual. This manual consists of a general part and one of the following application-specific parts: Operation and configuration Gas metric application Liquid metric application Gas customary units application Liquid customary units application Volume III The Advanced configuration manual, for solutions that exceed our standard applications.

4 4 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Spirit IT Flow-X products Introduction The Spirit IT Flow-X product line is a modular setup used within different enclosures with no need for separate boards. The flow computer is usable for (fiscal) oil and gas measurement, both in Metric and USC standards. The product line consist of: Flow-X/M modules Flow-X enclosures Flow-X/S Flow-X/P Flow-X/K Flow-X/R Flow-X/C Flow-Xpress configuration software Basic Professional Online Flow-X/M All products are based on the same flow module (Flow-X/M) Generic flow module to be used in different enclosures (Flow-X/S, Flow-X/P, Flow-X/R and Flow-X/K) One Flow-X/M is used for one meter run LCD display with 4 lines for local display of measured & calculated data Navigation buttons to scroll through the displays Extensive I/O capabilities No separate boards needed Figure 1 Flow-X/M Figure 2 Flow-X/M display and navigation buttons

5 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 5 A single Flow-X/M has the following I/O possibilities Table 1 Flow-X/M in- and outputs Signal type Nr Description Analog input 6 Analog transmitter input, 0.008% accuracy full range 4-20mA, 0-20mA, 0-5V, 1-5V. Inputs are fully floating (optically isolated) HART input 4 Independent HART loop inputs, on top of the analog inputs 1 through 4 Support for multi-drop HART communication 4-wire PRT inputs 2 High accuracy PT-100 inputs (DIN and American) Digital I/O 16 Each channel can be one of the following: Pulse input 1 Single or dual pulse input - Frequency range 0-10 khz Densitometer inputs 4 Periodic time input, 100μs μs Status inputs 16 Digital status inputs Prove detector inputs 4 For pipe and piston provers. Detect time resolution 0.5 microseconds Pulse outputs 4 Open collector, max. 100 Hz Status outputs 16 Digital status outputs, open collector Prover outputs 1 Pulse output for proving systems with separate prover flow computers Analog outputs 4 Analog outputs for flow control, pressure control. 4-20mA, outputs floating. Serial 2 RS485/RS232 serial inputs up to 115kb Ethernet 2 RJ45 Ethernet interface, TCP/IP Power supply 2 External, VDC, nominal 24 VDC, with redundant connections Flow-X/S The single enclosure is called Flow-X/S and can be used for one single run. This Flow-X/S has screw terminals, an 8- pins power supply connector and two separate network terminals. Figure 3 Flow-X/S

6 6 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Characteristics: Single stream (meter run) DIN rail enclosure with direct screw terminals for field connections Interfaces include dual Ethernet with built-in web-server via RJ45 connectors Graphical LCD display with 4 lines for local display of measured & calculated data The Flow-X/S may be mounted in 3 ways: Horizontally on DIN-rail Vertically on DIN-rail Wall mounted Figure 4 Ways of mounting a Flow-X/S X1A: terminal A (39 pins) X1B: terminal B (39 pins) Power 24 V: Power terminal (8 pins) LanA: TCP/IP connector LanB: TCP/IP connector Figure 5 Flow-X/S connection terminals

7 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 7 Pin Function Pin Function Pin Function Pin Function 1 24 V DC out 21 Dig 9 X1A X1B 1 PRT 1 pwr+ 21 A-in V 22 0 V 2 PRT 1 22 A-in common 3 Dig 1 23 Dig 10 3 PRT 1 23 A-out V 24 0 V 4 PRT 1 24 A-out common 5 Dig 2 25 Dig 11 5 A-in common 25 A-out V 26 0 V 6 PRT 2 26 A-out common 7 Dig 3 27 Dig 12 7 PRT 2 27 A-out V 28 0 V 8 PRT 2 28 A-out common 9 Dig 4 29 Dig 13 9 PRT 2 29 A-out V 30 0 V 10 A-in common 30 A-out common 11 Dig 5 31 Dig A-in V 12 0 V 32 0 V 12 A-in common 32 COM 1 Sig+ Tx+* 13 Dig 6 33 Dig A-in 2 33 COM 1 Tx Sig- Tx- * 14 0 V 34 0 V 14 A-in common 34 COM 1 Rx Rx- * 15 Dig 7 35 Dig A-in 3 35 COM 1 Rx+ * 16 0 V 36 0 V 16 A-in common 36 COM 2 Sig+ Tx+* 17 Dig V DC out 17 A-in 4 37 COM 2 Tx Sig- Tx- * 18 0 V 38 0 V 18 A-in common 38 COM 2 Rx Rx- * V DC out V DC 19 A-in 5 39 COM 2 Rx+ * 20 0 V 20 A-in common Figure 6 Flow-X/S connections Flow-X/P The panel enclosure is called Flow-X/P and can be used for maximum 4 runs and station functionality. This Flow-X/P has connector terminals, a 8-pins power supply connector and two separate network terminals for the panel. Figure 7 Flow-X/P

8 8 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Characteristics: Panel mounted flow computer orizontal or vertical position Up to 4 flow modules Additional station module with: 7 multi-lingual color touch-screen 3 additional serial ports 2 Ethernet ports Figure 8 Flow-X/P mounting kit Field connections are available in Flow module connectors (8 x 37-pin D-sub) 3 additional COM ports (3 x 9-pin D-sub) 2 Ethernet ports (2 x RJ45) Power supply (24 VDC) Figure 9 Flow-X/P connection terminals

9 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 9 Pin COM 1 (RS-232 only) COM 2 / COM 3 RS-232 COM 2 / COM 3 RS-485 (2-wire) COM 2 / COM 3 RS-485 (4-wire) 1 Rx 2 Rx Rx Rx + 3 Tx Tx Sig Tx 4 Sig + Tx V 0 V O V 6 7 RTS 8 CTS 9 Figure 10 Flow-X/P serial connections 1 20 Connector A Connector B Pin Function Pin Function Pin Function Pin Function 1 COM1 Sig+ Tx+* 21 0V, Dig common 1 COM2 Sig+ Tx+* 21 0V, Dig common 2 COM1 Tx Sig Tx * 22 Dig 5 2 COM2 Tx Sig Tx * 22 Dig 13 3 COM1 Rx * 23 0V, Dig common 3 COM2 Rx * 23 0V, Dig common 4 COM1 Rx Rx+* 24 Dig 6 4 COM2 Rx Rx+* 24 Dig V out 25 0V, Dig common 5 24V out 25 0V, Dig common Dig 1 26 Dig 7 6 Dig 9 26 Dig V, Dig common 27 0V, Dig common 7 0V, Dig common 27 0V, Dig common 8 Dig 2 28 Dig 8 8 Dig Dig V, Dig common 29 0V, Dig common 9 0V, Dig common 29 0V, Dig common 10 Dig 3 30 A-out 2 10 Dig A-out V, Dig common 31 A-out common 11 0V, Dig common 31 A-out common 12 A-out 1 32 A-in 1 12 A-out 3 32 A-in 4 13 A-out common 33 A-in common 13 A-out common 33 A-in common 14 A-in common 34 A-in 2 14 A-in common 34 A-in 5 15 PRT 1 power + 35 A-in common 15 PRT 2 power + 35 A-in common 16 PRT 1 signal + 36 A-in 3 16 PRT 2 signal + 36 A-in 6 17 PRT 1 signal 37 A-in common 17 PRT 2 signal 37 A-in common 18 PRT 1 power 18 PRT 2 power 19 A-in common 19 A-in common 20 Dig 4 20 Dig 12 Figure 11 Flow-X/[P][C][R][K] connections

10 10 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Flow-X/C This is a Compact panel mounted flow computer with one integrated Flow-X/M module with a 7 multi-lingual color touch screen and one additional serial port. Figure 12 Flow-X/C Characteristics: Panel mounted flow computer Horizontal or vertical position 1 integrated flow module 7 multi-lingual color touch-screen 3 serial ports 2 Ethernet ports Flow-X/R The rack enclosure is called Flow-X/R and can be used for maximum eight modules, including station functionality. This Flow-X/R has connector terminals, 4-pins power supply connectors and two separate network terminals for each module. Figure 13 Flow-X/R

11 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 11 Pin Description 1 24 V DC Primary 2 24 V DC Secondary 3 0 V 4 0 V Figure 14 Flow-X/R power connections The I/O connections are exactly the same as the connections of the Flow-X/[P][K], see Figure 11: Flow-X/[P][C][R][K] connections. Characteristics: Efficient use of cabinet space Holds up to 8 X/M modules Used as separate meter runs or as combinations 37-pin D-Sub type connectors for I/O 2 Ethernet connections individually per flow module. Separate power connection for each module Flow-X/K The small rack enclosure is called Flow-X/K and can be used for one stream and station functionality. This Flow-X/K has two connector terminals, one 4-pins power supply connector and two separate network terminals for each module. Pin Description 1 24 V DC Primary 2 24 V DC Secondary 3 0 V 4 0 V Figure 15 Flow-X/K Figure 16 Flow-X/K power connections For the I/O connections see Figure 11: Flow-X/[P][C][R][K] connections. Characteristics: Efficient use of cabinet space 37-pin D-Sub type connectors for I/O 2 Ethernet connections individually per flow module.

12 12 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Tamper switch The Flow-X/C flow computer as well as each Flow-X/M module have a mechanical tamper switch to prevent changing of the application and vital parameters within that application. All enclosures have the option of locking the flow computer with a lead seal by an authorized body, to prevent access to the tamper switch of the individual modules Figure 17 Tamper switch

13 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 13 Set up the Spirit IT Flow-X Device setup Before a Spirit IT Flow-X can be put in operation, the device has to be set-up correctly. The following settings need to be set locally on each Flow-X/M module and on the Flow-X/P panel display: Device name Bus set-up Stand alone Flow-X/C Flow-X/P1 - Flow-X/P4 Flow-X/R (DO NOT USE) Network IP address After making changes in the bus set-up, the flow computer needs to reboot to in order for the changes to take effect. After setting up the IP address in the Flow-X it is possible to reach the module using a web browser by typing the IP address on the top. Network setup - individual Flow-X modules For all Flow-X module, the network set-up for the two Ethernet ports has to be such that these are in a different network segment. A subnetwork, or subnet, is a logically visible subdivision of an IP network. ETH 1 IP-address 1 e.g Subnet 1 e.g ETH 2 IP-address 2 e.g Subnet 1 e.g Figure 18 Example of setting up the IP address of a Flow-X/S It is not allowed to use the same subnet for ETH1 and ETH2. When the network IP addresses are in the same segment, the Flow-X will show an Unknown error.

14 14 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL This is a valid combination: Subnet mask: ETH1 IP address: ETH2 IP address: Figure 19 Network configuration error ETH1 IP address: Subnet mask: ETH2 IP address: Subnet mask: UNKNOWN ERROR Solution 1 ETH1 IP address: Subnet mask: ETH2 IP address: Subnet mask: Solution 2 ETH1 IP address: Subnet mask: ETH2 IP address: Subnet mask:

15 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 15 Flow-X/P The IP address of the first module must be the IP address of the panel + 1, the IP address of the second module must be the IP address of the panel + 2, etc. For a Flow-X/P it is very important that the device type is set correctly. Figure 20 Example of setting the IP address of a Flow-X/P Communication check When you want to check the Ethernet setup connection, connect a compter or laptop to the Flow-X and set-up the network configuration of the computer to be in the same segment of the Flow-X. Thenyou open a command window and type in: PING The Flow-X/P will respond with a good response. When you want to check the connection with module 1 of the panel you type in: PING Module 1 of the panel will now respond with a good response. Module 2 can be checked as follows: PING Module 2 of the panel will now respond with a good response.

16 16 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Figure 21 Connect a pc directly to the Flow-X/P Ways of working with Spirit IT Flow-X Display Check I/O signals and values Change settings Web browser: Check I/O signals and values Change settings Spirit IT Flow-Xpress Basic: Configuring standard Flow-X applications Read application from Flow-X Write application to Flow-X Spirit IT Flow-Xpress Professional: Flow-Xpress Basic Extend / adapt standard Flow-X applications Create your own applications from scratch The web display looks as follows:

17 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 17 Figure 22 Web display EXERCISE Device setup 1. Set the Flow-X to be Standalone 2. Set the IP-address of the Flow-X to be in the same range (but not the same) as your laptop (use PIN or ) 3. Make an Ethernet connection between the Flow-X and your laptop 4. Start a web browser on your laptop (like Chrome or Internet Explorer) 5. Type the IP-address of the Flow-X into the address bar of your browser 6. Look around what s there 7. Log in with user name administrator and password admin or log in with user a and no password

18 18 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Spirit IT Flow-Xpress Spirit IT Flow-Xpress is the software for the configuration of the Spirit IT Flow-X. When connected with an Ethernet interface you can read, configure and write the flow computer application. Figure 23 Spirit IT Flow-Xpress overview Spirit IT Flow-Xpress can be installed running the setup. The license determines if you have a basic version or professional version. The license usually is a software key. To obtain a licnese: Start the License Manager Export the license information or copy the text marked as Machine Identification Code Send this information to nl-spiritit-support@abb.com You will get a file with an Authorization Key and a License Number Enter the Authorization Key and License Number into the appropriate fields and click Install At the top of the dialog, you should now see the word Authorized in green. Basic edition With Spirit IT Flow-Xpress Basic it is possible to read configuration applications from hard disk and send them to all types of Spirit IT Flow-X devices. With Spirit IT Flow-Xpress Basic it is also possible to read the configuration from the Spirit IT Flow-X device and write it to hard disk. Device setup Flow-X/S (Single) Flow-X/P (Panel) Set up communication protocols (Modbus / HART / Ethernet) Modify or add display pages Define additional languages Add user names and passwords Add user definable calculations Modify or add reports The following menu items are available:

19 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 19 File menu The File menu is used for reading an application from file or device. After the configuration is finished it can be saved on hard disc or can be sent to the device. Figure 24 Flow-Xpress File menu View menu The View menu makes it possible to select the individual setup settings, like device settings, port settings, displays, parameters. Figure 25 Flow-Xpress View menu Build menu The purpose of the Build menu is to compile the application and check on errors. Figure 26 Flow-Xpress Build menu

20 20 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Debug menu From the Debug menu, Debug offline can be started to do an offline check. Figure 27 Flow-Xpress Debug menu Tools menu Through the Tools menu some options can be set and it is possible to read the debug info from a device. Figure 28 Flow-Xpress Tools menu Help menu Through the Help menu the manuals can be reached. Figure 29 Flow-Xpress Help menu Online mode In the online mode it is possible to connect to one of the modules to check and edit the parameters or users online. Figure 30 Online mode Professional edition Besides the Basic functionality you also have additional functionality with Spirit IT Flow-Xpress Professional. With Spirit IT Flow-Xpress Professional it is f.e. possible to change the configurations or add your own functionality and drivers.

21 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 21 Reading and writing applications When reading/writing an application with Spirit IT Flow-Xpress: Only flow computers that comply with the device setup can be selected for writing Write with or without parameters Write with or without users Write with or without COM-port settings Figure 31 Device selection Figure 32 Write to selected device EXERCISE - Flow-Xpress installation 1. Install Flow-Xpress software on your laptop 2. Run the Flow-Xpress_(<version>).exe installation file 3. Provide user name, company name and computer name 4. Obtain and install the license for Flow-Xpress Basic Figure 33 Flow-Xpress Basic

22 22 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL EXERCISE - Read and write application 1. Start Flow-Xpress Start -> Programs -> Flow-Xpress 2. Read the application from the Flow-X 3. Look up the files that have been saved to your harddisk (My Documents -> Flow-Xpress -> Received) 4. Write the application to the Flow-X Use the default user name: a and no password (leave empty)

23 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 23 Master applications Standard Spirit IT Flow-X applications The following standard Spirit IT Flow-X applications are available: Gas Metric Liquid Metric Gas US Customary Liquid US Customary Standard Spirit IT Flow-X application properties Supports both single meter runs and metering stations consisting of several meter runs. Supports any type of smart meters with flow rate / total output through analog, HART or Modbus signal Automatic use of backup signal for smart meters with an additional pulse output Analog, HART and Modbus options for live inputs Last good, keypad and fallback option for failing input signals. Automatic switching from HART to analog signal in case of HART failure Data valid input (in combination with a pulse input) Support of turbine, PD, ultrasonic, coriolis, orifice, venturi and V-cone flow meters Built-in support for Micro Motion and Endress & Hauser coriolis flow meters Orifice, venturi and V-cone standards: ISO-5167, AGA-3 One, two or three dp cells 1 cell full range 2 cells Low/High range 2 cells full range 3 cells Low/Mid/High range 3 cells Low/High/High range 3 cells full range User definable HART and Modbus interface to any other type of flow meters and other devices (such as gas chromatographs) One or two densitometers on run and station levels Meter body correction for pressure and temperature Selectable meter factor and meter K-factor interpolation curves (12 points each) Master meter proving Hourly and daily totals and averages of in-use and input data Additional 2 freely definable periods for totals and averages Cross-module I/O sharing Generating of period- and manually generated reports Indication of total rollover on reports Indication of input override / failure on reports Diagnostic displays for smart meters Station functionality

24 24 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Forward / reverse totalizers Maintenance totalizers Valve control (Re)printing of reports directly to a printer Gas metric Application functionality The gas metric application supports the following in addition to the standard application functionality: One or two specific gravity transducers on run and station levels One or two gas chromatographs on run and station levels Remote gas composition through Modbus on run and station levels Process inputs for density, base density and specific gravity Several compressibility algorithms for line and base conditions: AGA-8, ISO-6976, SGERG, NX-19, GPA-2172 and GERG-2008 Built-in support for Sick, Elster-Instromet, Daniel, RMG, Krohne and General Electric (GE) ultrasonic flow meters Built-in support for Micro Motion Coriolis flow meters Built-in support for ABB, Siemens, Elster-Instromet, Yokogawa and Daniel gas chromatographs AGA-10 for speed of sound verification Calculations Liquid metric Application functionality The liquid metric application supports the following in addition to the standard application functionality: Process inputs for density, standard density, viscosity and BS&W Viscosity correction

25 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 25 Batch totals and averages of in-use and input data Built-in support for Daniel, Caldon, General Electric (GE) and Krohne ultrasonic flow meters Built-in support for ABB, Micro Motion and Endress+Hauser Coriolis flow meters Several standards for standard density calculation: API-2540, API MPMS 11.1:2004, API MPMS 11.2, GPA-TP27 Valve sequencing PID control with cascading feature Sampler control Support of bi-directional and unidirectional ball provers Support of Brooks compact prover, Calibron, and Flow MD piston provers Up to 4 prove detector switch inputs Calculations Coriolis Mass

26 26 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL EXERCISE - Write new application 1. Create new application from Master -> Gas_Metric Master.fxm or Liquid_Metric Master.fxm 2. Set device to be Flow-X/S 3. Write the application to the Flow-X a) Use the default user name: a and no password (leave empty) b) Wait until the flow computer has rebooted EXERCISE - Flow-X menu structure 1. Log in as operator (user name: operator, password: operator) 2. Investigate the display menu structure of the application a) Look up how to set alarm limits for temperature, pressure and flow rate b) Look up how to set and activate override values for temperature and pressure c) Look up how to acknowledge alarms d) Look up the event log / audit trail 3. Log in as engineer (user name: engineer, password: engineer) a) Investigate the display menu structure of the application b) Look up the configuration settings c) Look up the IO configuration settings and calibration displays Figure 34 Web GUI

27 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 27 I/O Grounding Flow-X uses the following separate ground earth connections: Chassis ground: through the chassis grounding screw 0 V: common ground for main power supply, digital inputs and digital outputs Ain common: isolated common ground for the analog inputs Aout common: isolated common ground for the analog outputs No isolated common available then connect Ain common/aout common to 0 V Figure 35 Ground wiring Digital connections 16 general-purpose digital channels Sampled at 10 MHz Digital signals Digital status input Digital status output Pulse input Time period input (e.g. densitometers) Pulse output (e.g. counters) Detector inputs (proving) Prover bus output (to prover flow computer)

28 28 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Figure 36 Digital channel circuit Digital status inputs Each digital channel can be configured as digital status input Max 16 digital inputs on each Flow-X/M Sampled at 10 MHz Each input is sampled: Unfiltered Filtered with 8ms debounce period (shorter periods are ignored) Powered: Internally Externally Selectable threshold level: Channel 1 to 8: 1.25 or 12 V Channel 9 to 16: 3.75 or 12 V Figure 37 Digital inputs Pulse inputs Each digital channel can be configured as pulse input Max. 1 (single) or 2 pulse inputs (dual) per Flow-X/M module Threshold levels: Channel 1 to 8: 1.25 or 12 V Channel 9 to 16: 3.75 or 12 V Pulse integrity checking (dual pulse only) Max. frequency 10 khz

29 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 29 Figure 38 Pulse inputs Digital status outputs Each digital channel can be configured as digital status output Acts as an open collector Internally powered digital output Externally powered digital output Connecting a digital output to a digital input Figure 39 Digital outputs Time period inputs Digital channels 1-4 can be configured as time period input Used for densitometers and specific gravity transducers Max. 4 time period inputs per Flow-X/M module Analog signals Analog signals: 6 analog inputs 4 analog outputs 2 PT100 inputs Max 4 HART inputs Analog inputs Configurable as: 4 20 ma (internal resistor of 250Ω is activated) 0 20 ma (internal resistor of 250Ω is activated)

30 30 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 1-5 Volt 0 5 Volt Figure 40 Analog current inputs Figure 41 Splitting up analog voltage inputs (analog inputs configured as 1-5V) Figure 42 Analog current input with barrier

31 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 31 Figure 43 Analog voltage input HART inputs Analog inputs 1-4 of each Flow-X/M module can be configured as HART inputs The flow computer supports both a single HART transmitter and multiple HART transmitters per loop Figure 44 HART inputs PT100 inputs Each Flow-X/M flow module provides two PT100 inputs Figure 45 PT100 inputs

32 32 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Analog outputs 4-20 ma Output circuits are floating in relation to the other type of I/O Each analog output can drive a load up to 650 Ohm Figure 46 Analog outputs Serial ports Flow-X/M 2 serial ports RS-232 or RS-485 Flow-X/P 3 additional serial ports COM 1: RS-232 COM 2, COM 3: RS-232 or RS-485 RS-485: 2-wire (half duplex) or 4-wire (full duplex) Figure 47 Serial ports Connecting I/O EXERCISE - Digital input 1. Connect a switch to Digital Channel 8 a) Look up connection diagram and pin lay-out in installation manual b) Use a pull-up resistor between digital input and 24 V out c) Configure digital 16 signal type as Digital Input 2. Configure polarity so that pressing the switch = ON

33 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Verify input signal on Diagnostics display page 4. Verify working of digital input force EXERCISE - Pulse input 1. Connect a (single) pulse to Digital Channel 1 a) Pulse generator with voltage output b) Look up connection diagram and pin lay-out in Installation manual c) Configure digital 1 signal type as Pulse input A 2. Verify input signal through Diagnostics display page 3. Verify working of pulse input force 4. Dual pulse: See what is happening if you configure a second digital channel as Pulse input B EXERCISE - Analog input 1. Connect a transmitter to analog input 1 a) Look up connection diagram and pin lay-out in Installation manual b) Don t forget to connect common ground to analog input ground c) Configure input type as 4-20mA d) Configure scaling as -50 to 200 EU 2. Verify input signal via Diagnostics display page a) Try several input values b) Verify working of transmitter low failure at lowest current 3. Configure analog input 2 a) Input type 4-20 ma b) Scaling 0 to 100 EU 4. Force analog input 2 at 50% EXERCISE - Pulse output 1. Use the web display to configure digital channel 7 as pulse output 1 2. Force the pulse output in the Force IO display 3. Check the pulse using a LED or lamp with resistor between 24V output and digital channel 7 4. Investigate the function of parameters max frequency and pulse width 5. Read the application file to your laptop and save it

34 34 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL I/O Calibration The following signals can be calibrated: Analog input signals PT100 inputs Calibration settings Configure 1 5 calibration points for analog inputs Configure 1 5 calibration points for PT100 inputs Inactivity timeout limit for automatic disabling the calibration if not disabled manually Figure 48 I/O Calibration settings Example to calibrate analog inputs (4-20mA) with 5 points: Point Current % span 1 4 ma ma ma ma ma 100 Calibration of analog inputs The first thing to calibrate an analog input is to select the analog input.

35 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 35 Figure 49 Analog input calibration I After selecting an analog input, the first calibration point is shown. Figure 50 Analog input calibration II Now the calibration points can be checked one by one by clicking on the Next Calibration Step button. Be sure a 4-20mA loop calibrator is connected to the right analog input. When point 1 (4mA) is checked be sure 4 ma is set on the loop calibrator.

36 36 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Figure mA loop calibrator After pressing the Recalibrate this point button, the current value is set to the reference value. In this case 4mA. This way al the other points can be checked and recalibrated if necessary. Figure 52 Analog input calibration III At the end of the calibration don t forget to set the Selected analog input to none to switch off the calibration mode.

37 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 37 Calibration of PT100 inputs When calibrating a PT100 select the PT100 input first. Figure 53 PT100 input calibration I After selecting a PT100 input, the first calibration point is shown. Figure 54 PT100 input calibration II Now the calibration points can ber checked one by one by clicking on the Next Calibration Step button. After clicking the Recalibrate this point button, the current value is set to the reference value.

38 38 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL At the end of the calibration don t forget to set the Selected PT100 input to none to switch off the calibration mode. EXERCISE - Analog input calibration 1. Set up the following analog input calibration points: 0%, 25%, 50%, 75%, 100% 2. Connect an analog simulator to the analog input 3. Select the analog input for calibration 4. Check the different calibration steps from 0% to 100% 5. Deselect the analog input

39 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 39 Configure the Spirit IT Flow-X with web GUI Spirit IT Flow-X configuration 1. Set up Spirit IT Flow-Xpress configuration (before writing to the Flow-X) Device setup Ports & Devices Displays Languages Reports User names and passwords Custom calculations 2. Set up configuration parameters: before writing the application: Flow-Xpress after writing the applications: Flow-X display Web interface Flow-Xpress online mode First configure the following parameters: Overall setup Run setup Configuration screens are shown or hidden based on these parameters Next you can do the detailed configuration Overall setup Run functionality Figure 55 Run functionality Station functionality

40 40 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Figure 56 Station functionality Flow computer type The following flow computer types are available: Standalone run Station only Proving only Station / Run Proving / Run Station / Proving Station / Proving / Run Prover IO server Table 2 Flow computer types Local run(s) Station functionality Proving functionality Communicate to remote run(s) X/P panel acts as station X/P panel acts as prover Standalone run Station only Proving only Station / Run *) Proving / Run *) Station / Proving Station / Proving / *) Prover IO server *) optional Flow meter configuration Select meter dedevice type: Pulse Smart meters

41 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 41 Smart meters with pulses Pulse primary Serial primary Differential pressure meters Orifice Venturi V-Cone Nozzle Pulse meters K-factor Only for pulse meters Converts number of pulses into amount Volume pulses/m3 (Metric) pulses/bbl (USC) Mass pulses/ton (Liquid Metric) pulses/kg (Gas Metric) pulses/lbm (USC) Fixed value or curve depending on pulse frequency Indicated flow rate = Meter frequency / K-Factor The meter is considered inactive if the measured value is below the Low flow cut-off frequency Smart & Pulse meters Meter factor For pulse meters and smart meters Correction factor based on calibration / proving Fixed value or curve depending on flow rate Represented as Meter Factor (~1.000) or Meter error (~0.000%) Meter factor = 100 / (100 + Meter Error) Gross flow rate = Indicated flow rate x Meter factor Meter body correction Correction factor to compensate for the pressure / temperature effect on the meter body Smart flow meter OR Flow-X Gross flow rate = Indicated flow rate x Meter factor x Meter body correction The following picture shows how the K-factor and meter factor are applied by the Flow-X: Figure 57 K-factor and meter factor The meter is considered inactive if the measured value is below the Low flow cut-off flow rate Differential pressure flow devices Device types Orifice plates

42 42 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Nozzles Venturi tubes V-Cone Calculation standards AGA-3 ISO-5167 GOST8-586 (2005) (not configured in Master Applications) The meter is considered inactive if the measured value is below the Low flow cut-off dp Temperature & Pressure Transmitters Transmitter input type Always override value Analog / PT100 input HART Fallback to analog Custom input (Modbus) Smart Meter Run setup Single transmitter Dual transmitter Dual transmitter mode Auto A Auto B Average Deviation limit Density configuration (Liquid) Run setup: Meter device type Observed density input type Standard density input type Meter density calculation method Here an overview is shown of the determination of the density for liquids:

43 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 43 Figure 58 Density determination for liquid Density configuration (Gas) Run setup: Meter device type Observed density input type Base density input type Meter density calculation method SG input type Gas composition input type Here an overview is shown of the determination of the density for gas: Figure 59 Density determination for gas Alarms & Events The Spirit IT Flow-X contains two pages for Alarms & Events: Active & Unacknowledged alarms Historical Events

44 44 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Figure 60 Alarm display Figure 61 Events display EXERCISE - Single run flow computer 1. Use the web display to set up the Flow-X for the following configuration: Standalone run Smart / Pulse meter (IP-address: ) Liquid: ABB Coriolis (port 505) Gas: FlowSick600 (port 504) Analog pressure transmitter Analog temperature transmitter

45 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 45 Fixed product / density Gas : Always use override composition Liquid : Always use override standard density (from product table) / Always use override BS&W 2. Force the inputs (only if no live inputs available) 3. Check if the flow rates are <> 0 and if the totalizers are counting EXERCISE - Meter factor curve 1. Enable meter factor curve interpolation 2. Use the web display to configure the following meter factor curve: Flow rate Meter factor 10 m3/h m3/h m3/h m3/h Modify the meter frequency and see how the in-use meter factor changes EXERCISE - Bidirectional flow 1. Use the web display to configure digital channel 8 as a flow direction digital input: a) Verify that the reverse totalizers are enabled (Configuration Overall setup Common settings) b) Enable flow direction input (Configuration Run Flow meter Flow direction) c) Select digital input channel 8 d) Fill in the reverse meter factor curve Flow rate Meter factor 10 m3/h m3/h Press the switch or force the input and see how the forward and reverse totalizers behave EXERCISE - Analog outputs 1. Use the web display to configure: A gross volume flow rate output ( m3/hr) on analog output 1 A temperature output ( C) on analog output 2 A pressure output (0-100 barg) on analog output 3 2. Check on the IO Diagnostics displays if the outputs are working 3. Check the current of the analog outputs using a multimeter EXERCISE - Pulse output 1. Use the web display to configure a gross volume pulse output on digital channel 10 a) Configure the quantity per pulse such that one pulse is given at each 10 m3 2. Check the pulse using a lamp or LED on digital channel 10 a) Be sure the pulse output is not forced!

46 46 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Application development with Spirit IT Flow- Xpress Parameter editor With the parameter editor it is possible to: Configure Spirit IT Flow-X offline Load parameter set from file Save parameter set to file Print parameter set Figure 62 Parameter editor EXERCISE Parameter editor 1. Read the application from the Flow-X and load it in Flow-Xpress a) Open the parameter editor and browse through the settings b) Notice that all the parameters that you have modified are shown BOLD 2. Modify a number of parameters in the parameter editor a) Write the application to the Flow-X b) Select the parameters check box to ensure that parameters are written as well c) Check if the parameters have been implemented in the Flow-X Debug offline Debug Offline can be used for: Full flow computer simulation No Flow-X hardware needed to test Flow-X application

47 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 47 Flow-X software running on laptop Update parameters offline, save into file and write to Flow-X later After activating Debug Offline the following dialog is shown: Figure 63 Debug Offline EXERCISE - Flow-X/P1 1. Use Flow-Xpress and Debug offline to set up the Flow-X for the following configuration: Flow-X/P with one run Standalone run Turbine meter with digital input 1 as pulse A Pressure transmitter on analog input 2 Temperature transmitter on PT100 input 1 2. Force the inputs and check if the flow rates are <> 0 and the totalizers are counting EXERCISE - Flow-X/P2 1. Use Flow-Xpress and Debug offline to add a second run: a) Change the configuration to Flow-X/P2 with two runs b) Add a second turbine meter with digital input 1 as pulse A on module 2 c) Add a pressure and temperature transmitter as analog inputs on module 2 2. Force the inputs and check if the flow rates are <> 0 and the totalizers are counting Ports & Devices In this window you can: Configure serial ports Configure HART communication devices Configure serial Modbus devices Configure Modbus TCP/IP devices Configure printers

48 48 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Figure 64 ports & devices Through Ports and devices it is possible to activate communication drivers for communication to devices through serial, HART or Ethernet ports. To activate a device on a COM, Ethernet or HART port, right click on the port. This brings up the list of available devices: Figure 65 Device selection on COM1

49 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 49 Now activate one of the devices. When a device is selected, the right part of the screen shows the applicable device settings. Figure 66 Device settings HART communication HART devices are to be connected to the analog input. HART communication is a digital communication protocol over a 4-20 ma analog line. By using a HART modem data can be read from and written to a device. Figure 67 HART communication For HART communication a listen mode is supported, which makes it possible to connect one HART transmitter to two or more flow computers, as shown here: Figure 68HART communication with listen mode This way multiple masters can use one and the same slave device.

50 50 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL One (active) master sends requests to a slave device and another (passive) master is picking up data by listening to the communication between the active master and the slave device. When the active master stops communicating, the passive master will start sending requests and becomes the active master. Modbus serial There are three ways of serial communication: RS-232 RS wire RS wire Using Modbus there is normally one master and one or more slave devices. The master sends commands (questions) to a slave device that will respond with an answer. Figure 69 Modbus master / slave serial communication The Flow-X also supports a Listen mode using RS-485. In that case the configuration looks as follows: Figure 70 Modbus serial communication with listen mode Modbus TCP/IP With Modbus TCP/IP there can be multiple client and multiple server systems on the network as shown here:

51 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 51 Figure 71 Client/server configuration How to check the communication? To check the communication between the Flow-X and a gas chromatograph it is possible using your web browser on your laptop. Connect your laptop to the flow-x by the Ethernet Start the web browser, e.g. Chrome or Internet Explorer Go to the flow computer web GUI Browse to System -> Diagnostics -> Communications Figure 72 Check communication via the web browser The following dialog is shown:

52 52 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Figure 73 Communication ports in the web browser Select one or more ports for debugging. After pressing Start Logging you can check the communication as follows: Figure 74 Communication messages In red you can see the requests sent by the Flow-X and in blue you can see the responses from the device.

53 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 53 Debug information You can view debug logs with the web browser: Enable debug logging: System / Modules / Panel / Diagnostics / Debug Logs View logs with web browser: System / Modules / Panel / Diagnostics Figure 75 Read debug info from device Using Spirit IT Flow-Xpress it is possible to download information log files. Start Spirit IT Flow-Xpress and select Read debug info from device from the Tools menu. Then select the IP address from the list on the dialog, login and store the file on hard disc. The stored file is a zip file and contains the debug information. Figure 76 Read debug info from device EXERCISE Download debug info 1. Download the debug information of your flow computer and store it on your hard disc. 2. Investigate what kind of files have been downloaded.

54 54 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Adding a printer The following picture shows how to connect a network text printer to the flow computer: Figure 77 Add network printer The printer is added to the list and the printer properties can be filled in: Figure 78 Network printer properties The printer name is to be filled in in Spirit IT Flow-Xpress. The IP address is to be configured later on the flow computer display, after writing the application:

55 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 55 Figure 79 Define the IP address of the printer The printer settings can be found at the display System -> Printers.

56 56 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Report configuration Configure for each report on which printer it shall be printed Configure the number of copies that are printed when the report is generated Configure the number of printed copies at a reprint command Figure 80 Number of (re-)printed reports The number of generated copies and reprinted copies are set to 0 by default. If a report needs to be printed automatically Generate copies needs to be set to 1 or more. To enable manual report reprinting, Reprint copies has to be set to 1 or more.

57 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 57 Security editor Features: Add or remove user names Assign user levels to users Change passwords and PIN codes Assign tasks to security levels Define the minimum security level of tags that are blocked by the hardware security switch Figure 81 Security editor The security settings can also be changed in online mode. Figure 82 Online mode

58 58 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL EXERCISE - Online mode 1. Use the online mode to add a username, security level 2000, with password and PIN code 2. Select Write all changes to device 3. Log on to the flow computer through the web browser using the new username and password 4. Log on to the flow computer through the flow computer LCD using the new PIN code Versions It s good practice to add a revision after you ve done some modifications to the application Include a description of the modifications At each revision the 4th digit of the version number is augmented Figure 83 Application revisions EXERCISE Applications revisions 1. Add a revision a) Enter your name, a status indication and a description b) Click Add Revision 2. Verify that your revision has been appended to the Revision History 3. Verify that the version number has been augmented

59 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 59 Miscellaneous settings The following settings are available: Date and time settings Home display settings Security settings Figure 84 General settings of the Flow-X Spirit IT Flow-Xtract A new tool has been developed which enables you to easily and quickly extract archived data and reports from your Spirit IT Flow-X flow computer. The tool comes as a lightweight Excel add-in and provides a simple user interface from which you can select the desired data. To install the add-in: 1. Open Excel 2. Open the add-in 3. Enable macros when prompted Once loaded, the interface can be accessed via a dedicated Flow-Xtract ribbon in the Excel interface. Figure 85 Flow-Xtract excel add-in

60 60 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL Via the Settings option, you can set the ip-address, the folder where reports will be stored, the file format in which reports are stored and whether you want to overwrite previously stored reports. Figure 86 Flow-Xtract excel add-in Before report and archive data can be extracted, you will be prompted to supply login details. Once logged in, the available report or archive types will be listed. You can select one or more items from this list and extract the data. You can filter the returned data by applying a filter on the period for which you want the data to be extracted. Figure 87 Flow-Xtract excel add-in

61 SPIRIT IT FLOW-X LEVEL 1 TRAINING MANUAL 61 Document Control Version 1.0 Author: Eric van Boxtel Date: February 2016 First release of level 1 manual Version 1.1 Author: Eric van Boxtel Date: March 2016 Updated release of level 1 manual Version 1.2 Author: Eric van Boxtel Date: June 2016 Updated release of level 1 manual Version 1.3 Author: Louis Joosten Date: Februari 2017 Updated release of level 1 manual Version 1.4 Author: Peter van Deurzen Date: November 2017